Yamaha G14, G11, G16, G19, G20 Service & Repair Manual PDF

G14-A, G14-E
GOLF CAR SERVICE MANUAL
G14A,G14E
SERVICE MANUAL
1999 by Yamaha Motor Manufacturing
Corporation of America
3rd edition, June 1999
Printed in U.S.A.
P/N/ LIT-19616-00-00
(Rev. 8/96) (Rev. 6/99)

INTRODUCTION
This manual has been written by Yamaha Motor Manufacturing Corporation of America for use by
Authorized Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechan
ic's education into a manual, so it is assumed that persons using this book to perform maintenance
and repairs on Yamaha golf cars have a basic understanding of the mechanical concepts and proce
dures inherent to these products. Without such knowledge, attempted repairs or service to this golf
car may render it unfit to use and/or unsafe.
Yamaha Motor Manufacturing Corporation of America is continually striving to further improve all
models manufactured by the company. Modifications are therefore inevitable and will, where applic
able, appear in future editions of this manual.
TECHNICAL SERVICE DEPT

GOLF CAR SALES GROUP
YAMAHA MOTOR
MANUFACTURING CORP OF
AMERICA
HOW TO USE THIS MANUAL

Read This Important Information!
Particularly important information in this manual is distinguished by the following notations:
The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS

INVOLVED!
A WARNING Failure to follow WARNING instructions could result in severe injury or death to
golf car occupants, a bystander, or a person inspecting or repairing the golf
car.
This message describes special precautions that must be taken to avoid damage
to the goH car.
NOTE: This message provides additional key information.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information
has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
• Bearings:
Pitting/Damage --. Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
<D ® Symbol Identification
I~EF~I~I lh~Jinl Symbols <D to ® are designed as thumb tabs

to indicate the contents within a chapter.
@
CD General information
® ® Periodic inspection and adjustment
lcHAsl~l I~RI®I!01
® Chassis
@ Power train
® Engine overhaul
@ Carburetion
® @ (J) Electrical
IENG l'-1 lcARslfl

® Troubleshooting
® Specifications
(J) ®
IELECI iiii I ~~~~~? I

®
IsPEel P~l Symbols ®> to ® are used to identify specifi

@) ®
~ ~
cations within the text.
®> Filling fluid
® Lubricant
@ Special tool
@) Tightening torque
@ @)
~ ~
® Wear limit, clearance
® Engine speed
®) Q,V, A
® ®
®
~ § ®
Symbols ® to @) are used in the exploded
[I IT) l
diagrams to indicate the grade and location of
lubricant.
® Apply locking agent
@) Apply engine oil
@) @) @ @) Apply gear· oil
l l l @ Apply molybdenum disulfide oil
m
@ Apply wheel bearing grease
@ @
Gj
@)
a @ Apply lightweight lithium soap base grease
@) Apply molybdenum disulfide grease
~ ~ ~
ii
-----------'~1~1 CHAPTER 1
GENERAL INFORMATION
SAFETY PRECAUTIONS ....... ............................ 1-1
GENERAL SERVICE INFORMATION ............... 1-3

FRAME SERIAL NUMBER .......................... 1-3
WASHING AND CLEANING ......................1-4
THE RIGHT TOOLS ................................... 1-4
KEEP IT NEAT ............................................. 1-4
TIGHTENING TORQUE ..............................1-4
ALL REPLACEMENT PARTS ...................... 1-5
GASKETS, OIL SEALS AND 0-RINGS ...... 1-5
LOCK WASHERS/PLATES AND
COTTER PINS .......................................... 1-5
BEARINGS AND OIL SEALS ...................... 1-5
CIRCLIPS ..................................................... 1-6
DISASSEMBLY AND ASSEMBLY
SUGGESTIONS ....................................... 1-6
SPECIAL TOOLS ............................................... 1-7

FOR TUNE UP ............................................. 1-7
FOR ENGINE SERVICE ...............................1-7
FOR POWER TRAIN ...................................1-8
FOR CHASSIS SERVICE ............................. 1-9
FOR ELECTRICAL COMPONENTS .......... 1-10
(Rev. 6/99)
GENERAL INFORMATION I~~~ IA I
SAFETY PRECAUTIONS
A WARNING
Follow these safety precautions and exercise
caution when performing service work to pre
vent serious accidents.
PREPARE FOR EMERGENCIES

Be prepared for possible injury or fire. Keep the
following items handy:
• First aid kit
• Fire extinguisher
• Emergency phone numbers
HANDLE FUEL SAFELY

Use care when handling fuel- it is highly flam
mable. Do not smoke or have open flames or
sparks nearby when handling fuel.
Always clean up spilled fuel and dispose of

cleaning materials properly.
HANDLE BATTERIES SAFELY

Batteries produce explosive gases. Keep sparks
and flames away from batteries. Check battery
electrolyte level using a flashlight.
Never check battery state of charge by connect

ing the battery posts with a conductor. Use a
voltmeter or hydrometer. Always disconnect
the negative (-)cable first and connect it last.
Do not charge a battery if the battery is frozen.

Allow the battery to warm first.
Always charge batteries in a well venti lated

area to preve~t the build-up of explosive hydro
gen gas which is created when batteries are
being charged.
Battery electrolyte contains sulfuric acid and is

poisonous and highly caustic. Avoid contact
with skin, eyes, or clothing. If electrolyte con
tacts the eyes, flush with water for 15 minutes
and get prompt medical attention.
1-1
GENERAL INFORMATION
WEAR PROTECTIVE CLOTHING
I~EF"b 14'(;1.,I
Many permanent injuries could be prevented by
wearing appropriate safety equipment during
work. Whenever applicable, put on the follow
ing:
• Safety glasses with side shields or goggles

when performing work like grinding, chisel
ing, spraying or any other activity that could
result in an object or chemical striking the
eye
• Earmuffs or earplugs when performing loud
work that could harm hearing
• Safety shoes when working with heavy
objects that could be dropped
• Respiratory protection when performing
work involving dust, vapors, or gases that
can cause respiratory problems
Avoid wearing loose clothing and jewelry which

could become caught in moving parts causing
injury.
KEEP WORK AREA CLEAN

Properly ventilate work area to prevent build-up
of dangerous gases and keep the oxygen level
above OHSA's 19.5 percent minimum level.
Keep shop floor clean and dry to prevent acci

dents due to slips.
1-2
-A-----------., GENERAL SERVICE
I~~ r---~
INFORMATION
FRAME SERIAL NUMBER
The machine serial number is stamped in the
location shown.
!AI G14-A
[:aJ G14-E
1-3
IMPORTANT INFORMATION~~~~~~~
WASHING AND CLEANING
Before servicing, thoroughly clean the exte
r ior of the car body and engine. W h ile
cleaning, take care to protect the electrical
parts, such as relay switches, motor, resis
tors, controllers, etc., from high pressure
water splashes.
RIGHT TOOLS
Be sure to use the right special too l for the
right part in order to protect the part from
damage.
KEEP IT NEAT
Keep the removed parts organized in sepa
rate groups so that they will not be mis
placed.
TIGHTENING TORQUE
Be sure to foll ow tightening torque specifi
cations. When tightening bolts, nuts, and
screws, start w ith large r-diameter ones and
work from inner-positioned ones to outer
position ed ones in a criss-cross pattern .
Refer to "Tightening Torque" section of
CHAPTER 9.
1-4
IMPORTANT INFORMATION ~~~~IAI
ALL REPLACEMENT PARTS
We recomme nd you use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for assem
bly and adjustment.
'• -
-.......
.... .. .
:,:...
J
GASKETS, OIL SEALS, AND 0-RINGS

All gaskets, sea ls, and 0-rings shou ld be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and 0-rings
m ust be cleaned.
LOCK WASHERS/PLATES AND COTTER

PINS
All lock washers/plates <D and cotter pins
must be replaced when they are removed.
Lock tabs should be bent along the bolt or
nut flats after the bolt or nut has been prop
erly tightened.
BEARINGS AND OIL SEALS

Inst all bearings <D and oil seals ® w it h
their m anufact urer's m arks o r num bers fac
ing outwa rd. (In other words, the stam ped
let te rs must be on the sid e exposed to
view.) W hen insta ll ing oil seals, apply a
light coating of light-weight lithium base
g rease to the seal lip(s). Oil the bearings lib
erally when installing.
Do not use compressed air to spin the bearings

dry. This causes damage to the bearing surfaces.
1-5
IMPORTANT INFORMATION U~JF~ I"""I
r--- - - - - - - - - - - - - - , CIRCLIPS
All circlips should be inspected carefully
before reassembly. Always replace piston
pin clips after one use. Replace distorted
circlips. When installing a circlip Q) , make
sure that the sharp-edged corner ® is
positioned opposite to the thrust ® it
receives.
300·001
@shaft
DISASSEMBLY AND ASSEMBLY

SUGGESTIONS
Follow these guidel ines when disassembling

and assembling parts:
• Clean and dry parts whenever they are dis

assembled.
• Oil contact surfaces of moving parts when

they are assembled.
• After parts are assembled, make sure each

of the moving pa rts operates norm ally.
1-6
SPECIAL TOOLS ~~~~l-s4UI
SPECIAL TOOLS
The proper special tools are necessary for com
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or improvis
ed techniques. To order the tools specified on
the following pages, please contact Kent-Moore
for pricing and availability at: 1-800-345-2233.
FOR TUNE UP
1. Inductive Tachometer
P/N YU-8036-A
This tool is for measuring engine rpm.
2. Compression Gauge
P/ N YU -33223
This gauge is used to measure the engine com
pression .
FOR ENGINE SERVICE

1. Heavy-Duty Universal Puller
P/N YU-33270-B.
This tool is used to remove the flywheel.
2. Valve Spring Compressor

P/N YM-1253
This tool is needed to remove and install the
valve assemblies.
1-7 (Rev. 6/99)

SPECIAL TOOLS I~EF~I~I
,....., 3. Valve Seat Cutter Set
P/N YM-91043-C
~I~ ~H H~
This tool is used to resurface the valve seat.
/~®®0~
c~
4. Valve Adjuster
P/N YM -08035
This tool is used to adjust the valve clearance.
5. Piston Ring Compressor

P/N YU-33294
This tool is used to squeeze ring ends together
while piston is pushed into cylinder.
FOR POWER TRAIN

1. Primary Sheave Holder
P/N YS-1880-A
This tool is used to hold the primary sheave
when removing or installing the primary sheave
securing bolt.
2. Primary Sheave Puller

P/N YG-1876
This tool is used for removing the primary
sheave.
1-8 (Rev. 6/99)

SPECIAL TOOLS ~~'i:-~1•1
3. Secondary Sheave Holder
P/N YG-40103-A
This tool is used to compress the sheave spring
when removing or installing the secondary
sheave securing nut.
FOR CHASSIS SERVICE

1. Drift punch (6 mm) or Valve Guide Remover
P/N Y M-4064-A
This tool is used to remove the spring pins for
steering knuckle.
2. Mityvac® Pressure Tester

P/N YB-35956-A
This tool is used for vacuum pressure testing.
1-9 (Rev. 6/99)

SPECIAL TOOLS I~EF~I•I
FOR ELECTRICAL COMPONENTS
1. Pocket Tester
P/N YU-3112-C
This instrument is invaluable for checking the
electrical system.
2. Hyd rometer
P/N YU-03036
This gauge is used to measure the specific
gravity of battery electrolyte.
3. Dynamic Spark Tester

P/N YM -34487
This tester is necessary for checking the ignition
system components.
1-10 (Rev. 6/99)

---------~'~1&1 CHAPTER2
PERIODIC INSPECTION
AND ADJUSTMENT
PERIODIC MAINTENANCE .................................2-1 CHASSIS ............................................................2-26

MAINTENANCE CHART FOR G14-A .......... 2-1 BRAKE CABLE INSPECTION ..................... 2-26
MAINTENANCE CHART FOR G14-E ........... 2-2 PARKING BRAKE ADJUSTMENT ............. 2-27
MAINTENANCE CHART FOR BRAKE SHOE LINING INSPECTION .........2-27
G 14-A AND G 14-E ..................................... 2-3 BRAKE AND ACCELERATOR PEDALS ..... 2-29
STEERING INSPECTION ............................ 2-30
INSPECTION AN D ADJUSTMENT .................... 2-6 STEERING LINKAGE INSPECTION ...........2-32
ENGINE (FOR G14-Al ..........................................2-6 WHEEL ALIGNMENT .................................2-33
VALVE CLEARANCE ADJUSTMENT .......... 2-6 TIRE AN D WHEEL INSPECTION ............... 2-35
ENGINE OIL LEVEL MEASUREMENT ........ 2-8 FRONT WHEEL BEARING INSPECTION ..2-35
ENGINE OIL REPLACEMENT ......................2-8 REAR AXLE BEAR ING INSPECTION ........2-36
OIL DELIVERY HOSE INSPECTION .............2-9 SHOCK ABSORBER INSPECTION ............2-36
AIR FILTER CLEANING ..............................2-10
ENGINE BRACKET ADJUSTMENT ........... 2-11 ELECTRICAL (FOR G14-A) ................................2-37
COMPRESSION PRESSURE SPARK PLUG INSPECTION .......................2-37
MEASUREMENT ..................................... 2-11 STARTER BELT INSPECTION .................... 2-38
CARBURETOR ADJUSTMENT.. ................2-13 BATTERY INSPECTION ..............................2-39
ACCELERATOR STOP SWITCH BATTERY CHARGING ................................2-40
INSPECTION/ACCELERATOR PEDAL
POSITION ADJUSTING BOLT ELECTRICAL (FOR G14-El ................................ 2-41
HEIGHT ADJUSTMENT ..........................2-14 BATTERY CHARGING ................................2-41
THROTTLE CABLE ADJUSTMENT ........... 2-14 BATTERY INSPECTION ..............................2-44
SPEED LIMITER ADJUSTMENT................2-16 CHARGE RECEPTACLE INSPECTION ....... 2-46
CHOKE CABLE ADJUSTMENT .................2-17
FUEL PUMP INSPECTION .........................2-18
FUEL FILTER INSPECTION ........................2-20
FUEL HOSE INSPECTION .......................... 2-20
POWER TRAIN ...................................................2-21

TRANSMISSION OIL LEVEL
MEASUREMENT .....................................2-21
TRANSMISSION OIL REPLACEMENT ......2-22
DRIVE BELT INSPECTION (FOR G14-A) ... 2-23
PRIMARY SHEAVE LUBR ICATION
(FOR G14-A) .............................................2-24
SHEAVE INSPECTION ................................2-25
SH IFTING CABLE ADJUSTMENT
(FOR G14-A) .............................................2-25
(Rev. 6/99)
~~~~~~~~~~~~~~
PERIODIC INSPECTION AND ADJUSTMENT
PERIODIC MAINTENANCE
Regular maintenance is most important for best performance and safe operation.
A WARNING
Be sure to tum off the main switch and apply the parking brake when you perform maintenance
unless otherwise specified.
FORG14A
C ·CHECK CA · CHECK AND ADJUST R ·REPLACE S ·SERVICE CL · CLEAN AND LUBRICATE L ·LUBRICATE
20 Rounds 125 rds 250 rds 500 rds 1000 rds
Pre- 20hours 125 hrs 250 hrs 500hrs 1000 hrs
Remarks Opera- 100mlles 600mls 1200mls 2500mls 5000mls
tion 160kms 1000kms 2000kms 4000kms 8000kms
(Every (Every& (Every (Every (Every
month) months) year) 2years) 4years)
PRE·OP Check engine oil c c c
Check air cooling duct c c c c c c
Check fuel lines for leakage c c c c c c
Check fuel level c c c c c c
Check for looseness c c c c c c
and corrosion of battery
terminals and hold downs
EVERY Check fuel filter for clogging c c c c c
MONTH Check wear of drive belt c c c c c
Check operation of c c c c c
forward'reverse shifting
EVERY6 Wash pre-filter, check air s s s s
MONTHS cleaner element
Check spark plug and plug cap c c c c
condition•• I Check compression
EVERY Replace engine oil R R R
YEAR Adjust throttle cables, •• CA CA CA
choke cable, check carburetor
throttle shaft for wear**
Check starter V-belt for c c c
damage and tension
Check drive belt for slippage, c c c
wear or scratches
Check sliding sheave and CL CL CL
ramp shoes; Grease secondary
sheave bearing.
Grease primary sheave L L L
Check operation of speed limiter c c c
**Related to emission control system.
2-1 (Rev. 6/99)

----------~'~161
FORG14A
C- CHECK CA - CHECK AND ADJUST R - REPLACE S- SERVICE CL- CLEAN AND LUBRICATE L- LUBRICATE
20 Rounds 125 rds 250 refs 500 rds 1000 rds

Pre- 20 hours 125 hrs 250 hrs 500hrs 1000 hrs
Remarks Opera- 100 miles 600mls 1200 mls 2500mls 5000mls
tlon 160 kms 1000kms 2000 kms 4000 kms 8000kms
month) months) year) 2 years) 4years)
EVERY Apply battery terminal protectant s s s

YEAR Check wiring connections c c c
and insulation
EVERY Check brushes for wear and c s
2YEARS commutator for dirt
EVERY Replace fuel filter and R
4 YEARS fuel hoses
Check tightness of cylinder CA
head I Adjust valves
FORG14E
C - CHECK CA -CHECK AND ADJUST R - REPLACE S - SERVICE CL- CLEAN AND LUBRICATE L- LUBRICATE
20Rounds 125 rds 250rds 500 refs 1000 rds

Remarks Opera- 100 miles 600mls 1200mls 2500mls 5000mls
tion 160kms 1000kms 2000kms 4000kms 8000kms
(Every (Every& (Every {Every (Every
month) months) year) 2 years) 4years)
PRE-OP Charge s s s s s s
Clean tops, check for tightness of s s s s s s
hold-down screws and terminals
EVERY Check electrolyte level c c c c c
MONTH Check for loose or broken c c c c c
connections
EVERY6 Check all wire insulation for c c c c
MONTHS cracks and/or wom spots
EVERY Perform a discharge test s s s
YEAR Apply terminal protectant s s s
2-2 (Rev. 6/99)

FOR G14A & G14E
C ·CHECK CA ·CHECK AND ADJUST R ·REPLACE S ·SERVICE CL ·CLEAN AND LUBRICATE L ·LUBRICATE
2.0 Rounds 125rds 250 rds 500 rds 1000 rds

Remarks Opera- 100mlles 600mls 1200mls 2500mls 5000mls
tlon 160kms 1000kms 2000kms 4000kms 8000kms
month} months} year} 2 years} 4years)
PRE-OP Check brake pedal freeplay and c CA CA CA CA CA
adjust if necessary
Check steering operation c c c c c
Check tire pressure, tread depth, c CA CA CA CA CA
tire surface for damage
Check body and chassis for damage c c c c c c
Check tightness of all bolts, nuts, c c c c c c
and screws
Check reverse buzzer operation c c c c c c
EVERY Clean I Lube pedal control area CL
MONTH
EVERY6 Check shock absorbers for oil leaks c c c c
MONTHS and damaged springs
EVERY Check shoe lining thickness and c c c
YEAR rear axle bearing play
Check kingpin play, seal, and cap I CA CA CA
Adjust wheel alignment
Check wheel nut tightness, front c c c
wheel bearing play
Check gear box oil level c c c
and leakage
Check operation and adjust pedal CA CA CA
stop if necessary
EVERY4 Replace gear box oil R
YEARS Check for grease leakage; adjust CA
gearbox if necessary
Keep high pressure water away from all electrical parts.
2-3 (Rev. 6/99)

NOTES
2-4
NOTES
2-5
____________________________e_N_G_tN__ EI~8fl~l
INSPECTION AND ADJUSTMENT
ENGINE (G14-A)
VALVE CLEARANCE ADJUSTMENT
NOTE:-----------------------
Valve clearance must be measured when the
engine is cool to the touch.
1. Remove the seat.

2. Position:
• Shift lever
to neutral position.
3. Disconnect:
• Crankcase breather hose G)
• Oil delivery hose ®
• Spark plug lead @
4. Remove:
• Spark plug
• Cylinder head cover @
5. Set the piston at top dead center (TDCl on
compression stroke.
NOTE=------------------------
Measure and adjust valve clearance when piston
is at TDC on compression stroke only.
Y·201
How to set the TDC on compression stroke:

• Set the piston at TDC.
NOTE:
You can find TDC by inserting a screwdriver into
the spark plug hole and rotating the prima
ry sheave until the screwdriver reaches its high-
est position.
• Paint matching marks onto the sheave and

crankcase.
• Rotate the sheave counterclockwise half a
turn from the TDC position.
If intake rocker arm G) moved--. Rotate sheave
another 1/2 turn and you will be at TDC on
compression stroke. If both rocker arms did not
move - Return sheave to its initial position
(this is TDC, compression stroke.)
2-6 (Rev. 6/99)

____________________________e_N_GI_N_EI~8fl~l
6. Measure:
• Valve clearance
Use feeler gauge
Out of specification -+ Adjust.
Intake Valve (Cold):

0.1 mm (0.004 in)
Exhaust Valve (Cold):
0.1 mm (0.004 in)
Valve clearance adjustment steps:

• Loosen the locknut G) while holding the
adjusting screw with Valve Adjuster@.
~
Valve Adjuster:
YM-08035, 90890-01311
• Insert the feeler gauge (specified thickness).

• Screw in the adjusting screw ® until the
rocker arm @contacts feeler gauge lightly.
• Tighten the locknut G) while holding the
adjusting screw with Valve Adjuster@.
NOTE:
Check feeler gauge fit. It should have a notice-
able drag but not require excessive force.
• Rotate primary sheave two complete revolu-

tions, and recheck valve clearance specifica-
tion. Perform adjustment steps over if neces-
sary.
:~
Locknut:
14 Nm (1.4 m • kg, 10ft •lb)
NOTE:-----------------------
Before replacing the cylinder head cover, thor-
oughly clean all gasket material from sealing sur
faces.
7. Install:
• Cylinder head cover with new gasket
• Spark P.lug
• Oil delivery hose
• Crankcase breather hose
• Spark plug lead
Bolts (Cylinder Head Cover):

10 Nm (1.0 m • kg, 7.2 ft •lb)
Spark Plug:
20 Nm (2.0 m • kg, 14ft • lb)
2-7
______________________________e_N_G_IN__ E~~~~~ifii~
ENGINE OIL LEVEL MEASUREMENT
1. Place the vehicle on a level surface.
2. Inspect:
• Engine oil level
Below MIN mark-+ Add sufficient oil.
Engine oil level measurement step:

• Place vehicle on level surface.
• Remove the seat.
• Remove the dipstick G), and wipe it with
clean rag.
• Insert the dipstick into the crankcase until it
firmly seats in place.
• Pull up the dipstick, and make sure the oil
Y-133
level is between the MAX and MIN level.
NOTE:-----------------------
The distance between the dipstick marks repre-
sents approx. 1/2 US qt (1/2 L) of oil.
I MIN IXXXXXI MAX ) Recommended Oil:
VAMALUBE 4-cycle oil or
SAE 10W30 [If temperature
does not go below
Y·130 2•c (35.F): SAE 20W40)
Oil Change Quantity:
0.9 L (1.0 US qt, 0.191mp gal)
Oil Capacity:
1.1 L (1 .16 US qt, 0.241mp gal)
NOTE:-----------------------
Recommended engine oil classification; API
Service "SE", "SF", or "SG" type or equivalent.
Do not allow foreign material to enter the

engine, and use care not to fill past the MAX
dipstick mark.
ENGINE OIL REPLACEMENT

2. Warm up .the engine for several minutes,
then place an oil pan under the engine.
A WARNING
L - - - - - - - - - - - - - - - - . . . ;v...;
-1,;;,;
31_, Use caution not to touch hot engine oil, or hot
engine parts, during the following procedure.
3. Remove:
• Drain plug
Drain the engine oil
2-8
___________________________E_N_G_IN_EI~8JI~I
4. Install:
• Drain plug
• New drain plug gasket
Drain Plug:
30 Nm (3.0 m • kg. 22ft • lb)
5. Remove:
• Filler cap
6. Fill
• Crankcase
Recommended Oil:
VAMALUBE 4-cycle oil or
does not go below
2·c (35.f): SAE 20W401
0.9 L (1.0 US qt, 0.191mp gal)
Oil Capacity:
1.1 L (1.16 US qt, 0.241mp gal)
NOTE:-----------------------
Service "SE", "SF", or "SG" type or equivalent.

engine, and use care not to fill past the MAX dip
stick mark.
7. Install:
• Filler cap
NOTE:---------------------
It is acceptable to change the oil more frequently
if desired.
OIL DELIVERY HOSE INSPECTION

1. Inspect:
• Crankcase breather hose G)
• Oil delivery hose ®
Poor connection -+ Reconnect.
Cracks/damage -+ Replace.
Y-200
2-9
____________________________e_NG_I_Ne_l~~j~~~
AIR FILTER CLEANING
1. Disconnect:
• Rubber joint CD from carburetor.
• Crankcase breather hose @.
2. Unhook:
• Rubber straps
3. Remove:
• Case cap
Y-134
• Filter elements
4. Remove:
• Foam element@
• Paper element ®
From the case cap.
5. Clean:
• Foam element@
Wash it with soap and water and allow it to
dry.
• Paper element ®
Y-135
Tap it by hand to remove the dust.
• Do not apply oil to the element cover; resis

tance to air flow will be increased and
adversely affect the performance.
• Do not wash the paper filter or use pressur
ized air which will damage the element.
• Do not use filters made from any other mater
ial. Engine life will be reduced.
Y-136
6. Install:
• All components
NOTE:-----------------------
When assembling the air filter, reverse the
removal procedure. Note the following caution.
• Before replacing elements, lightly lubricate

Y- 137
the 0-ring in the top of filter element. Be care
ful not to dislodge the 0-ring or engine dam
age may re~ult.
• When placing the filter elements back into the
case, align the two small projections on the
inside of the filter cap with the straight edges
of the paper element's steel end plate.
Y-210
2-10
ENGINE I~8JI~E~I
--------------------------------------------
ENGINE BRACKET ADJUSTMENT
1. Disconnect:
• Rubber joint from carburetor.
• Corrugated air intake hose.
• Crankcase breather hose.
2. Remove:
• Holding bolts CD
• Air cleaner case.
3. Measure:
• Free play ® (Engine bracket tensioner)
Out of specification-. Adjust.
Engine Bracket Tensioner:

Free play® : 2 mm (0.08 in)
Free play adjustment steps:

• Loosen the locknut G).
• Adjust free play by turning the adjustment
nut@.
Y-212
To Reduce
To Increase -- Turn locknut ® clockwise.
Turn locknut ® counterclock-
wise.
• Tighten the locknut.
COMPRESSION PRESSURE MEASURMENT

NOTE:-------------------------
Insufficient compression pressure will result in
Y-213
performance loss.
1. Measure:
• Valve clearance
Out of specification -. Adjust.
Refer to "VALVE CLEARANCE ADJUST
MENT' section.
2-11
___________________________ E_N_G_IN_E~~~r~~~
2. Warm up the engine.
3. Remove:
• Drive belt
• Spark plug
4. Measure:
• Compression pressure
Compression pressure measurement steps:

• Install the Compression Gauge G) using an
adapter.
Y-214
Compression Gauge:
YU-33223, 90890-03081
A WARNING
Before cranking the engine, disconnect ignition
coil lead (Red/White, Orange).
• Crank over the engine with the electric

starter (be sure the battery is fully charged)
with the throttle wide-open and choke
"OFF" until the compression reading on the
gauge stabilizes.
• Check readings against specified levels (See
chart).
Compression Pressure (at sea level):

Standard:
1,250 kPa (12.5 kg/cm2, 178 psi)
Minimum:
1,000 kPa (10.0 kg/cm2, 142 psi)
Maximum:
1,400 kPa (14.0 kg/cm2, 199 psi)
• If pressure falls below the minimum level:

1. Squirt a few drops of motor oil into the
cylinder.
2. Measure the compression again.
Compression pressure
(with oil introduced into cylinder)
Reading Diagnosis
Higher than without Worn or damaged

oil piston or ring.
Bad valves, cylinder

Same as without oil head gasket or worn
guide.
Inspect cylinder head,

valve surfaces, or
Above maximum level piston crown for car-
bon deposits.
2-12
____________________________ E_N_GI_N_E~~~r~~~
CARBURETOR ADJUSTMENT
NOTE=-----------------------
Remove anti-tamper cover by removing the two
TORX® head screws that hold it in place.
1. Adjust:
• Pilot screw <D
Pilot screw adjustment steps:

Y-217
• Lightly screw in the pilot screw (D.
• Back it out from its seated position .
Standard Turned Out:

1 and 1/2 turns
• Adjust mixture by turning the pilot screw 1/8

- 1/4 turn each time.
Too Lean -+ Turn pilot screw counterclock-

wise.
Too Rich -t Tum pilot screw clockwise.
2. Adjust:
• Throttle stop screw@
Throttle stop screw adjustment steps:

• Screw out the throttle stop screw @ to clear
the throttle arm @.
• Slowly screw in the throttle stop screw@
until it is lightly touching the throttle arm@,
then give it another 1/4 turn.
Standard Turned In:

1/4turn
w . , . . :- :
~t~::.~. i.. "
;;t' < . '
. =· < ~=i~
•• -:w;;;:s-:
-·
~ • • ........... • • " '......'!< - - - - - - - - - - -
Do not use any other setting or adverse perfor

mance will resutt.
3. Re-install ~nti-tamper cover.
2-13 (Rev. 8/96)

____________________________ E_NG_I_NE_I~8fl~l
ACCELERATOR STOP SWITCH
POSITION ADJUSTING BOLT HEIGHT
ADJUSTMENT
1. Remove:
• Service lid
2. Inspect:
• Stop switch
Dirt deposits---.. clean.
Unsmooth movement ---.. Replace switch.
3. Measure:
• Adjusting bolt height @.
Out of specification - Adjust.
Accelerator Pedal Position Adjusting

Bolt Height @:
18.00- 18.40 mm (0.708- 0.720 in)
0
t Y-127
THROTTLE CABLE ADJUSTMENT
NOTE:------------
Before performing throttle cable adjustment, per-
form above switch inspection and bolt adjust
ment.
Full Throttle Adjustment

1. Turn the main switch to "OFF".
2. Block the wheels.
3. Remove:
• Rear access panel
NOTE:--------------
There are two separate throttle cables: 1) from
accelerator pedal to speed limiter, and 2) from
speed limiter to carburetor. Each cable requires
adjustment for free play and full throttle opera
tion.
2-14 (Rev. 8/96)

4. Adjust:
• Throttle cable 2 (Governor-Carburetor)
Throttle cable 2 adjustment steps:

• Swing the governor lever counterclockwise
until it stops completely.
• While keeping the lever at this position,
check that the throttle valve in the carburetor
is fully open.
• If not, adjust the throttle cable 2 by turning
the adjusting nuts in or out.
THROTTLE
STOP
SCREW
THROTTLE THROTTLE
VALVE VALVE
"CLOSED" "OPEN"
i Y-100
5. Adjust:
• Throttle cable 1
(Accelerator pedal-Governor) G)
Throttle cable 1 adjustment steps:

• Depress the accelerator panel G) to limit.
• While keeping the pedal at this position,
check that the throttle valve in the carburetor
® is fully open.
--- -) • If not, adjust the throttle cable 1 ® by turn
ing the adjusting nuts @ in or out.
/
NOTE:-----------------------
Throttle valve should reach fully open at the
same time the accelerator pedal reaches its limit.
If the throttle valve is fully open before the accel
erator pedal reaches its limit, cable 1 is too tight.
Free play adjustment

I
I 1. Measure:
I
I
I • Free play (Throttle cable 2) ®
2 I
I Out of specification -+Adjust.
~~~~ .---~-~.~:
Free Play (Throttle Cable 2):
I
I 0.5 mm (0.02 in)
®I 1
~
2-15
------------------------------EN_G_IN_E_I~~jli@il
2. Adjust:
• Free play (Throttle cable 2)
Throttle cable 2 free play adjustment steps:

• Loosen the locknut G) .
• Turn the adjuster ® in or out until the cor-
rect free play is obtained.
Turn in Free play is decreased.
Turnout Free play is increased.
3. Measure:
• Free play (Throttle cable 1) @
Out of specification --+Adjust.

0.2 - 0.5 mm (0.008 - 0.020 in)
4. Adjust:
• Free play (Throttle cable 1) @
Throttle cable 1 free play adjustment steps:

• Turn the adjuster ® in or out until the cor-
rect free play is obtained.
Turn in Free play is decreased.
Turnout Free play is increased.
• Tighten the locknut .
SPEED LIMITER ADJUSTMENT

Adjustment
The speed limiter is properly adjusted at the fac
tory, so no adjustment is normally required.
Standard Limiter Setting:

APPROX. 3,050 r/min at
19 km/h (12 mph)
NOTE:------------------------
• The golf car maximum speed should be
checked, and the speed limiter setting adjusted
as necessary, when service is performed on
the throttle cables or governor parts.
2-16
------------------------------EN_G_I_Ne_l~~fi'Mil
• Before performing repairs, mark the present
limiter setting with a paint mark for future ref
erence. Return the adjustment to the original
setting after repairs are complete, then test
vehicle speed.
• The speed limiter can be adjusted so that the
maximum speed is 10 mph- 14 mph (16- 22
km/h).
A WARNING
Do not exceed the maximum speed setting of 14
mph (22 km/hl under any circumstances.
1. Check:
• Setting speed
Compare the maximum speed with another
2 golf car driving parallel. (The golf car used
for comparison should be representative of
other cars in the same fleet).
Improper setting -+ Readjust.
G) Locknut
® Adjusting bolt
@ Limiter lever
@Torsion spring
Limiter setting adjustment steps:

• Before getting started, mark the present set
ting position with a paint mark.
• Adjust the distance @ by turning locknut G).
To Reduce Max. Speed -+ Turn locknut G)

counterclockwise 181.
To Increase Max. Speed -+ Tum locknut CD
clockwise IBl.
2-17
-----------------------------E_N_GI_N__
E
CHOKE CABLE ADJUSTMENT
~~~:~~~
1. Measure:
• Free play (Choke cable) ®
110 Out of specification -+Adjust.
Free Play (Choke Cable) ®

1.0 mm (0.04 in)
<D Cable clamp

2. Adjust:
• Free play (Choke cable)
Choke cable free play adjustment steps:

• Make sure the choke knob and carburetor
choke lever are in the "at rest" or off posi
tion.
• Loosen the cable clamp G).
• Slide cable forwards or backwards in cable
clamp until free play specification is met.
• Tighten the cable clamp screw.
NOTE:-----------------------
After adjusting the choke cable, make sure that
the choke moves smoothly, and that the choke
opens fully when the choke knob is pulled all the
way out.
FUEL PUMP INSPECTION

Fuel Supply to Pump
1. Remove:
• Drive belt
A WARNING
Gasoline is highly flammable. Aim the fuel hose
into a receptacle. Keep away from any spark,
flame, or other source of ignition. Wipe up any
spilled fuel immediately.
2. Disconnect:
• Ignition coil lead (Red/White, Orange)
• Fuel feed hose <D
from carburetor.
3. Place a pan or other receptacle under the
hose end.
4. Crank over the engine with starter motor.
5. Check to see if fuel flows out from the feed
hose end.
If fuel does not flow out, check pulse hose,
fuel filter, and hose from tank to pump.
Cracked/plugged -+ Replace.
If pump appears leaky, replace it.
2-18
____________________________e_NG_I_Ne_I~8JI~I
Fuel Pump Test
NOTE:-------------------------
This inspection requires "wet condition," or the
presence of some fuel in the pump. A totally dry
pump will not function due to air leaks through
valve gaps in the pump.
1. Mark fuel pump hoses to allow for re-connec

tion in their proper location after test.
2. Disconnect:
• Hoses
from fuel pump.
During the following steps, do not apply more

pressure than the specification given.
Y-388
3. Connect pressure hose from Mityvac® to
pump inlet spigot from fuel tank delivery
hose (Diaphragm Test).
4. Block fuel outlet spigot G) and pressurize to
7.0 ± 1.0 psi.
5. Check:
Pressure being maintained.
Pressure loss_. Replace pump.
Y-1 23
6. Connect pressure hose from Mityvac® to vac

uum side of pump tool (Inlet Valve Test).
7. Apply negative pressure to 300mb± 10%.
8. Check:
Pressure is not released all at once.
Sudden pressure release-. Replace pump.
Y· 124
9. Connect p~essure hose from Mityvac® to

pump outlet spigot from fuel pump to carbu
retor (Outlet Valve Test).
10. Pressurize to 7.0 ± 1.0 psi.
11. Check:
Pressure being maintained.
Pressure loss_. Replace pump.
Y·125
2-19 {Rev. 6/99)

____________________________E_NG_I_Ne_l~8fl~l
Never attempt to disassemble the fuel pump.
12. Connect:
• Hoses
to fuel pump.
FUEL FILTER INSPECTION

1. Disconnect:
• Fuel hose
from fuel pump.
• Fuel hose
from gas tank.
2. Remove:
• Fuel filter G)
3. Inspect:
v-m • Fuel filter
Contamination -+ Replace.
FUEL HOSE INSPECTION

1. Inspect:
• Fuel hoses
Damage/Cracks -+ Replace.
Poor connection -+ Reconnect.
2-20
________________________P_o_w_e_R_TR_A_IN_I~Jfl~l
POWER TRAIN
TRANSMISSION OIL LEVEL
MEASUREMENT
1. Place golf car on a level surface.
2. Remove the rear access panel.
3. Check:
• Oil level
Oil level low -+ Add sufficient oil.
G14A Transmission oil level inspection steps:

• Remove the oil level plug CD and vent cap ®
(G14-A).
NOTE:
Place an oil pan under the transmission case.
• Add sufficient oil little by little into the vent

hole (G14-A) or level plug hole (G14-E) until
Y-148
oil flows out from the level plug hole @.
~
G14E Recommend Oil:
SAE 90 gear oil
Oil Capacity:
G14-A:
800 cc (0.70 Imp qt, 0.85 US qt)
G14-E:
300 cc (0.26 Imp qt, 0.32 US qt)
Y-149 ~*111~11-1.~~~~~~
transmission case.
• Allow excess oil to flow out until it stops .

• Install the oil level plug and vent cap (G14-A) .
~
Oil Level Plug:
ForG14-A:
14 Nm (1.4 m • kg, 10ft •lb)
ForG14-E:
Y-150 44 Nm (4.4 m • kg, 32ft • lb)
G14E
Y-151
2-21 (Rev. 6/99)

POWER TRAIN I~8!IRI
TRANSMISSION OIL REPLACEMENT
1. Place golf car on a level surface.
2. Place an oil pan under the transmission case.
G14-A
3. Remove:
• Vent cap
• Drain plug
Drain the transmission oil.
Y-143
G14-E
3. Remove:
• Transmission case bolts
• Transmission case cover
Drain the transmission oiL
NOTE:-----------------------
Separate the transmission case cover from the
case assembly using a gasket scraper G).
Use care not to damage the case sealing surface

or deform the transmission case cover.
4.1nstall:
• Drain plug (G14-Al
• Vent cap (G14-Al
Drain Plug (G14-A):

14 Nm (1.4 m • kg, 10ft •lbl
• Transmission case cover (G14-El

Refer to "POWER TRAIN FOR G14-E
TRANSMISSION, ASSEMBLY" in Chapter 4.
2-22
__________________________P_o_w_eR__TR_A_tN_I~JJI~I
5. Fill:
• Transmission case
Refer to "TRANSMISSION OIL LEVEL MEA
SUREMENT" section. (Page 2-21)
Recommended Oil:
SAE 90 gear oil
Oil Capacity:
G14-A:
800 cc (0.70 Imp qt, 0.85 US qt)
G14-E:
300 cc (0.26 Imp qt, 0.32 US qt)
Do not allow foreign material to enter the trans

mission case.
DRIVE BELT INSPECTION (FOR G14-A)

1. Remove the seat.
2. Remove the drive belt.
Drive belt removal steps:

• Set the shift lever halfway between "F" and
''R".
• Pull out the primary sliding sheave_
Y-138
• Pull the belt outward over the edge of the
secondary fixed sheave.
• Rotate the secondary sheave clockwise and
the belt will roll off of the secondary sheave.
• Slip the belt over the primary sheave to
completely remove.
3. Inspect:
• Drive belt
lr=~~
Scratches/Slippage/Damage_. Replace.
4. Measure:
• Beltwidth
~--o--~
I
I I
I
Out of specification _. Replace.
r~
I I
I
I 1
I
Wear Umit ®:
L-- ---'
~ _27 .0 mm (1.06 in}
CD New belt width: 31.0 mm ( 1.22 in)
2-23
__________________________P_ow
__ ER__TR_A_IN_I~8fl~l
5. Install the drive belt.
Drive belt installation steps:

• Slip the belt over the primary sheave.

• Push the belt firmly into the secondary
sheave at about the 10:00 o'clock position.
• Rotate the secondary sheave clockwise until
the belt has rolled into position on the sec
ondary sheave.
PRIMARY SHEAVE LUBRICATION

(FOR G14-A)
1. lubricate:
• Primary sheave
Recommended Grease:
Molybdenum disulfide grease
Grease Amount:
Three shots (Manual grease gun)
Three seconds (Automatic grease
gun)
2. Inspect:
• Remove sheave cap and inspect link
weights and pivot pins.
Worn -+ Replace.
Clean any excess grease from link weights

before reinstalling sheave cap. Link weight piv
ots must be clean and dry. Oil or grease will
attract dirt and cause premature wear. Be sure
that no grease gets on drive belt.
2-24
_________________________P_o_w_E_R_T_R_AI__ NI~~r~~~
SHEAVE INSPECTION
1. Inspect:
• Sliding sheave movement (Primary and
secondary)
Check for condition by moving with hand.
Obstruction ---+ Disassemble sheave, and
inspect component parts.
Refer to CHAPTER 4 "PRIMARY SHEAVE"
and "SECONDARY SHEAVE" section.
2. Measure:
• Ramp shoe thickness (Secondary spring
seat)
Out of specification ---+ Replace.
~~
r~
Wear Umit @:
1.0 mm (0.04 in)
<D Spring seat cam

SHIFTING CABLE ADJUSTMENT
(FOR G14-A)
1. Measure:
• Shift stroke
Out of specification ---+ Adjust.
Shift Stroke @:
15 - 17 mm (0.59 - 0.67 in)
Shift stroke adjustment:

"R" and pin lever in place with a bolt or pin
with 8 mm diameter.
• Loosen the locknuts @ .
• Adjust the shift stroke by turning the adjust-
ing nuts (D.
To Reduce ---+ Turn adjusting nut <D clock-

wise.
To Increase ---+ Turn adjusting nut <D coun-
terclockwise.
• Tighten the locknuts @ .

• Un-pin the shift lever.
NOTE:-----------------------
Check shifting operation after adjusting shift
stroke.
Y-226
2-25
___________________________c_H_A_ss_ls_(~j~~~
CHASSIS
BRAKE CABLE INSPECTION
1. Remove:
• Service lid.
• Be careful not to scratch body
Y-141
2. Inspect:
• Brake cables CD
• Brake rod®
• Clevis pins @
• Cotter pins @
• Brake equalizer @.
Wear/Damage --+ Replace.
Y-227
3. Measure:
• Brake pedal free play.
Press against the pedal (using light force)
and measure the distance the pedal travels
before resistance is felt
Out of specification --+ Adjust.
Brake Pedal Free Play:

25-30 mm (0.98- 1.18 in)
Y-139
Free play adjustment steps:

• Loosen the locknut.
• Adjust the free play by turning the adjusting
nut in or out until specification is met
NOTE: The adjusting nut has a cam shape,
allowing the nut to be turned only in incre
ments of 1ao·.
.___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _v;..
-1;.;.;4o;.jl To Reduce --+ Turn adjusting nut clock-
Freeplay wise.
To Increase ....,. Turn adjusting nut counter
Freeplay clockwise.
A WARNING
Overly tight cables will prevent proper brake
self-adjuster action, reducing braking perfor
mance.
2-26 (Rev. 6/99)

___________________________c_H_A_ss_l_sl~~j~~~
PARKING BRAKE ADJUSTMENT
NOTE:-----------------------
Before performing parking brake adjustment,
adjust brake pedal free play.
1. Turn the main switch to "OFF", and remove

the key.
2. Remove the service lid.
3. Inspect:
• Parking brake ratchet CD
• Ratchet stopper@
Wear/Damage-+ Replace.
4. Apply the brake, hook the stopper @ at the
second notch on the ratchet G).
5. Measure:
• Free play (Release timing) ®
Free Play (Release Timing):

0-0.3 mm
Release timing adjustment steps:

• Loosen the locknut @ .
• Adjust the release timing by turning the
adjusting bolt @.
To Advance -+ Turn adjusting bolt @

counterclockwise.
To Retard -+ Turn adjusting bolt @
clockwise.

• Recheck the release timing .
BRAKE SHOE LINING INSPECTION

1. Turn the main switch to "OFF", and remove
the key.
2. Apply parking brake, loosen the wheel nuts.
3. Block the front wheels. Jack up the rear of the
car.
4. Release parking brake by depressing the
accelerator pedal.
5. Remove the wheel nuts and rear wheel.
2-27 (Rev. 6/99)

6. Remove:
• Brake drum <D
To loosen the drum, screw bolts ® onto
the drum as shown.
NOTE:-----------------------
If it is very hard to remove the drum, screw in the
adjusting nut @ in the shoe plate. (Brake drum
shown removed for clarity).
Y-230 Y·231
7. Inspect:
• Drum inner surface
Oil --. Clean completely with non-oily
solvent.
Scratches -+ Lightly polish evenly with
emery cloth.
8. Measure:
• Drum inside diameter
v -2a2 Out of specification --. Replace drum.
Maximum Inside Diameter:

161 mm (6.34 in)
Right and left side brake shoe sets (passenger

side and driver side) are not interchangeable. If
more than one set is to be removed at a time,
mark sets so they can be installed in their origi
nal positions.
9. Inspect:
• Shoe lining surface
Oil --. Replace/Clean completely with non
oily solvent, and emery cloth.
Scratches -+ Lightly polish with emery
cloth.
10. Measure:
• Shoe lining thickness
Out of specification -+ Replace.
Refer to CHAPTER 3 "BRAKE" section.
Minimum Uning Thickness:

0.75 mm (0.029 in)
.___ _ _ _ _ _ _ _ _ _ _ _ _ _ ___...v-1o_.1
.- G) Measuring points
2-28
CHASSIS ~~8.rl&l
Replace the brake shoes as a set if either is found
to be worn to the wear limit. Replacement right
side and left side brake shoe sets have different
part numbers, and are $tamped "'R.H. SIDE" (pas
senger side) and •t.H. SIDE" (driver side), respec
tively. Use care to install replacement shoes in
their proper locations - shoe sets are not inter
changeable.
11. Install:
• Brake drum
• Rearwheel
Y·121
A WARNING
Make sure that no grease or water comes in con
tact with the brake drum and/or shoe surfaces.
12. Install:
• Wheel nuts
NOTE:-----------------------
First finger-tighten a top nut, then the rest diago-
nally. Let the vehicle down till the weight is on
the wheels. Finish tightening the nuts.
Wheel Nut G):

90 Nm (9.0 m • kg, 65 ft • lb)
13. After assembling, depress the brake pedal

about 10 times to adjust the shoe-drum clear
ance.
BRAKE AND ACCELERATOR PEDALS

1. Check:
• Pedal movement
Disconnect the brake rod and throttle cable.
Roughness -+ Lubricate pivoting parts.
Recommended Lubricant:
SAE 10W30 Motor Oil
2-29
___________________________c_H_A_ss_ls_l~~~~~
2. Check:
• Pedal side free play
Try to move the pedals from side to side.
1111 11111111 11 Noticeable free play -+ Replace pivoting
• parts.
Pedal Side Play Limit:

I 5 mm (0.20 in) (Measured at top of
pedal)
STEERING INSPECTION
Steering Shaft Axial Play Adjustment
1. Check:
• Axial play
Pull and push the steering wheel.
Looseness -+ Retighten steering wheel
and/or steering gearbox.
Y-102
2. Tighten:
• Nut (Steering wheel)
• Bolts (Gear box)®
Nut (Steering Wheel):

39 Nm (3.9 m • 8 kg, 28 ft • lb)
Bolt (Gear Box Securing) ® :
32 Nm (3.2 m • kg, 23 ft • lb)
3. Recheck:
• Axial play
Still excess play -+ Adjust the steering
wheel axial free play.
Axial free play adjustment steps:

• Tighten the steering shaft adjustment bolt ®
until the shaft does not move.
Y-102
• Loosen the adjustment bolt ® completely. Be
sure the b~aring race does not fall out of its
seat.
• Retighten the adjustment bolt ® until the
steering shaft has no axial looseness, but
rotates smoothly to the left and right limits of
the wheel rotation.
• Tighten the locknut G).
~ Locknut (!):
~ 25 Nm (2.5 m • kg, 18ft • lb)
2-30 (Rev. 6/99)

___________________________c_H_A_ss_l_si~8JI~l
Steering Wheel Free Play Adjustment
1. Check:
• Steering wheel free play
Turn the steering wheel lightly.
Out of specification~ Adjust.
Steering Wheel Free Play @:

Umit: 30 mm (12 in)
Y·103
Steering wheel free play adjustment steps:

• Set vehicle with front wheels pointed
straight ahead.
• Loosen the locknut G) .
\ • Tighten the free play adjusting screw until it

stops (to fully seat the pitman arm).
• Loosen the free play screw 1/2 turn (180°) .
• Tighten locknut G) .
I~
Locknut G):
15 Nm (1.5 m • kg, 11ft •lb)
2. Recheck:
• Steering wheel free play
Still free play ~ Disassemble the steering
gearbox and check the components.
Refer to CHAPTER 3 "STEERING SYSTEM"
section.
2-31 (Rev. 8/96)

_____________________________c_H_As_s_•s_I~8JI1Ail
STEERING LINKAGE INSPECTION
Tie-Rod End (Universal joint)
1. Remove:
• Cotter pin
• Locknut
• Tie rod CD
NOTE:------------------------
When removing the locknut, hold the rod end
Y-235 using a 14 mm wrench @.
2. Check:
• Rod end
Unsmooth movement CD -+ Replace.
Noticeable free play ®-+ Replace.
Bent bolt ® -+ Replace.
Refer to CHAPTER 3 "STEERING SYSTEM"
section.
3. Install:
• Tie rod CD
Tie-Rod-Idler Arm,
Knuckle Arm-Tie Rod:
35 Nm (3.5 m • kg, 25 ft • lb)
Knuckle
1. Check:
• Kingpin free play
a. Park the vehicle on a level surface and
apply parking brake.
b. Raise the front wheels with a suitable lift.
c. Gently rock the font wheel side to side.
Noticeable free play-+ Replace kingpin and
bushings.
~ Free Play Umit (j):

[61 5 mm (0.20 in)
Refer to CHAPTER 3 " FRONT SUSPEN

SION" section.
2-32 (Rev. 8/96)

___________________________c_HA_s_s_lsi~~JI~l
WHEEL ALIGNMENT
Toe-In
2. Push the empty car forward 20ft. to stabilize
suspension. Coast to a stop with front wheels
pointed straight ahead.
NOTE:-----------------------
Do not push the car backward or apply the brakes
to stop. Either one will change toe-in.
3. Measure:
• Toe-in
Out of specification _. Adjust.
Toe-In:
Unloaded:
1 - 11 mm (0.04 - 0.43 in)
Fully loaded: Zero mm (Zero in)
Toe-in measurement steps:

• Place the Toe Measuring Gauge between the
inner sidewalls of the front tires approxi
mately 2-1/ 4 in (60 mm) behind the face of
the front tire. The height indicator chains
should just touch the floor evenly on each
side.
~ Toe Measuring Gauge:

~- YC--39526
• Zero the scale on the gauge by sliding the

moveable scale so the pointer is at 0.
• With gauge in place, roll the car forward 1/2
turn of the wheels. The height indicator
chains should again just touch the floor.
NOTE:-----------------------
Move the car by pushing from the rear, or
.....__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
v--104_ , pulling directly on the front bumper. Make sure
the front of the car is not lifted or pushed down,
which would cause an inaccurate measure
ment.
• Read the toe-in measurement on the gauge

scale.
2-33
CHASSIS 1~8!IPJJI
Toe-in adjustment steps:
• Jack-up the front of the vehicle. Apply park-
ing brake.
• Loosen the locknuts (D.
• Adjust the toe-in by turning the tie rods®.
To Reduce -+ Turn the tie rods ® to make

their lengths longer (more toe-
in).
To Increase -+ Turn the tie rods ® to make
their lengths shorter (less toe-
in).
NOTE:
• When loosening or tightening the locknuts
CD. hold the tie-rod at a flat section ®with a
wrench.
• The length of the threads @ of both rod
ends must be same.
• Tighten the locknuts.
I~
Rod End Locknut:
43 Nm (4.3 m • kg, 31 ft • lb)
• Place the vehicle back on the ground .

• Compress the suspension by pushing down
on the front bumper.
4. Recheck:
• Toe-in
Out of specification -+ Repeat adjustment
steps.
2-34
____________________________c_H_As_s_ls_l~~fl~l
TIRE AND WHEEL INSPECTION
1. Measure:
• Air pressure
Out of specification -+Adjust.
Tire Pressure: (Front and Rear)

FOR G14-A:
108kPa (1 .1 kg/cm2, 16psi)
FORG14-E:
Y-142 137 kPa (1.4 kg/cm2, 20 psi)
2. Inspect:
• Tire surfaces
Wear/Damage/Cracks/Imbedded objects
-+Replace.
• Wheels
Damage/Bends-+ Replace.
Never attempt even small repairs to the
wheel.
3. Measure:
• Tire tread depth ®
Minimum Tire Tread Depth ®:

(Front and rear)
1.0 mm (0.04 in)
Y-143
FRONT WHEEL BEARING INSPECTION

1. Apply parking brake. Jack up the front of the
car.
2. Spin the wheel by hand. Touch the knuckle or
kingpin CD while spinning the wheel.
Excessive vibration -+ Replace bearings.
Refer to CHAPTER 3 "FRONT WHEEL" sec
tion.
2-35
____________________________c_H_A_ss_l_sl~~fl~l
REAR AXLE BEARING INSPECllON
1. Apply the parking brake, loosen the rear
wheel nuts.
2. Block the front wheels. Jack up the rear of the
car.
3. Remove:
• Rear wheels
• Brake drums
4. Turn CD the rear axle slowly by hand.

Roughness --. Replace bearing.
5. Gently rock ® the rear axle up and down.
Noticeable free play --. Replace bearing/
Replace axle (G14-A). Refer to CHAPTER 3
"REAR AXLE WHEEL" section.
SHOCK ABSORBER INSPECTION

1. Inspect:
• Oil leakage
Oil leaks --. Replace shock absorber.
• Coil spring
Fatigue/Cracks/Damage --. Replace shock
absorber.
Refer to CHAPTER 3 uFRONT SUSPEN
SION " and "REAR SUSPENSIONn section.
Pivot Bolt-Nut:
(Upper and Lower)
32 Nm (3.2 m • kg, 23 ft • lb)
2-36
ELECTRICAL (FOR G14-Al ~~~.rl~~~al
ELECTRICAL (FOR G14-A)
SPARK PLUG INSPECTION
1. Remove:
• Remove:
• Spark plug
2. Inspect:
• Spark plug type
Incorrect--. Replace.
Standard Spark Plug:

BPR2ES or BPR4ES
3. Inspect:
• Electrode CD
Wear/Damage--. Replace.
• Insulator®
Abnormal color--. Replace.
Normal color is a medium-to-light tan
color.
4. Replace spark plug if cleaning appears neces
sary.
5. Measure:
• Plug gap@
Use a Wire Gauge or Feeler Gauge.
Out of specification --. Regap.
Spark Plug Gap:

0.7 .. 0.8 mm (0.028- 0.031 in)
6. Tighten:
• Spark Plug
Spark Plug:
20 Nm (2.0 m • kg, 14ft •lb)
A WARNING
When removing or installing the spark plug, be
careful not to damage the insulator. A damaged
insulator could allow external sparks, which
could lead to explosion or fire.
NOTE:------------------------
• Before installing a spark plug, clean the gasket
and mating plug surface.
• Finger-tighten the spark plug before tightening
at the specified torque.
2-37
ELECTRICAL (FOR G14-A) I~Jf 1&1
STARTER BELT INSPECTION
1. Disconnect:
• Rubber joint from carburetor
• Corrugated air intake hose
• Crankcase breather hose
2. Remove:
• Holding bolts CD
• Air cleaner case
3. Inspect:
• Starter belt
Wear/Cracks/Damage - Replace.
4. Check:
• Belt tension
Out of specification -Adjust.
Use a belt tension indicator (e.g., Gates
'Krikit' or equivalent), or depress the center
of the belt with a finger.
Starter Belt Tension @:

8 ... 12 mm/10 kg
(0.31 ... 0.47 in/22 lbl
Y-105
Belt tension adjustment steps:

• Loosen the nut G).
• Loosen the belt tension bolt ® .
• Adjust the tension by swinging the starter
@.
• Tighten the tension bolt® first, then tighten
the nut G).
I~
Y-241 Belt Tension Bolt-Nut®:
14 Nm (1.4 m • kg, 10ft • lb)
Holding Bolt-Nut CD
53 Nm (5.3 m • kg, 38 ft • lb)
NOTE=------------------------
If the specified value can not be obtained with the
tension adjusting position at the maximum,
replace the belt.
2-38
-------------------------------------------------IA
INDSJPI~I ~
BATTERY INSPECTION
A WARNING
Battery electrolyte is dangerous; it contains sul
furic acid and is therefore poisonous and highly
caustic.
Always follow these precautionary measures:
• Avoid bodily contact with electrolyte as it can
cause severe burns or permanent eye injury.
Y-144
• Wear protective eye gear when handling or
working near batteries.
Antidote (EXTERNAL):
• SKIN - flush with water.
• EYES - flush with water for 15 minutes and
get immediate medical attention.
Antidote (INTERNAL):
• Drink large quantities of water or milk, follow
with milk of magnesia, beaten egg, or veg
etable oil. Get immediate medical attention.
Batteries also generate explosive hydrogen gas.
Therefore you should always follow these pre
cautionary measures:
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks, or open
flames (e.g., welding equipment, lighted ciga
rettes, etc.)
• DO NOT SMOKE when charging or handling
batteries.
KEEP BATTERIES AND ELECTROLYTE OUT OF
REACH OF CHILDREN.
1. Inspect:
• Battery case
Cracks/Damage- Replace.
• Battery hold-down bracket
Loose -Tighten.
• Dirty - Clean with wire brush or solution of
baking soda and water.
Poor connection - Correct.
NOTE:-------------------------
After cleaning the terminals, apply grease lightly
to the terminal posts.
Replace the battery if:

• Battery v oltage will not rise to manufactur
er's specified value. (Usually a stabilized
open circuit voltage of 12.4 volts).
• Battery case or terminals are damaged.
2-39
--------------------------------------------------------
IA
INDSJPI~I ~
BATTERY CHARGING
A WARNING
Follow charger manufacturer's instructions when
charging batteries. Never use a charger without
these instructions.
~~::tHIIII.tl:l~tli~~ - - - - - -
If maintenance-free batteries are charged at
ampere rates or periods of time greater than
those specified by the manufacturer, the life of
the battery may be shortened.
• Charge battery following manufacturer's

instructions on the charger.
A WARNING
Always tum the charger to the "'OFF" position
before connecting the leads to the battery.
NOTE:-----------------------
Periodic charging is necessary during extended
storage.
2-40
ELECTRICAL {FOR G14-E) I~J>JI~J~~al
ELECTRICAL (FOR G14-E)
BATTERY CHARGING
The batteries must be charged properly before
using for the first time. This initial charge will pro
long the life of the batteries.
~~j~M~~IIDB.II~l1~:~~ - - - - - - -
To insure maximum battery performance be sure
to:
• Charge a new battery before use.
• Maintain proper electrolyte level.
Be especially careful not to overfill the batter
ies, or allow the electrolyte level to drop
below the top of the plates.
• Do not overcharge the batteries.
Failure to observe these points will result in a
shortened battery life.
NOTE:-----------------------
storage.
Battery charging steps:

• Before charging: only add distilled water if
fluid is below the top of the plates, and then
add just enough to cover plates.
• After charging: check that the fluid level is
approximately 1/ 4 to 1/ 2 inch above the
plates. If the fluid level is low, carefully add
distilled water. Adding distilled water after
charging prevents boil over.
• Add only distilled water after a battery has
been placed in service, never add more acid
to battery.
A WARNING
Battery electrolyte is dangerous; it contains
sulfuric acid and is therefore poisonous and
Y·145 highly caustic.
• Avoid bo'dily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
2-41
ELECTRICAL (FOR G14-El (~.rlwl
• Wear protective eye gear when handling or
• SKIN- Flush with water.
• EYES - Flush with water for 15 minutes and
• Drink large quantities of water or milk, fol
low with milk of magnesia, beaten egg, or
vegetable oil. Get immediate medical atten
tion.
Batteries also generate explosive hydrogen
gas. Therefore you should always follow these
precautionary measures:
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment, light
ed cigarettes, etc.)
batteries.
REACH OF CHILDREN.
The following is a summary of the charging

steps. Do not attempt to recharge the golf car's
batteries without thoroughly reading and
understanding the owner's manual provided
with your charger.
• Turn the main switch to the OFF position.
• With the charger properly connected and
grounded (see charger's owner's manual),
insert the DC output plug into the golf car
receptacle.
• Monitor the ammeter on the charger accord
ing to instructions found in the charger' s
owner's manual.
• The charger will turn off automatically when
Y-146
the batteries reach full charge.
A WARNING
Do not unplug the charger from the receptacle
of the car until the charger is turned off.
Unplugging an operating charger will cause
sparks which could ignite explosive gases.
• After the charger has turned off, disconnect

the DC output plug from the golf car recepta
cle by grasping the plug body and pulling
the plug straight out of the receptacle.
2-42
ELECTRICAL (FOR G14-El I~Jfl&]
• Check the specific gravity of each cell with a
hydrometer. If the hydrometer reading is
below the specification, additional charging
is necessary.
Temperature Satisfactory Uncorrected

Of oc Hydrometer Reading
120 48.9 1.244
110 43.3 1.248
100 37.8 1.252
90 32.2 1.256
80 26.7 1.260
70 21.1 1.264
60 15.6 1.268
50 10.0 1.272
40 4.4 1.276
30 -1 .1 1.280
• Install the filler caps, and thoroughly wipe

off the fluid around the filler caps.
Preferable charging:
• For the first ten rounds, new batteries
should go only 18 holes between charges.
• A 20 minute charge between rounds helps
extend battery life.
• Organize and store the cars so that they can
be used equally.
• The batteries should be charged every day if
used. If they are not used and checking
shows that catch-up charging is not
required, they should not be charged.
2-43 (6-99)
IINDSJPI~I
A
--------------------------------------------
~
BATTERY INSPECTION
1. Remove:
• Battery leads
• Batteries
A WARNING
• Always disconnect the negative lead CD first.
• Insulate wrenches with tape to avoid short cir
cuiting of the batteries.
®To solenoid relay.
2. Wash the battery tops, sides, and surround

ing area with baking soda dissolved in water.
Be careful not to get this solution into the bat
teries. After drying, coat the battery tops with
a earwax.
3. Inspect:
• Lead terminals
• Battery terminals
Corrosion --t Clean.
Terminal cleaning steps:

• Spray the terminals with a baking soda and
water mixture, then allow a few minutes for the
solution to work.
• Rinse with low pressure water
• Allow terminals to dry and coat with anti-corro
sion spray.
4. Inspect:
• Hold-downs
Use a wire brush.
Corrosion --t Clean/Replace.
After cleaning , rinse with water. Then
repaint with a corrosion resistant paint.
2-44 (Rev. 6/99)

-------------------------------------------------- IA
INDSJPI~I ~
5. Check:
• Electrolyte level@
Below level -+ Add distilled water after charging.
@ Proper fill level - DO NOT OVER FILL!
CD Level indicator
®Cap
@ Plate
6. Inspect:
• Cap vent
Contamination -+ Clean.
7. Measure:
• Specific gravity
Use a Hydrometer.
Less than 1.260-+ Charge battery.
Refer to " BATIERY CHARGING" section.
Hydrometer:
YU-03036, 9089()...()3036
8. Install the battery trays in place as shown.
D D
D
9. Install:
• Batteries
Battery Holder:
2 Nm (0.2 m • kg, 1.4 ft •lb)
Y· 147
2-45 (Rev. 6/99)

ELECTRICAL (FOR G14-E) _
10. Connect:
1 ~8fl~l _~ _
• Battery leads
See illustration
CD Forward
@To relay
®To controller
® Between batteries
Y-152
Terminal Nut:
6 Nm (0.6 m • kg, 4.3 ft • lb)
A WARNING
Connect the negative lead ® last.
Using a wire brush, clean both the contact sur

face of the battery terminal and lead clamp until
both have a bright metallic shine for good electri
cal contact.
Apply specially treated felt washers, an anti
corosion spray, or grease, to prevent corrosion.
®To solenoid relay
CHARGE RECEPTACLE INSPECTION

1. Inspect
• Receptacle contacts
Damage/Loose/Burned -+ Replace recepta
cle.
A WARNING
Damaged receptacle contacts can cause exces
sive resistance (heat) and lead to fire.
2-46
Design a schedule that allows discharge testing
A WARNING on one car per day or at least every other day.
Batteries also generate explosive hydrogen Follow your plan faithfully. Test each car once
gas. Therefore you should always follow these the first year and twice each succeeding year. If
precautionary measures: your course exceeds the national average of
250 rounds each year then your discharge test
• Charge batteries in a well-ventilated area. ing schedule must be increased accordingly.
• Keep batteries away from fire, sparks, or Consult your Yamaha service representative for
open flames (e.g., welding equipment, light help with schedule adjustments. If you start out
discharge testing an older fleet with suspicious
batteries then at least 10% (i.e. 10 cars out of
• DO NOT SMOKE when charging or handling 100) should be tested. These results will give
batteries. you a feel for your replacement battery needs.
Obtain a good quality discharge tester such as
REACH OF CHILDREN. the Lester 17770. Carefully follow the procedure
found in the Section 3 "Step by Step" Testing.
1. Battery Discharge Testing- Why
Remember that seventy minutes is the industry
The purpose of the discharge load test is to standard considered adequate for 36 holes of
determine how many minutes it will take to play but as cars enter their third and fourth
bring the total voltage of a freshly charged 48 years of service, it is normal for a few batteries
or 36 volt battery pack to 42 or 31.5 volts to fail. Widespread failures or lack of 36-hole
performance in the second year is not normal.
respectively. This test represents the maxi
mum work or run time capability of a 48-volt Ambient temperature has an effect on dis
battery pack at 80°F to fall to 42 volts. A good charge times. When temperatures are low, dis
set of 36-volt batteries should also take charge times decrease. The chart on page 2-49
approximately 70 minutes to drop to 31 .5 is helpful in predicting the effects of tempera
volts. Seventy minutes should deliver 36 ture on discharge testing.
holes of golf for most courses. A shorter time
period will indicate that one or more batteries Be sure that you do the loaded individual bat
need service or replacement. tery measurements with the battery pack fully
charged to 42 (48-volt) or 31.5 (36-volt). If you
When you are load testing, you will need a do not do this part of the test immediately after
the tester shuts off, the batteries will "recover"
load tester and a high quality digital volt
as they sit. Recovered batteries will give false
meter capable of reading at least 55 volts DC. readings. If more than a few minutes elapse
Use the voltmeter to monitor the overall volt before you do individual battery measure
age decrease of the pack and the decreasing ments, turn the discharge tester back on. Allow
voltage of each individual battery during test the tester to run until the total battery pack volt
ing. Individual batteries that decrease at a age is again approaching the shut off point
faster rate are the weaker ones. Note the (31.5 volts for 36-volt cars and 42 volts for 48-
weak batteries. The weaker batteries will volt cars). This will prevent a false "good" volt
require careful measurement after the dis age measurement from a recovered battery. Be
charge tester shuts off. Once the weaker bat certain you understand this paragraph before
teries are identified they need to be replaced you turn your discharge tester on for the first
time. You cannot achieve accurate results with
with ones of comparable age and strength of
out a complete understanding of the testing
the remaining pack. process.
2. Battery Discharge Testing - Things to Be 3. Battery Disc.h arge Testing "Step by Step"
Aware Of
Before you start testing do the following prelim
Non-functioning chargers (or just unplugged inary checks.
chargers) can create frustrating problems,
especially if cars are not returned to the a. Fully charge the batteries (a full
same charger every night. Look for tripped charger cycle).
circuit breakers, damaged cords and plugs. b. Inspect all cables and connections.
c. Check the water level in each cell
Battery problems may be charger induced.
and add water as necessary.
2-47 (Rev. 6/99)

d. Start the charger and let it finish 1. Record surface voltage from the discharge
charging again. tester readout panel. Record the ambient
e. Let the batteries cool for 5 minutes. temperature.
2. Turn on the discharge tester. Wait at least
A WARNING 3 minutes. If you have a bad connection
(or reverse polarity) the tester will shut off
Batteries also generate explosive hydrogen in 3 minutes. Correct any problems.
gas. Therefore you should always follow these 3. Let the tester run until it shuts off and
precautionary measures: immediately record the surface voltage
• Charge batteries in a well-ventilated area. from the discharge tester readout. Restart
• Keep batteries away from fire, sparks, or the charger and let it run until the voltage
reaches 42 volts (48-volt car) or 31.5 volts
(36-volt car).
ed cigarettes, etc.) 4. While the tester is still connected measure
• DO NOT SMOKE when charging or handling and record each individual battery voltage.
batteries. Look over the voltage measurements you
KEEP BATTERIES AND ELECTROLYTE OUT OF just recorded. A difference of 0.5 volts
REACH OF CHILDREN. from the highest to lowest measurement
indicates a weak battery.
5. Turn off the discharge tester. Wait until
The following instructions are specifically for the fan stops and then disconnect the bat
the Lester 17770 Discharge Tester. You will tery leads.
need a thermometer, discharge tester and a
digital voltmeter for the following tests. Attach
the discharge tester, be sure to observe polari H the fan is running and you disconnect the unit
ty. Heavily coated battery terminals may not
provide good electrical connections. Clean if a spark will be produced. The chart on 2-50 is a
necessary. handy place to record your measurements.
2-48 (Rev. 6/99)

1 mrl~l
1
DISCHARGE MINUTES ADJUSTED FOR TEMPERATURE
Temperature (F 0 )
80 30
105 105
100 103 107
95 98 101 105
90 93 96 100 103 107
85 88 91 94 97 101 105
80 83 85 88 92 95 99 103
75 77 80 83 86 89 93 97 101 105
C/)
C1l
70 72 75 77 80 83 87 90 94 98 103
'5
c: 65 67 69 72 75 77 80 84 87 91 96
~
60 62 64 66 69 71 74 77 81 84 88
55 57 59 61 63 65 68 71 74 77 81
50 52 53 55 57 60 62 64 67 70 74
45 46 48 50 52 54 56 58 60 63 66
40 41 43 44 46 48 50 52 54 56 59
35 36 37 39 40 42 43 45 47 49 51
30 31 32 33 34 36 37 39 40 42 44
25 26 27 28 29 30 31 32 34 35 37
20 21 21 22 23 24 25 26 27 28 29
15 15 16 17 17 18 19 19 20 21 22
10 10 10 11 11 11 12 12 13 13 14 15
ADJUSTED DISCHARGE DISCHARGE MINUTES

MINUTES = 1-(((80-TEMP) /100)*.64)
2-49 (Rev. 6/99)

BATTERY DISCHARGE CHART
CAR# DATE I I
Record Battery Voltage For

Each Battery In The Blank
r--1-._-A-,___...v
( Tester Ran Minutes )
CAR# DATE I I
F~O/VT

CAR# DATE I I

r-~-'A'J!,..-----...Y
• Record test results Including Individual battery voltages imme(liately after discharge test.
Restart the Discharge Tester aft~n it reaches 42 volts or 31.5 volts (48 V car or 36 V car)
immediately measure and record each battery's voltage_in the boxes provided above.
2-50 (Rev. 6/99)

CHAPTER 3
CHASSIS
FRONT AND REAR BUMPER .......................... 3-1 ACCELERATOR PEDAL.. ...................................3-30

REMOVAL ................................................... 3-1 FOR G 14-A ..................................................3-30
INSTALLATION .......................................... 3-1 FOR G14-E ...................................................3-31
BUMPERS .....................................................3-2
STEERING SYSTEM ..........................................3-32
SEAT ................................................................ 3-3 REMOVAL ................................................... 3-33
REMOVAL ................................................... 3-3 DISASSEMBLY ...........................................3-34
INSTALLATION .......................................... 3-3 INSPECTION ...............................................3-34
ASSEMBLY .................................................3-36
FRONT COWLING ............................................ 3-5 INSTALLATION ...........................................3-36
REMOVAL ................................................... 3-5
INSTALLATION .......................................... 3-6 FRONT SUSPENSION .......................................3-39
FRONT COWLING ...................................... 3-7 REMOVAL ...................................................3-40
INSPECTION ...............................................3-42
REAR COWLING ............................................... 3-8 INSTALLATION ...........................................3-42
REMOVAL ................................................... 3-8
INSTALLATION .......................................... 3-9 REAR ARM SUSPENSION ................................ 3-44
REAR COWLING FOR G14-A .....................3-10 FOR G14-A ..................................................3-44
REAR COWLING FOR G14-E .....................3-11 FOR G 14-E ...................................................3-45
REMOVAL ...................................................3-46
FRONT WHEEL ............................................... 3-12 INSPECTION ...............................................3-47
REMOVAL ................................................. 3-13 INSTALLATION ...........................................3-47
INSPECTION ............................................. 3-14
INSTALLATION ........................................ 3-15 CABLE MAINTENANCE ....................................3-48
REAR AXLE WHEEL FOR G14-A ......................3-16 FRAME ................................................................3-50

REMOVAL ................................................. 3-17 FOR G14-A ..................................................3-50
INSPECTION ............................................. 3-17 FOR G 14-E ...................................................3-51
INSTALLATION ........................................ 3-18
REAR AXLE WHEEL FOR G14-E ......................3-20

REMOVAL ...................................................3-21
INSPECTION ...............................................3-22
INSTALLATION ...........................................3-22
BRAKE ................................................................3-23
BRAKE PEDAL ...................................................3-24
DISASSEMBLY ...........................................3-25
INSPECTION ...............................................3-26
ASSEMBLY .................................................3-27
FRONT AND REAR BUMPER lcHASI~l
CHASSIS
FRONT AND REAR BUMPER
REMOVAL
1. Remove:
• Bolts
• Front bumper
• Cage nuts
2. Remove:
• Bolts
• Rear bumper
INSTALLATION
1.1nstall:
• Front bumper
Reverse the "REMOVAL" procedures.
Tightening torque:
23 Nm {2.3 m • kg, 17ft • lb)
2.1nstall:
• Rear bumper
Tightening torque:
64 Nm {6.4 m • kg, 46 ft • lb)
3-1
FRONT AND REAR BUMPER ICHAS~~~
BUMPERS
CD Front bumper
® Front bumper stay
® Rear bumper
@ Rear bumper stay
I
I
~
164 Nm (6.4 m • kg, 46ft • Ib) I
3-2
SEAT
REMOVAL
1. Remove:
• Seat
• Rear access panel
Y·246
2. Remove:
• Bolts
• Seat back support
Y·247
INSTALLATION
1 . Install:
Tightening torque:
30 Nm (3.0 m • kg, 22 ft • lb)
Y·248
2. 1nstall:
• Seat
3-3
SEAT
CD Seat (J) Seat retainer
®Back seat @ Tapping screw
@Arm rest ® Self-JoekIn. g nut
@ Seat back support @ Silencer pad
@Seat hinge 2 ® Seat hinge 1
® Seat back cover
3-4
BODY COWLING lcHAS~~~
FRONT COWLING
REMOVAL
1. Remove:
• Screws
• Emblem
Y-249
2. Remove:
• Screws
• Plate
Tightening Torque:
7 Nm (0.7 m • kg, 5.0 ft • lb)
Y-250
3. Remove:
• Nuts
• Washers
Tightening Torque:
2 Nm (0.2 m • kg, 1 ft • lb)
Y-251
4. Remove:
• Front cowling with trim
NOTE:-----------------------
Use care not to pull rubber trim off of the plates it
is mounted to.
Front Storage Panel Removal

1. Remove:
• Scorecard holder
• Steering wheel nut
• Washer
• Steering wheel
NOTE:----------------------
The scorecard holder is removed by pressing its
mounting pins from the back of the steering
wheel.
3-5
FRONT cowuNG lcHAsl~l
2. Remove:
• Cap nuts that hold front storage panel
in place.
Tightening Torque:
8 Nm (0.8 m • kg, 5.8 ft • lb)
3. Remove:
• Rivets
• Floor mat CD
NOTE:-----------------------
Remove plastic rivets by depressing the pin in the
center of the rivet with a punch or small screw
driver.
Y-252 Y-253
4. Disconnect:
• Main switch lead
• Oil warning lamp lead (G14-A)
5. Remove:
• Screws
• Beverage holder
Y-413 Y-254
6. Remove:
• Front storage
INSTALLATION
Reverse the "REMOVAL" procedure.
Steering Wheel Nut Tightening

Torque:
39 Nm (3.9 m • kg, 28 ft • lb)
3-6
FRONT COWLING jcHAS~~~
FRONT COWLING
CD Front cowling (J) Tapping screw
® Front panel @ Beverage holder
@ Body protect plate ®Hole cover
@Plate @)Warning label
® Holder housing ®Protector
@ Protector cap @ Body protect plate
@ Protector 1
3-7
REAR COWLING ICHAS~~~
REAR COWLING
REMOVAL
1. Remove:
• Seat
2. Disconnect
• Corrugated hose G) to air filter (G 14-A)
• Choke cable (G14-A)
3. Remove:
• Hairpin clip G)
from handle shaft behind handle
• Shift handle ®
• Bolts @
• Hinges @
• Screws @
Y·258
Rear Floor Cover Removal
1. Remove:
• Rivets
• Screws
• Rear floor cover
Y·259
3-8
4. Remove:
• Rear cowling
INSTALLATION
3-9
REAR COWLING FOR G14-A
G) Rear cowling @ Access panel
® Rear floor cover (J) Protector
®Blind rivet @Spring nut
@)Screw @ Hex head socket bolt
®Silencer pads @)Floor mat
®Screw, with washers
A USE NEW RIVETS
3-10
REAR COWLING FOR G14-E
<D Rear cowling
® Rear floor cover
@ Access panel
@ Blind rivet
@ Spring nuts
@Screw
(f) Receptacle guide
@ Blind rivet
® Screw, with washers
3-11
_____________ FR_o_N_r_w_H_E_E_L~H~~~
FRONT WHEEL
(!)Wheel nut A TIRE SIZE: 18 x 8.50-8.00/4PR E RIM SIZE: 7.00-1-8.00
®Dust cover
TIRE TYPE: F WHEEL ALIGNMENT:
®Cotter pin
B TUBELESS (Sawtooth tread pattern) Toe-in
®Hub nut
@ Conical washer G Unloaded/Fully loaded:
® Hub bearing TIRE PRESSURE: 1 - 11 mm (0.04 - 0.43 in)/Zero mm (Zero in)
(j) Spacer For G14-A
Camber:
@Hub c 108 kPa (1.1 kg/cm2, 16 psi) H
Fully loaded: Zero deg (non-adjustable)
®Oil seal For G14-E
137 kPa (1.4 kg/cm 2, 20 psi) I Caster: 7 deg (non-adjustable)
@Knuckle
® Front wheel D WEAR LIMIT: 1.0 mm (0.04 in) J
King pin inclination:
3 deg (non-adjustable)
NOTE:----------------------
Camber is not adjustable, but is affected by toe-
in settings .
CD 88 Nm (8.8 m • kg, 64ft • lb)
3-12
_____________ F_~_N_T_w_H_E_E_L~~~~
REMOVAL
2. Apply parking brake.
3. Loosen:
• Nuts (Front wheel)
4. Jack up the front wheels by placing a suitable
stand under the frame.
5.Remove:
• Front wheel
6. Check:
• Movement (Wheel bearing)
Rotate the hub by hand.
Roughness -. Replace bearing.
7. Check:
• Free play (Wheel bearing)
Gently rock the hub back and forth.
Looseness/noticeable free play --. Retighten
the hub nut.
Still play -. Replace bearing.
Y·261
8.Remove:
• Dust cover CD
Y·262
3-13
9. Remove:
• Cotter pin
• Hub nut
• Conical washer
10.Remove:
• Hub (Front wheel)
Tap the hub out using a soft hammer.
INSPECTION
1.1nspect:
• Wheel
Cracks/Bends/Warpage -+ Replace.
2.1nspect:
• Wheel hub
Cracks/Damage -+ Replace.
3.1nspect: ·
• Bearings (Wheel hub) CD
Bearings allow play in the wheel hub or the
wheel turns roughly -+ Replace.
• Oil seal®
Wear/Damage -+ Replace .
3-14
_____________F_Ro_N_r_w_H_e_e_L~H~~~~
Wheel bearing and oil seal replacement steps:
• Clean the inside of the wheel hub.
• Remove the oil seal and the bearing using
a general bearing puller.
• Install the new bearing and oil seal by
reversing the previous steps.
NOTE:-----------------------
Use a socket CD that matches the outside
. diameter of the race of the bearing and oil

seal.
~~&~ J ________________
Do not strike the center race ® or balls @

of the bearing. Contact should be made only
with the outer race @ .
INSTALLATION
Note the following points.
1.1nstall:
• Hub CD
• Conical washer ®
• Hub nut@
NOTE:-------------------------
Install the conical washer® with the tapered side
facing inward.
Hub Nut@:
92 Nm 9.2 m • kg, 66 ft • lb)
2.1nstall:
• Cotter pin @(New)
• Dust cover
A WARNING
Always use a new cotter pin.
3.1nstall:
• Front wheel
Nut (Front Wheel):

88 Nm 8.8 m • kg, 64 ft • lb)
3-15
REAR AXLE WHEEL (G14-Al ICHAS~~~
REAR AXLE WHEEL (G14-A)
CD Rear axle A TIRE SIZE: 18 x 8.50-8.00/4PR E RIM SIZE: 7.00-1-8.00
®Axle housing right TIRE lYPE: F WHEEL ALIGNMENT:
B
® Axle housing left TUBELESS (Sawtooth tread pattern)
G Toe-in: Zero mm (Zero in)
®Brake drum TIRE PRESSURE:
@Axle bearing
c 108 kPa (1.1 kgf/cm 2, 16 psi) H Camber: Zero deg (non-adjustable)
@Bearing cover D WEAR LIMIT: 1.0mm (0.04 in) REAR AXLE RUNOUT:
I
Limit: 0.30 mm (0.012 in)
AXLE FLANGE DEFLECTION:
J
Limit: 0.15 mm (0.006 in)
90 Nm {9.0 m • kg, 65 ft • lb)
3-16
REAR AXLE WHEEL FOR G14-A ICHAS~~~
REMOVAL
2. Apply parking brake and block the front
wheels.
3. Loosen:
• Nuts {Rear wheel)
4. Jack up the rear wheels by placing a suitable
5. Remove:
• Nuts {Rear wheel)
• Rearwheel
accelerator pedal.
7. Remove:
• Brake drum G)
To loosen the drum, screw bolts® into the
drum as shown.
NOTE:-----------------------
adjusting nut@ in the shoe plate.
8. Remove:
• Cotter pin G)
• Clevis pin ®
• Brake cable
Y·265
9. Remove:
• Bolts {shoe plate)
Align the holes of the axle flange with the
bolts to loosen.
10. Remove: ·
• Rear axle
• Brake assembly
INSPECTION
1. Inspect:
• Wheel
• Cracks/Bends/Warpage ~ Replace.
3-17
REAR AXLE WHEEL FOR G14-A ICHAS~~~
2.1nspect:
• Axle bearing movement
Rotate bearing by finger.
Roughness/Wear--+ Replace rear axle.
NOTE:------------------------
The axle bearing cannot be removed from the
rear axle.
Y-268
3. Measure:
• Axle shaft runout
Use a centering device and the Dial Gauge.
Out of specification -> Replace.
Dial Gauge:
VU-03097, 90890-03097
r~
Al
Runout limit:
o.3o mm ,o.o12 in)
4. Measure:
• Axle flange deflection
Use a centering device and the Dial Gauge.
Dial Gauge:
VU-03097, 90890-03097
Deflection Limit:
0.15 mm (0.006 in)
INSTALLATION
1. Lubricate:
• Bearing outer surface
lightweight Lithium Soap

Base Grease
Y-268
3-18
REAR AXLE wHEEL FoR G14-A JcHAsi~J
2.1nstall:
• Rear axle
Bolts (Shoe Plate):

30 Nm (3.0 m • kg, 22ft • lb)
3.1nstall:
• Brake drum
• Rear wheel
Nut (Rear Wheel):

90 Nm (9.0 m • kg, 65ft •lb)
3-19
REAR AXLE WHEEL FOR G14-E lcHAS~~~
REAR AXLE WHEEL (G14-E)
CD Rear axle shaft A TIRE SIZE: 18 x 8.50-8.00/4PR F WHEEL A LIGNMENT:
®Brake drum TIRE TYPE: G Toe-in: Zero mm (Zero in)
B
@Bearing TUBELESS (Sawtooth) H Camber: Zero deg (non-adjustable)
® Rear axle hub c TIRE PRESSURE: REAR AXLE RUNOUT:
I
@ Circlip 137 kPa (1.4 kgf/20 psi) Limit: 0.30 mm (0.012 in)
D WEAR LIM IT: 1.0 mm (0.04 in) AXLE FLANGE DEFLECTION:
J
E RIM SIZE: 7.00-1-8.00 Limit: 0.15 mm (0.006 in)
11 15 Nm (11.5 m • kg, 85ft • lb) I
3-20 (Rev. 6/99)

REAR AXLE WHEEL FOR G14-E ICHAS~~~
REMOVAL
3. Loosen:
• Nuts (Rear wheel)
Block the front wheels.
5. Remove:
• Nuts (Rear wheel)
• Rear wheels
accelerator pedal.
7. Remove:
• Brake drum CD
To loosen the drum, screw bolts® into the
drum as shown.
NOTE:-----------------------
adjusting nut@ in the shoe plate.
8. Remove:
• Cotter pin CD
• Clevis pin ®
• Brake cable
9. Remove:
• Plastic hub cap CD
• Cotter pin ®
• Nut@
• Washer@
• Rear axle hub®
Y·269 Y·270
10. Remove:
• Bolts CD
• Brake assembly®
Y-271
3-21
BRAKE AXLE WHEEL FOR G14-E ICHAS~~~
11. Remove:
• Circlip CD
From axle housing
12. Remove:
• Rear axle shaft with bearing
NOTE:------------------------
To remove the rear axle shaft, first install the rear
axle hub and nut back onto the axle. Then
v-212 remove the axle shaft by tapping the back of the
hub with a soft hammer as shown.
INSPECTION
1. Inspect:
• Wheel
Cracks/Bends/Warpage -+ Replace.
2. Inspect:
• Axle bearing movement
Rotate bearing.
Y·273
Roughness/Wear -+ Replace.
NOTE:------------------------
To remove bearing from axle shaft, support the
inner race of the bearing on an arbor press, and
apply pressure to the threaded end of the axle
shaft.
3. Measure:
• Axle shaft runout
• Axle flange deflection
See instructions for G14-A axle on page
3-18.
INSTALLATION
Note the following points:
1. Lubricate
• Bearing outer surface

Base Grease
• Hub nut threads with an anti-seize lubri

Y·274
cant.
Rear hub nut G14-E

115 Nm (11 .5 m ·kg, 85ft ·lb)
3-22
BRAKE lcHASI~l
--------------------------------------------
BRAKE
CD Brake shoe plate BRAKE SHOE LINING THICKNESS:
® Brake shoes A Standard: 4.0 mm (0.16 in)
@Repair parts kit limit 0.75 mm (0.029 in)
®Oust cover BRAKE DRUM INSIDE DIAMETER:
@Bolt B Standard: 160 mm (6.30 in)
@Washer Limit: 161 mm (6.34 in)
30 Nm (3.0 m • kg, 22 ft • lb)
3-23
_____________ s_R_A_~_P_E_o_A_L§~~~
BRAKE PEDAL
CD Brake pedal
®Parking brake pedal
(j) Brake equalizer
® Brake cable
A I
BRAKE PEDAL FREE PLAY:
25- 30 mm (0.98- 1.18 in)
® Parking brake ratchet ®Brake arm
®Brake arm @Collar
® Parking brake rod (j}) Bushing
® Rachet stopper
48 Nm (4.8 m • kg, 35ft • lb)
3-24
~~~~~~~~~~~~-e_M_K_E~HA~~~
DISASSEMBLY
1.Remove:
• Rear wheel
• Brake drum
For G14-A: For G14-E:
• Rear axle • Rear axle hub
(through step 10 (th rough step 9 of
of Rear Axle Wheel Rear Axle Wheel
for G14-A for G14-E
Removal section.) Removal section.)
2. Hold the brake shoe plate using two shoe

plate bolts CD (G14-A).
NOTE:-----------------
Step 2 above is not necessary for G14-E. The
brake shoe plate for G 14-E remains in place after
the rear axle hub is removed.
3. Remove:
• Shoe clamp springs CD
While depressing the spring CD with a
spring removal tool or pliers, turn it to align
the spring slot with the pin head.
Y-276
4. Remove:
• Brake shoes (with tension springs)
5. Remove: ·
• Bolts CD
Y-277
3-25
___________sR_AK_e§~~~
INSPECTION
Brake Shoe and Brake Drum
Refer to CHAPTER 2 "SHOE LINING INSPEC
TION" section.
Right and left side brake shoe sets are not inter
changeable. If more than one set is to be
removed at a time, mark sets so they can be
installed in their original positions.
Brake Shoe Plate

1.1nspect:
• Brake shoe plate CD
Bends/Cracks/Damage - Replace.
2.1nspect:
• Dust cover ®
Cracks/Wear __. Replace.
3. Check:
• Lever holder
Unsmooth movement - Lubricate with
high temperature grease.
4. Turn the adjusting bolt @ in completely by
hand. Do not tighten it so that movement is
not free. This bolt must rotate freely.
NOTE=--------------
Lubricate the adjusting bolt with high tempera-
ture grease.
@
® Adjusting nut
3-26
BRAKE ICHAS~~~
-------------------------------------
Brake Pedal
1. Check:
• Pedal movement
• Side free play
Refer to CHAPTER 2 "BRAKE AND
ACCELERATOR PEDALS INSPECTION "
section.
2.1nspect:
• Parking brake ratchet CD
• Ratchet stopper ®
Wear/Damage--+ Replace.
ASSEMBLY
Reverse the " DISASSEMBLY" procedure.
Brake Shoe
1. Install:
• Shoe plate
• Brake shoes
Reused right and left side brake shoe sets must

be installed in their original positions {as marked
at removal).
Replacement right and left side brake shoe sets
are stamped "R.H. SIDE .. {passenger side) and
"LH. SIDE.. {driver side), respectively
Always replace the shoes as a set, and use care
to install shoe sets in their proper locations -
shoe sets are not interchangeable.
Brake shoe assembly steps:

• Apply a light coat of high temperature
grease to each end of both brake shoes.
A WARNING
Keep hands dean while handling brake shoes.
Be sure that no grease gets on the lining sur
face.
3-27
BRAKE ICHAS~~~
--------------------------------------------
• Hook the upper spring (larger) onto the
shoes.
• Install the shoes onto the shoe plate.
Align the shoe end with slot of the adjusting

bolt head.
• Install the clamp springs.

• Install the lower springs (smaller) onto the
shoes.
• Lightly polish the new lining surfaces with
emery cloth.
Y-281
3. Remove:
• Bolts <D (G14-A only)
NOTE:-----------------------
For G14-E, the shoe plate bolts can remain in
place while completing the rear wheel hub instal
lation.
4. Lubricate:
• Bearing outer surface (G14-A)

Base Grease
Y-268
3-28
___________ sR_A_~~~~~~
5. Install:
• Rear axle, G14--A/Rear wheel hub, G14-E
• Brake drum
• Rear wheel
Refer to "REAR AXLE WHEEL -INSTALLA
TION" section.
Bolt (Shoe Plate) G14-A:

30 Nm (3.0 m • kg, 22ft • lb)
6. Adjust:
• Freeplay (Brake cable)
Refer to CHAPTER 2 "BRAKE CABLE
INSPECTION" section.
Freeplay (Brake cable):

25 ... 30 mm (0.98 --1.18 in)
7 .Adjust:
• Free play (Release timing)
Refer to CHAPTER 2 "PARKING BRAKE
ADJUSTMENT" section.
Free Play (Release Timing):

1.0 mm (0.04 in}
8. Adjust:
• Parking rod length (Parking brake pedal) @
Parking Rod Length

148.5 :t 1 mm (5.85 :t 0.04 in}
' 1 mm-3mm@
Rod length adjustment step:
• Engage first notch of parking brake.
• Check clearance A
Y-106
~ ~<.1mm-3mm
• Adjust length of parking rod by loosening
the locknut and turning the adjuster nut as
required.
3-29 (Rev. 8/96)

ACCELERATOR PEDAL ICHAS~~~
ACCELERATOR PEDAL
FOR G14-A *ACCELERATOR PEDAL
CD Accelerator pedal @ Throttle cable POSITION ADJUSTING BOLT
® Pedal cover (J) Bushing HEIGHT@:
A
mmij~'
@ Pedal bracket · @ 0-ring 18.00-18.40 mm
@ Pedal shaft @Spring pin (0.708- 0.720 in)
@ Accelerator arm @l Tension spring
6
Apply adhesive
(TB-1747C/or equal)
8 Nm (0.8 m • kg, 5.8 ft • lb)
3-30 (Rev. 8/96)

ACCELERATOR PEDAL ICHAS~~~
FOR G14-E
CD Accelerator pedal (j) Spring pin *ACCELERATOR PEDAL
® Pedal cover @Tension spring POSITION ADJUSTING BOLT
@ Crank pedal lever ®Bushing HEIGHT@:
®Pedal bracket ®) 0-ring A
~~I (0.708- 0.720

@ Pedal shaft 18.00-18.40 mm
@Accelerator arm in)
7 Nm (0.7 m • kg, 5.1 ft • Ib) ~
8 Nm (0.8 m • kg, 5.8 ft • lb) 16 Nm (1.6 m • kg, 11 .6 ft • lb)
3-31 (Rev. 8/96)

STEERING SYSTEM ICHAS~~~
STEERING SYSTEM
CD Steering wheel (j) lie rod @Locknut
®Steering gearbox @Bearing @ Pitman shaft adjusting bolt
@Oil seal ® Steering shaft @ Gear box cover
@Idler arm ®Bearing @Gasket
® Lock washer @ Steering shaft adjusting bolt @Pitman arm
®lie rod end @ 0-ring
Lithium Soap base grease

A Steering gearbox
90 cc {3.17 Imp oz, 3.04 US oz)
15 Nm {1.5 m • kg, 11ft • lb)
32 Nm {3.2 m • kg, 23ft • Ib)
7 Nm {0.7 m • kg, 5. 1 ft • lb)
85 Nm (8.5 m • kg, 61 ft • lb)

\
~·
25 Nm (2.5 m • kg, 18ft • lb)
3-32 (Rev. 8/96)

REMOVAL
4.Remove:
• Scorecard holder
• Steering wheel nut
• Washer
• Steering wheel CD
NOTE:-----------------------
The score card holder is removed by pressing its
mounting pins from the back of the steering
wheel.
5.Remove:
• Cotter pin
• Locknut
• Tie rod CD
NOTE:-------------------------
using a 14 mm (0.6 in) wrench @.
6. Bend:
• Lock washer tab
7. Remove:
• Locknut@
• Lock washer@
8. Disconnect:
• Idler arm CD
From the pitman shaft @.
Use a two-jaw universal puller.
3-33
9. Remove:
• Bolts®
• Steering gearbox assembly (j)
DISASSEMBLY
1.Remove:
• Bolts CD
• Gearbox cover ®
• Gasket®
• Pitman arm <!)
• Locknut®
• Steering shaft adjusting bolt ®
(with 0-ring <D)
• Bearing (lower) ®
• Steering shaft ®
• Bearing (Upper) ®
INSPECTION
1.1nspect:
• Steering shaft bearings @ @
• Bearing outer races
Pitting/Damage_. Replace.
NOTE:-----------
Always replace the bearing and race as a set.
2.1nspect:
• Steering worm gear
Wear/Scratches/Damage -. Replace steer
ing shaft.
3.1nspect:
• Pitman arm pins
Wear/Damage -. Replace.
3-34
STEERING SYSTEM lcHAS~~~
4. Inspect:
• Upper bushing (not shown)
• Steering shaft®
• Wear/Damage -+ Replace.
5. Inspect:
• Pitman arm shaft @
Wear/Damage -+ Replace.
6.1nspect:
• Gasket@ (Gearbox cover@)
Cracks/Damage - Replace.
7. 1nspect:
• 0-ring <V (Locknut @)
8.1nspect:
• Rod end
Unsmooth movement CD - Replace.
Noticeable free play ®- Replace.
Bolt bent® --. Replace.
NOTE: ________________________
• When loosening or tightening the locknuts CD,
hold the tie-rod at a flat section ® with a
wrench.
• The length of the threads ® of both rod ends
must be same.
Locknut (Rod End):

42 Nm (4.2 m • kg, 30 ft • lb)
3-35 (Rev. 8/96)

ASSEMBLY
Reverse the "DISASSEMBLY" procedu re.
1. Lubricate:
• Bearings
• Worm gear
• Pitman arm shaft
• Oil sea l lip
• Upper bushing (not shown).
Uthium Soap Base Grease

Lightly Coat
2. 1nstall:
• Bea ring (Upper) CD
• Steering shaft ®
• Bearing (l ower)@
• A djusting bolt ®(with 0-ring @)
• Locknut®
NOTE=------------------------
Be sure that the bearings are installed in the
correct di rection (A] .
3. Add grease to the gearbox
Gearbox Grease:
Multi type grease
90 cc (3.17 Imp oz, 3.04 US oz)
4. 1nsta ll:
• Pitm an arm <D (with pins®)
• Gasket®
• Gearbox cover ®
• Bolts (Gea rbox cover) @
Bolt (Gearbox cover):

7 Nm (0.7 m • kg, 5.1 ft • lb)
INSTALLATION
Reverse the "REM OVAL" procedure.
Note t he following points.
1. Install:
• Steering gearbox assembly CD
• Bolts (Gearbox) ®
ont o the frame.
Bolt (Gearbox):
32 Nm (3.2 m • kg, 23 ft • lb)
3-36 (Rev. 8/96)

2_lnstall:
• Idler arm CD
onto the pitman arm shaft®-
NOTE=-------------------------
Aiign the LD. marks ® with the end of pitman
arm shaft, and idler arm.
3.1nstall:
• Lock washer @
• Locknut (Id ler arm) ®
Locknut (Idler Arm):
85 Nm (8.5 m • kg, 61 ft • lb)
4. Bend the lock washer tabs down tightly

against the nut flats.
5. Install:
• Tie rod
Nut (lie Rod End):

42 Nm (4.2 m • kg, 30ft • lb)
Y-282
6. Position the front wheels straight ahead.

7. Lightly grease the tapered portion and spline
of the steering shaft.
Lightweight Lithium Soap

Base Grease
3-37
8. Install:
• Steering wheel
• Washer
• Nut (Steering wheel)
Nut (Steering Wheel):

39 Nm (3.9 m • kg, 28ft •lb)
9. Adjust:
• Backlash (Worm gear-pitman pins)
Refer to CHAPTER 2 "STEERING INSPEC
TION - Steering Wheel Free Play Adjust
ment" section.
10.1nstall:
• Score card holder
11 . Adjust:
• •
I I
• Toe-in
Refer to CHAPTER 2 "WHEEL ALIGN
MENT" section.
Toe-in([§] -!All:
Unloaded:
1 - 11 mm (0.04 - 0.43 in)
Fully loaded: Zero mm (Zero in)
!Al Center-to-center at front side tire tread.

[§] Center-to-center at rear side tread.
3-38
FRONT SUSPENSION lcHAS~~~
FRONT SUSPENSION
CD Shock absorber assembly
® Front lower arm
®Bushing
@Bushing
@Kingpin
®Dust cover
(j) Spring pin
® Knuckle arm
®Knuckle
32 Nm (3.2 m • kg, 23ft • Ib)
48 Nm (4.8 m • kg, 35ft • Ib)
3-39
FRONT SUSPENSION ICHAS~~~
REMOVAL
3. Loosen:
5. Remove:
• Front wheel
Refer to "FRONT WHEEL - REMOVAL"
section. (Page 3-13)
6. Remove:
• Cotter pin
• Locknut
• Tie rod <D
From the knuckle arm.
NOTE:-----------------------
using a 14 mm (0.6 in) wrench®.
7. Remove:
• Shock absorbers <D
8. Check:
• Pivot bushings
Try to move the arm back and forth.
Noticeable free play • Replace pivot
bushings.
3·40
9. Remove:
• Spring pins
Use the Valve Guide Remover CD or drift
punch.
NOTE: -----------------------
Before removing the spring pins, remove a
knuckle arm bolt (knuckle side).
There are two spring pins. The inner pin
locks the outer and must be removed first.
Valve Guide Remover:

YM-4064-A, 90890-04064
® Inner pin
@Outer pin
10. Remove:
• Kingpin CD
• Knuckle
11. Check:
• Kingpin free play
Insert the kingpin CD into the bushings®
on t he lower arm, move the kingpin side
to side.
Excessive free play - Replace bushings @,
and/or kingpin G), or lower arm.
12. Remove: .
• Cotter pins
• Nuts
• Bolts <D
• Lowerarm
Y-283
3-41
INSPECTION
1.1nspect:
• Shock absorbers
Refer to CHAPTER 2 "SHOCK A BSOR
BER INSPECTION " section.
2. 1nspect:
• Lower arm
Bends/Damage -+ Replace.
A INCORRECT
3. 1nspect:
• Bushing (Lower arm pivot)
Wear/Damage -~ Replace.
Pivot bushing replacem ent steps:

• Remove the bushing using a hydra ulic
press CD.
• Inst all the new bushing.
NOTE=- - - - - - - - - - - -
Do not press the center collar and rubber of
the bushi ng. Contact should be made only
with the outer collar®.
4. 1nspect:
• Dust covers CD
• Bushings®
• Spring pi ns @
• Thrust washer@)
INSTALLATION
1. Install:
• Lowerarm
• Bolts <D
• Nuts
• Cotter pins (New)
Nut (Pivot bolt) G):

53 Nm (5.3 m • kg, 38 ft • lb)
Y·283
3-42
2. Lubricate:
• Kingpin
Lightweight Lithium Soap

Base Grease
3.1nstall:
• Knuckle
• Bolt (Knuckle arm)
• Shock absorber assembly
Nut (Shock Absorber Pivot):

32 Nm (3.2 m • kg, 23 ft • lb)
4.1nstall:
• Tie rod
• Front wheel
Nut (Tie Rod End):

42 Nm (4.2 m • kg, 30ft • lb)
Nut (Hub):
92 Nm (9.2 m • kg, 66ft • lb)
Nut (Front Wheel):
88 Nm (8.8 m • kg , 64ft • lb)
3-43
REAR ARM SUSPENSION ICHAS~~~
REAR ARM SUSPENSION
FOR G14-A
<D Shock absorber @ Inner panel
assembly <V Thrust cover
®Torsion bar @ Blind rivet
@Bushing @Bolt
@Rear arm @)Bushing
@ Inner panel ® Self-locking nut
32 Nm (3.2 m • kg, 23ft • lb)
3-44
REAR ARM SUSPENSION
FOR G14-E
<D Shock absorber assembl
®Torsion bar Y
®Bushing
®Rear arm
@Bolt
@Bushing
(J) Self-locking nut
32 Nm (3.2 m • kg, 23 ft • lb)
190 Nm (9.0 m • kg, 65 ft • lb) I
90 Nm (9·o m • kg, 65 ft • lb)
3-45
REMOVAL
Block the front wheels.
NOTE:-----------------------
When removing the shock absorbers, support the
rear arm with a jack.
3. Remove:
• Engine (For G14-A)
• Traction motor/rear axle assembly G14-E
• Transmission/rear axle assembly G14-A
Refer to CHAPTER 5 "ENGINE REMOVAL",
and CHAPTER 4 "TRANSMISSION" section.
4. Disconnect:
• Brake cables
5. Remove:
• Rear shock absorbers
6. Remove:
• Torsion bar bolt <D
• Rear arm pivot pin
• Rear arm
3-46
INSPECTION
1.1nspect:
• Shock absorbers
Refer to CHAPTER 2 "SHOCK ABSOR
BER INSPECTION" section.
2.1nspect:
• Rear arm
Bends/Damage --. Replace.
3.1nspect:
• Bushing (Rear arm pivot)
Refer to "FRONT SUSPENSION - INSPEC
TION" section. (Page 3-39)
4. Inspect:
• Torsion bar
Damage/Bends --. Replace.
• Torsion bar bushings
Damage/Wear--. Replace.
INSTALLATION
1. Install:
• Rear arm
• Transmission/rear axle assembly G14-A
• Engine (For G14-A)
• Traction motor/rear axle assembly G14-E
• Brake cables
• Torsion bar
Nut (Rear Arm Pivot):

90 Nm (9.0 m • kg, 65 ft • lb)
Bott ... Rear axle assembly to rear arm
64 Nm (6.4 m • kg, 46 ft • lb)
Bott ... Transmission case to rear arm
G14-A
23 Nm (2.3 m • kg, 17 ft • lb)
Nut ... Engine mount G14-A
35 Nm (3.5 m • kg, 25 ft • lb)
Nut .... Shock absorber pivot
32 Nm (3.2 m • kg, 23 ft • lb)
3-47
CABLE MAINTENANCE lcHAS~~~
CABLE MAINTENANCE
NOTE:------------------------
Cables must be kept properly lubricated to pre-
vent deterioration.
A WARNING
Improperly routed or adjusted cables may make
the golf car unsafe. Before connecting cables,
consult ·cABLE ROUTING" in Chapter 9 for
proper routing.
1. Disconnect clevis attachments by removing:

• Cotter pin CD
• Clevis pin ®
• Retaining clip®
Y-1 07
2. Disconnect pin attachments by disconnect

ing:
• Clevis end of cable
Turn cable so it aligns with slot and pull
upward.
3. Remove:
• Cables
From the clamps and bands.
Y· 108 4. Check:
• Cable free movement
Inspect for obstructions, wear, or damage.
Kinking/Frayed strands/Damage -+ Replace.
3-48
CABLE MAINTENANCE (CHASj~l
5. Lubricate:
• Cables
Use the Cable Injector.
Cable Injector:
ACC-11110-43-15, 90890-70054
NOTE=-------------------------
Choice of lubricant depends upon conditions
and preferences. The use of a semi-drying chain
and cable lubricant will perform adequately
under most conditions.
6. Install:
• Cables
Reverse the removal procedure.
7. Adjust:
• Free play (Brake cable}
• Free play (Throttle cable 1, 2} (For G 14-A)
• Free play (Choke cable) (For G14-A)
Refer to CHAPTER 2 "BRAKE CABLE
INSPECTION," " THROTTLE CABLE AD
JUSTMENT" and " CHOKE CABLE AD
JUSTMENT" section .
Free play (Brake Cable):

25 .. 30 mm (0.98 .. 1.18 in)
0.2 - 0.5 mm (0.008 - 0.020 in)
0.5 mm (0.02 in)
Free Play (Choke Cable):
1.0 mm (0.04 in)
3-49
~~;A;M;E------------~F~R~A~M~E(~H~~~~
FORG14-A .
CD Frame
®Bodym ounttng
· support
® Body protect plate
@Plate
16Nm(1 .6m•kg,12ft•lb)
j7 Nm (0.7 m • kg, 5.1 ft • lb) L

3-50
~FR~A;M;-e--------------------~FR~A~M~EicHAsl~l
FOR G14-E - .
CD Frame
®Bodymo
. · support
untmg
® Bhnd rivet
3-51
POWER TRAIN lpWR~
CHAPTER 4
POWER TRAIN
POWER TRAIN FORG14-A

PRIMARY SHEAVE .......................................... 4-1
REMOVAL ................................................... 4-2
DISASSEMBLY ........................................... 4-2
INSPECTION ............................................... 4-3
ASS EM BLY ................................................. 4-3
INSTALLATION .......................................... 4-4
SECONDARY SHEAVE ................................... .4-6

DISASSEMBLY ........................................... 4-7
INSPECTION ............................................... 4-8
ASSEMBLY ................................................. 4-8
DRIVE V -BELT ................................................ 4-10

INSPECTION AND REPLACEMENT ........ 4-10
TRANSMISSION ............................................ 4-11

REMOVAL ................................................. 4-12
DISASSEMBLY ......................................... 4-13
INSPECTION ............................................. 4-14
ASSEMBLY ............................................... 4-15
INSTALLATION ........................................ 4-16
POWER TRAIN FOR G14-E

TRANSMISSION ............................................ 4- 18
REMOVAL ................................................. 4-19
DISASSEMBLY ......................................... 4-19
INSPECTION ............................................. 4-21
ASSEMB LY ............................................... 4-21
INSTALLATION ........................................ 4-22
POWER TRAIN FOR G14-A IP<f':R~I
POWER TRAIN
POWER TRAIN FOR G14-A
PRIMARY SHEAVE
CDFixed sheave CD Weight assembly @Slider
®Drive belt ® Plastic washer (thin washer) @ Pivot pin (Sliding sheave)
@ Sliding sheave ® Plastic washer (thick washer) ® Pivot pin screw
® Grease nipple ®Sheave cap
@Oil seal @Securing bolt
®Spider @ Pivot pin (Spider)
DRIVE BELT WIDTH:
~
NEW:
31 mm (1.22 in.)
·-~---
A
WEAR LIMIT: . .
27 mm (1.06 in.) \.~
/. -·J
1~--------------~-----
85 Nm (8.5 m • kg, 61 ft • lb) I
II
~~ l 4 Nm (0.4 m • kg, 2.9 ft • Ib) I

(il~ ...........
4-1
POWER TRAIN FOR G14-A I~RI®I!01
REMOVAL
1. Remove:
• Seat
• Primary sheave cap screws
• Primary sheave cap G)
• Drive belt ®
• Starter belt@
2. Attach:
• Primary Sheave Holder <D
Primary Sheave Holder:

VS-1880-A, 90890-01701
3. Remove:
• Bolt (Primary Sheave) @
4. Attach:
• Primary Sheave Puller <D
Primary Sheave Puller:

VG-1876, 90890-01876
5. Remove:
• Primary sheave assembly@
When removing the sheave @, tighten the
sheave pu ller G).
DISASSEMBLY
1. Separate the sliding sheave <D from the fixed
sheave@.
2. Remove:
• Screws <D
• Pivot pins ®
• Screws@
• Sliders@
• Plastic washers ®
Y·288
4-2 (Rev. 6/99)

POWER TRAIN FOR G14-A I~R~I
3. Separate the sliding sheave from the spider.
Y·289
INSPECTION
1. Inspect:
• Weights@
Unsmooth operation/Damage - Replace.
• Pivot pins @
• Plastic washers @
• Collars@
• Sliders CD
Wear/Scratches/Damage- Replace.
• Oil seals@
Wear/Damage - Replace.
ASSEMBLY
Reverse the " DISASSEMBLY" procedure.
1. 1nstall:
• Sliders CD
• Screws®
On to sliding sheave.
2. 1nstall:
• Weights®
• Plastic washers @
• Collars®
• Pivot pins ®
On to sliding sheave.
• Screws <D
NOTE:-------------
Apply LOCTITE • to the pivot pin screws CD.
3. Position : ·
• Spider
Into sliding sheave.
4. Connect the link arm of the weight onto the
sliding sheave using the pivot pins CD and
washers.
5. lighten the screws ® holding the pivot pins
in place.
Y-290
4-3
POWER TRAIN FOR G14-A ~~~~
-------------------. 6. Grease the bushing CD and oil seal lips® in
side of the sliding sheave.
7 .Install:
• Sliding sheave
Onto fixed sheave.
Do not damage or deform the oil seal lips

during installation.
8. Engage the serration in the spider with the

fixed sheave.
NOTE:------------------------
The grease nipple CD must be in line with the
punch mark ® and the center @ of the crank
shaft as shown in the illustration.
INSTALLATION
1. Remove any oil and/or grease from the
tapered portion of crankshaft and primary
sheave using a non-oily solvent.
2.1nstall:
• Primary sheave assembly
• Sheave securing bolt
Lightly tighten the bolt in this step.
3. Check:
• Sliding sheave operation
Push and pull the sliding sheave by hand.
Unsmooth operation -+ Disassemble pri
mary sheave and reinspect.
4. Attach:
• Primary Sheave Holder CD
YS-1880-A, 90890-01701
5. Tighten :
• Bolt (Primary Sheave)®
Bolt (Primary Sheave):

85 Nm (8.5 m • kg, 61 ft • lb)
4-4 (Rev. 6/99)

POWER TRAIN FOR G14-A rwR~~
6. Install:
• Primary sheave cap
• Drive belt
Refer to CHAPTER 2 "DRIVE BELT
• Starter belt
4-5
POWER TRAIN FOR G14-A jPWRI®1!01
SECONDARY SHEAVE
CD Woodruff key (j) Fixed sheave @Ramp shoe
® Spring seat @ Plastic washer @Bolt
@ Compression spring @Oil seal
@Cotter pin @)Grease nipple
®Securing nut ® Sliding sheave
®washer @ Circlip
A SPRING HOLE POSITION:

Position "3"
SPRING TWIST ANGLE:

45°
SPRING HOLE POSITION:

Position "8"
4-6
DISASSEMBLY
rwRs 1
1. Remove the rear cowling.
Refer to CHAPTER 3 "REAR COWLING" sec
tion.
2. Remove the drive belt.
3. Put car in gear and set parking brake.
4. Attach:
• Secondary Sheave Holder G)
Y-291
Secondary Sheave Holder:
YG-40103-A, 90890-01705
5. Remove:
• Cotter pin
• Sheave securing nut
• Washer
Y-292
6. Attach:
• Universal Puller G)
• 6mm Bolts@
Universal Puller:
YU-33270-B, 90890-01362
6mm Bolt:
YU-90105-2
7. Remove:
• Fixed sheave
• Woodruff key CD
• Plastic washer ®
(from the input shaft)
8. Remove: .
• Secondary Sheave Holder
When removing the sheave holder, push in
the sliding sheave by hand.
9. Release spring force slowly, then remove the
sliding sheave.
10. Remove:
• Compression spring
• Spring seat
Y-295
4-7
POWER TRAIN FOR G14-A ~~~
INSPECTION
1.1nspect:
• Sliding sheave
• Fixed sheave
Warpage/Scratches/Damage - Replace.
• Circlip on input shaft
2. Measure:
• Free length (Secondary spring) ®
Less than specif ication - Replace.
Free Length (Secondary spring):

Limit: 100 mm (3.94 in)
3. Measure:
• Ramp shoe thickness
Out of specification - Replace.
r~
Al
Wear Limit:
1.0 mm (o.o4 in)
4. Inspect:
• Oil seal
• Bushing
Wear/Damage --. Replace.
ASSEMBLY
Reverse the "DISASSEMBLY" procedure.
1. Install:
• Spring seat
Onto the input shaft.
2. Grease the bushing and oil seal lips inside of
the sliding sheave.
3. Hook the spring end into the spring hole
" B" <D in the sheave.
4.1nstall the spring and sliding sheave onto the
input shaft.
5. Hook the other end of spring into the hole
"3" ® in the spring seat.
4-8
6.1nstall:
• Secondary Sheave Holder
Onto the sliding sheave.
Secondary sheave holder installation steps:

• Push the sliding sheave in while turning it
approx 45° clockwise to preload the spring.
Then hold the sheave in this position.
• Hook the Secondary Sheave Holder onto
the sliding sheave.
Secondary Sheave Holder:

VG-40103-A, 90890-01705

tapered portion of input shaft and fixed
sheave using a non-greasy solvent.
8. Install:
• Plastic washer ®
• Woodruff key G)
• Fixed sheave
• Washer
• Securing nut

YS-1880-A, 90890-01701
9. Tighten:
• Nut (Secondary sheave)
Nut (Secondary sheave):

60 Nm (6.0 m • kg, 43 ft · lb)
10. Install:
• Cotter pin (New)
11. Remove the excess grease from the sheaves
and input shaft.
12. Install the drive belt.
4-9
POWER TRAIN FOR G14-A IPWRI®1!01
--------------. DRIVE V -BELT
INSPECTION AND REPLACEMENT
1\'- o
~- -'1:
Refer to CHAPTER 2 " DRIVE BELT INSPECTION "
section.
I I Drive Belt Width:

I
I
I I
I
I
New <D: 31 mm (1 .22 in)
I
'---
1
---1
Wear limit ® : 27 mm (1.06 in)
4-10
POWER TRAIN FOR G14-A ~~~~~
TRANSMISSION
CD Transmission case (Right) @ Differential side gear @Shift fork
® Primary gear (Forward) @Ring gear ® Shift fork bar
@Input shaft @Counter gear 2 @Pin
® Idler shaft @Spacer @ Shift lever shaft
® Idle gear (Reverse) @ Counter gear (Forward) @ Shift lever
®Transmission case (Left) @ Counter shaft @ Shifting cable
(J) Differential case @Dog clutch @ Oil level plug
@ Differential side gear @Thrust washer ®Drain plug
® Differential pinion @ Counter gear (Reverse)
First: 20 Nm (2.0 m • kg, 14ft • lb)

G
Final: 25 Nm (2.5 m • kg, 18ft • lb)
A TRANSMISSION OIL:
RECOMMENDED OIL:
B
SAE 90 gear oil
OIL QUANTITY:
c 800 cm 3 (0. 17 Imp gal
0.85 us qt)
D REDUCTION RATIO:
E FORWARD; 11.34:1
F REVERSE: 15.25: 1
4-11
POWER TRAIN FOR G14·A I~R~I
REMOVAL
2. Remove:
• Drain plug
Y·297
3. Remove:
• Muffler
Refer to CHAPTER 5 "ENGINE REMOVAL
MUFFLER" section.
4. Disconnect:
• Throttle cables CD
From the speed limit lever ®.
5. Disconnect:
• Shifting cables (with shift lever) CD
from the shift lever.
6. Remove:
• Secondary sheave
7. Remove:
• Bolts
from the axle housing case CD and rear
arm@.
NOTE:------------
When removing the bolts, support the rear arm
with a jack.
8. Disconnect the axle shafts from the differen

tial gear.
9. Remove:
• Case mounting bolt
10. Remove:
• Transmission case assembly
Y·301
4-12
POWER TRAIN FOR G14-A _POTWR -~- I Rl~# I
DISASSEMBLY
1. Remove:
• Circlip CD
From the input shaft.
2. Remove:
• Speed limiter lever®
From the governor shaft.
3. Loosen:
• Knock pin plug @
Loosen the plug completely but do not
remove it in this step.
4. Remove:
• Bolts (numbers shown indicate loosening
sequence)
• Transmission case (Right)
Pull the case straight out from the trans
mission assembly.
v.ao3 Do not drive chisels, screwdrivers, etc. between

the case halves. Tap with soft mallet if necessary
to loosen case.
[A) LONGER BOLTS WITH DOWEL PINS

5. Remove:
• Ring gear assembly CD
• Input shaft (with governor) ®
• Thrust washer @
• Counter gear 2 @
Y-304
• Counter gear (Forward)@
• Idle gear (with shaft) ®
6. Remove:
• Dog clutch CD
(with shift fork/bar assembly) ®
• Counter shaft (with gear) @
• Plug
• Spring
• Knock pin
• Shift lever shaft
Y·305
7. Remove: ·
• Bolts
loosen in a criss-cross pattern.
B. Remove:
• Ring gear CD
• Differential case assembly
• Side gear (Right)
• Dowel pins
Y·306
4-13
9. Remove:
• Spring pin CD
• Pinion shaft ®
• Pinion gears ®
• Side gear (left) (!)
• Differential case ®
Y-307
10. Remove:
• Screws
• Governor fork <D
from the governor shaft.
11. Pull the governor shaft from the transmission
case (Left).
Y-308
INSPECTION
1. 1nspect:
• Gears
Damage/Wear-+ Replace.
• Bearings
Pitting/Damage -+ Replace.
• Oil seals
• Transmission cases
2.1nspect: ·
• Counter gear (Reverse) Q)
• Dog clutch ®
• Counter gear (Forward) ®
Wear/Cracks/Damage -+ Replace.
• Dog clutch
Damage -+ Replace.
4-14
POTWRRl~·I
--------------------------------------------------------
I ~
3.1nspect:
• Shift fork CD
• Guide bar®
• Pin@
Wear/Damage --+ Replace.
Y-309
4.1nspect:
• Pin G)
• Spring®
Wear/Damage -. Replace.
Y-310
ASSEMBLY
1. When installing the governor fork onto the
governor shaft, apply LOCTITP~ to the
holding screws.
2.1nstall the governor fork onto the governor
shaft.
3. Install:
• Differential case assembly
• Bolts
• Ring gear G)
• Dowel pins
Bolt (Differential Case):

34 Nm (3.4 m • kg, 24ft • lb)
LOCTITEe
Y-306
4. Make sure ·that the counter gears (Reverse CD

and Forward ® )are installed on the counter
shaft with the flush side ® facing the dog
clutch@.
4-15 {Rev. 6/99)

POWER TRAIN FOR G14-A ~~l®f!01
5.1nstall:
• Dog clutch CD
Before installing the clutch, engage the
shift fork® with groove of the clutch.
Then align the slot of the shift shaft lever
with pin.
Y·311
6.1nstall:
• Dowel pins
• Gasket (New)
• Transmission case (Right)
onto the left transmission case.
NOTE=------------------------
When installing the transmission case (Right),
make sure that the governor fork CD is fit in the
groove® of the lifter in the speed limiter.
Y·312
7. Tighten:
• Bolts (Transmission case)
Tighten them in the tightening sequence
shown in the photo.
Transmission Case:
First: 20 Nm (2.0 m • kg, 14ft • lb)
Final: 25 Nm (2.5 m • kg, 18ft· lb)
[A] LONGER BOLTS WITH DOWEL PINS

Y·303
8.1nstall:
• Speed limiter lever
onto the governor shaft.
• Circlip CD
onto the input shaft.
INSTALLATION
1. Connect:
• Shifting cables CD (with lever® )
onto shift shaft.
NOTE:-----------------------
Align the match marks on the lever and shaft.
Y·314
4-16
POWER TRAIN FOR G14-A lpWRI~I
2.1nstall:
• Case mounting bolt (finger tight)
NOTE:-----------------------
Do not tighten the mounting bolt until axle hous-
ing assembly bolts are in place.
3.1nstall:
• Axle housing assemblies.
Case Mounting Bolt:

40 Nm (4.0 m • kg, 29 ft • lb)
Transmission Case - Axle Housing G):
25 Nm (2.5 m • kg, 18ft • lb)
Axle Housing - Rear Arm @:
64 Nm (6.4 m • kg, 46ft • lb)
4. Remove:
• Transmission case vent cap
5. Tighten:
• Drain plug
Drain Plug:
29 Nm (2.9 m • kg, 21ft • lb)
6. Fill:
Recommended Oil:
SAE 90 gear oil
Oil Quantity:
800 cc (0. 70 Imp qt, 0.85 US qt)
7 . Install:
• Vent cap
B. Connect:
• Throttle cables
onto speed limiter.
9. Adjust:
• ThrottlE; cable free play
Refer to CHAPTER 2 "THROTTLE
CABLE ADJUSTMENT" section.
4-17 (Rev. 8/96)

POWER TRAIN FOR G14-E ~~~~
POWER TRAIN FOR G14-E
TRANSMISSION
<D Circlip @) Bearing @) Rear axle hub
® 0-ring ® 0 -ring ® Circlip
@ Bearing @ Counter gear ass'y @ Bearing
@ lnputshaft @ Bearing @ Circlip
® Bearing @ Ring gear @ Oil seal
® Case ass'y @> Differential ass'y ® Rear axle shaft
(j) Blind plug @ Bearing holder
® Circlip @ Transmission case cover
® 0-ring @ Hexagon nut
A TRANSMISSION OIL:
Reccommended oil:
B SAE 90 gear oil
Oil quantity:
c 300 cm 3 (0.06 Imp gal
0.32 US_qt)
REDUCTION RATIO:
D (1:11.965)
55 Nm (5.5 m • kg, 40ft • lb)

44 Nm (4.4 m • kg, 32ft • lb)
55 Nm (5.5 m • kg, 40ft • Ib)
4-18 (Rev. 8/96)

POWER TRAIN FOR G14-E ~~~~
REMOVAL
2.Remove:
• Drain plug <D
3. Jack up the rear of the vehicle, place a stand

under the f rame. Block the front wheel.
4.Remove:
• Rear wheels
• Rear axle shafts
• Refer to CHAPTER 3 uREAR AXLE WHEEL
FOR G14-E, REMOVAL" section.
5. Remove:
6. Remove:
• Bolts CD
from the rear arm.
7. Remove:
DISASSEMBLV
1. Remove:
• Bolts
• Transmission case cover using a putty
knife.
~$~~~~
~! ·=~~·~ - - - - - - - - - - -
4-19
POWER TRAIN FOR G14-E ~~~~~
2. Remove:
• Differential bearing holder bolts
~~::mr.~\--D-~~$1
- ~~t~ . .~ .m-l~ - - - - - - - - - -
--·
""'
·---. Mark bearing holders before removal so they can
be returned to their original position - bearing
- - holders are not interchangeable.
• Differential assembly with ring gear <D

Y-319
• Bearing holder®
• Bearing@
Y-320
3. Separate:
• Ring gear <D
• Differential assembly ®
Y-321
4. Remove:
• Blind plug <D (both sides
NOTE:-----------------------
Punch or drill near the center of blind plug. Insert
a suitable sized sheet metal screw until the plug
is forced out of the bearing bore.
4-20
POWER TRAIN FOR G14-E rwR~~
5. Remove:
• Circlip G)
(from counter gear bore)
• Counter gear®
• 0-ring of counter gear @
• 0 -ring of bearing @
• Bearing@
Counter gear removal steps:

1. Push out the counter gear shaft of input side
from bearing inner race.
2. Remove the bearing of input side using the
bearing puller.
3. Repeat the step 1 for counter gear bearing
on opposite side.
Y·111
6. Remove:
• Circlip G)
• Input shaft ®
• Bearing®
• 0 -ring@
• Bearing@
4-21
POWER TRAIN FOR G14-E jPWR~I
INSPECTION
1. Inspect:
• Ring gear CD
• Differential gear ®
Damage Wear -+ Replace
• Bearing@
Pitting/Damage-+ Replace
• 0-ring
Wear/Damage -+ Replace
ASSEMBLY
Reverse the "DISASSEMBLY" procedure. Note
the following points.
1. Tighten:
• Differential case bolts attaching ring gear
CD to differential assembly@.
Differential Case Bolts:
55 Nm (5.5 m • kg, 40 ft • lb)
Y·321
2. Tighten:
• Differential bearing holder bolts
Differential bearing holders must be installed in

their original locations.
Differential Bearing Holder Bolts:

55 Nm (5.5 m • kg, 40ft • lb)
Y·319
NOTE:-------------------------
Ciean the transmission case surface.
3. Apply:
• RTV Quick Gasket sealant (ACC-11 001-05-
01 l or Three bond 1215 (to the case surface
and into the 10 bolt holes)
4-22
POWER TRAIN FOR G14-E I~R~I
4. Tighten:
• Transmission case bolts
NOTE:-----------------------
Tighten the bolt in order starting with the small-
est number and torque the bolts in two stage.
Transmission Case Bolts:

32 Nm (3.2 m • kg, 23ft • lb)
Y-322
INSTALLATION
Reverse the "Removal" procedure.
1. Install:
• Rear arm bolts CD
Axel Housing - Rear Arm CD:

64 Nm (6.4 m • kg, 46 ft • lb)
2. Install:
• Traction motor
Refer to CHAPTER 7 "TRACTION MOTOR"
section.
Shock Absorber Pivot Bolt:

(Upper and Lower)
32 Nm (3.2 m • kg, 23 ft • lb)

Refer to CHAPTER 3 "REAR AXLE WHEEL
FOR G14-E, REMOVAL" section.
• Rear wheels
Rear Wheel:
90 Nm (9.0 m • kg, 65 ft • lb}
3. Tighten:
• Drain plug CD
Drain Plug CD:

44·Nm (4.4 m • kg, 32ft • lb)
4. Fill:
Recommended Oil:
Y-315 SAE 90 gear oil
Oil Capacity:
300 cc (0.26 Imp qt, 0.32 US qt)
4-23
ENGINE OVERHAUL I l'\.1
ENG
CHAPTER 5
ENGINE OVERHAUL
ENGINE REMOVAL .......................................... 5-1 CYLINDER HEAD ...................................... 5-33

PREPARATION FOR REMOVAL ................ 5-1 A IR SHROUD ............................................ 5-35
DRIVE BELT ................................................ 5·2 STARTER-GENERATOR .......................... 5-37
CARBURETOR ............................................ 5-2 REMOUNTING ENGINE .......................... 5-38
AIR CLEANER CASE .................................. 5-2
WIRING AND HOSE .................................... 5-3
M UFFLER .................................................... 5-3
ENGINE REMOVAL .................................... 5-3
ENGINE DISASSEMBLV .................................. 5-4

STARTER-GENERATOR ............................ 5-4
AIR SHRO UD .............................................. 5-4
CYLI NDER HEAD ........................................ 5-5
PRIMARY SHEAVE ..................................... 5-6
FLYWHEEL ................................................. 5·7
CRANKCASE COVER ................................. 5-7
CAMSHAFT .........................,...................... 5-8
BALANCER SHAFT AND CRANKSHAFT .. 5-8
PISTON AND CONNECTING ROD ............ 5-8
ENGINE BRACKET ..................................... 5-9
INSPECTION AND REPAIR ........................... 5-9

CYLINDER HEAD ........................................ 5-9
VALVE ....................................................... 5-11
VALVE SEAT ............................................ 5-12
VALVE SPRING ........................................ 5-15
VALVE INSTALLATION ........................... 5-16
ROCKER ARM .......................................... 5-17
CAMSHAFT .............................................. 5- 18
GEARS ...................................................... 5-19
CYLINDER AND PISTON ......................... 5-19
PISTON RING AND PIN ........................... 5-20
CRANKSHAFT AND CONNECTING ROD
.................................................................. 5-23
ENGINE ASSEMBL V AND ADJUSTMENT ... 5-27

ENGINE BRACKET ................................... 5-27
CRANKSHAFT, CAMSHAFT AND
BALANCER SHAFT ............................... 5-27
PISTON AND CONNECTING ROD .......... 5-28
CRANKCASE COVER ............................... 5-32
FLYWHEEL ............................................... 5-32
PRIMARY SHEAVE ................................... 5-33
ENGINE REMOVAL IENG l'\.1
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE=------------------------
It is not necessary to remove the engine in order
to remove the following components:
• Cylinder head assembly
• Carburetor
• Starter-generator
• Primary sheave
PREPARATION FOR REMOVAL

1. Remove all dirt, mud, dust, and foreign
material before removal and disassembly.
2. Use proper tools and cleaning equipment.

Refer to CHAPTER 1 "SPECIAL TOOLS".
~'~~--~~~~
~~~~'~"?.!.'!~( - - - - - - - - - -
Make sure all traces of cleaner are removed
before engine is reassembled. Engine oil can be
adversely affected by even small amounts of
cleaner.
NOTE=------------
When disassembling the engine, keep mated
parts together. This includes gears, cylinders,
pistons, and other parts that have been "mated"
through normal wear. Mated parts must be
reused as an assembly or replaced.
3. During the engine disassembly, clean all parts

and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are correctly
reinstalled in the engine.
4. Disconnect the battery negative lead.
5. Drain the engine oil completely.
Refer to CHAPTER 2 "ENGINE OIL RE
PLACEMENT" section.
5-1
ENGINE REMOVAL I l'\.1
ENG
DRIVE BELT
1.Remove:
• Drive belt
Refer to CHAPTER 2 " DRIVE BELT
A WARNING
Gasoline may be present in the carburetor and
fuel system. Use care during engine removal not
to spill gasoline. Gasoline is extremely flamma
ble, and its vapors can explode if ignited.
CARBURETOR
1. Disconnect:
• Fuel hose
2. Remove:
• Anti-tamper plate
• Choke cable clamp G)
3. Remove:
• Cotter pin
From clevis pin ® .
• Clevis p in
• Choke cable ®
4. Remove:
• Circlip <D
• Cotter pin ®
• Clevis pin @
• Throttle cable @
5. Remove:
• Carbu retor joint
6. Remove:
• Carburetor body holding nuts
• Carburetor assembly
• Gasket
• Intake manifold holding screws
• Intake manifold and gasket
AIR CLEANER CASE

1. Disconnect:
• Breather hose
2.Remove:
• Air cleaner case holding bolts G)
5-2
ENGINE REMOVAL
WIRING AND HOSE
I l'-1
ENG
1. Disconnect:
• Starter-generator lead to relay (Red) CD
• Starter-generator lead to neg battery post
(Black)
• Starter-generator lead to fuse (Black)
• Starter-generator charging coil leads (Red,
Green)®
2. Disconnect:
• Pickup coil lead (White/Red, White/Black,
Black) CD
• Oil level switch lead (Yellow)®
3. Disconnect:
• Pulser hose <D
From fuel pump.
• Ignition coil lead (Red/White, Orange)®
MUFFLER
1.Remove:
• Exhaust pipe holding nuts <D
• Muffler mount bolts®
• Gasket@
ENGINE REMOVAL
1 . Disconnect:
• Engine bracket tensioner cable CD
2. Remove:
• Muffler stay ®
Y-337 Y-338
5-3
ENGINE DISASSEMBLY
3. Remove:
I l'--1
ENG
• Engine mount nuts CD

• Engine {with starter-generator)
NOTE:-----------------------
The engine with starter-generator attached
weighs approximately 85-90 lbs.
ENGINE DISASSEMBLY
STARTER-GENERATOR
NOTE=-------------
With the engine mounted, the starter-generator
can be maintained by removing the following
parts.
1. Remove:
• Bolts and nuts CD®
• V-belt@
• Starter-generator @
Y-341
AIR SHROUD
NOTE:-------------------
With the engine mounted, the air shroud can be
maintained by removing the following parts.
• Muffler
1 . Disconnect:
• Plug cap CD
• Crankcase breather hose®
• Oil delivery hose @
5·4
ENGINE DISASSEMBLY I I'-I
ENG
2. Remove:
• Oil delivery hose <D
• Air shroud (Rear) ®
From exhaust side.
Y·343
3. Remove:
• Air shroud (Front) CD
From engine intake side.
Remove shroud with ignition coil.
4. Remove:
• Air shroud (Side) CD
From engine right side.
Y-345
CYLINDER HEAD
NOTE=-------------------------
With the engine mounted, the cylinder head
can be maintained by removing the following
parts.
• Muffler
• Carburetor
• Airshroud
1. Remove: ·
• Cylinder head cover CD
• Spark plug
2. Place the piston at TDC on the compression
stroke so that both valves are closed.
Refer to CHAPTER 2 "VALVE CLEA
RANCE ADJUSTMENT" section.
5-5
ENGINE DISASSEMBLY
3. Remove:
I l'\.1
ENG
• Cylinder head bolts

• Cylinder head
• Push rods (Exhaust/Intake)
NOTE:-------------------------
• Loosen nuts in numbered order in photo.
Start by loosening each nut 1/2 turn until all
are loosen.
• Mark both push rods so they can be reinstalled
Y-347
in their original locations.
Y-348
PRIMARY SHEAVE
1. Remove:
• Sheave cap
2.Remove:
• Sheave securing bolt CD
Use a Primary Sheave Holder@.

VS-1880-A, 90890-01701
3. Remove: ·
Use a Sheave Holder(Dand Primary Sheave
Puller®.

YS-1880-A, 90890-01701
YG-1876, 90890-01876
5-6
ENGINE DISASSEMBLY
FLYWHEEL (Cooling Fan)
I l"-1
ENG
NOTE=-------------------------
With the engine mounted, the flywheel can be
maintained by removing the following parts.
• Muffler
• Fuel tank
• Air shroud
1.Remove:
• Flywheel securing bolt
Use a Sheave Holder CD .

VS-1880-A, 90890-01701
2.Remove:
• Flywheel G)
Use a Universal Puller@.
Universal Puller:
VU-33270-8, 90890-01362
3. Remove:
• Woodruff key CD
• Pickup coil ®
CRANKCASE COVER
1. Remove:
• Left crankcase cover G)
NOTE=-----------
Numbers shown indicate proper tightening
sequence.
Y-357
5-7
ENGINE DISASSEMBLY
2. Remove:
ENG
111.-l
_ .._ _
• Gasket <D
• Dowel pins ®
Y-358
CAMSHAFT
1. Remove:
• Camshaft CD
NOTE:- - - - - - - - - - - - -
Before removing the camshaft, place the engine
with its left-sii::fe up to prevent the tappets from
falling out.
2. Remove:
• Tappets (Exhaust <D / Intake®)
NOTE:- - - - - - - - - - - - -
Mark both tappets so they can be reinstalled in
their original guide hole.
BALANCER SHAFT AND CRANKSHAFT

1. Remove:
• Balancer shaft <D
2.Remove:
• Connecting rod securing nuts ® (with
Oil splasher @ )
• Connecting rod cap
• Bolts
• Crankshaft
PISTON AND CONNECTING ROD

1. Remove:
• Connecting rod (With piston)
• Piston pin clips G)
• Piston pin @
• Piston®
NOTE:-----------------
If there is a carbon ridge at the top of the cylinder,
remove it before removing piston.
5-8 (Rev. 6/99)

INSPECTION AND REPAIR
ENGINE BRACKET
I I'-'
ENG
1. Remove:
• Engine bracket
• Oil level switch
From crankcase.
Y-365

CYLINDER HEAD
1.Remove:
• Rocker arm shaft CD
• Rocker arm (Exhaust) ®
• Rocker arm (Inta ke) @
2. Remove:
• Bolts@
• Rocker arm shaft support®
• Dowel pins
3.Attach:
• Adapter CD
• Valve Spring Compressor ®
Valve Spring Compressor.

YM-1253, 90890-01253
Y·122
4.Remove: ·
• Valve retainer <D
Use magnet or tweezers.
• Valve spring seat (Upper)®
• Valve spring @
• Oil seal @
• Va lve (Intake)®
5-9
5. Remove:
I l"-1
ENG
• Valve retainer CD
Use magnet or tweezers.
• Valve spring seat (Upper) ®
• Valve spring @
• Valve (Exhaust) ®
NOTE:------------------------
Deburr ® any deformed valve stem ® end. Use
an oil stone to smooth the stem end.
6. Remove:
• Carbon deposit.
Use rounded scraper.
NOTE=-------------------------
Do not use a sharp instrument and avoid damag-
ing or scratching:
• Spark plug threads
• Valve seat
• Cylinder head
7 . Measure:
• Cylinder head warpage
Out of specification -+ Resurface.
NOTE:-----------------------
Check cylinder head for flatness by laying it on a
surface plate and using a 0.002 in. feeler gauge
between the mating surfaces to detect any
warpage.
Cylinder Head Warp Limit:

Less than 0.05 mm (0.002 in)
CD Emery paper (400- 600 grit wet)
5-10
VALVE
I l'-1
ENG
CD-n- 1.1nspect:
• Va lve face
® ) • Stem end
L - Wear/Pitting ... Reface.
rpiJfJ Out of specification -+ Replace.
J®L ~
450
302.000
Margin Thickness (Service limit)
Intake 0.8 mm (0.031 in)
CD :
Exhaust 0.6 mm (0.024 in)
Beveled ® :
0.5 mm (0.020 in)
Minimum Length (Service limit) ®:
4.8 mm (0.189 in)
Seat Width (Valve face) ® :
1.4 mm (0.055 in)
2. Measure:
• Valve stem clearance
Valve stem clearance =

Valve guide inside diameter CD
Valve stem diameter ®
Out of specification -+ Replace either valve

and/or guide.
Use a Micromet er and Bore Ga uge ® .
Valve Stem. Clearance Maximum
Intake 0.037 - 0.067 mm O.t1 mm

(0.0015 - 0.0026 in) (0.043 in)
Exhaust 0.030 - 0.060 mm 0.11 mm

(0.0012 - 0.0024 in) (0.0043 in)
3.1nspect: ·
• Valve stem end
Mushroom shape/Larger diameter than rest
of stem --. Replace valve, valve guide, and
oil seal.
5-11
4 . Measure:
IENG l'--1
• Valve stem runout
Maximum Runout:
0.02 mm (0.0008 in)
//
302-()()4
VALVE SEAT
1. Clean:
• Valve face
• Valve seat
Remove carbon deposit.
2 . 1nspect:
• Valve seat
Pitting/Wear -+ Reface valve seat.
3. Measure:
• Valve seat width CD
Out of specification ~ Reface valve seat.
Valve Seat Width:

Std: 0.7- 0.9 mm
(0.028 - 0.035 in)
Wear Limit:
1.4 mm (0.055 in)
302·027
Valve seat width measurement steps:

• Apply Mechanic's bluing dye (Dykem) <D to
the valve face.
• Install the valve into the cylinder head.
• Press the valve through the valve guide and
onto the valve seat to make a clean pattern.
• Measure the valve seat width. Wherever the
valve seat and valve face made contact, blu
302 017
ing will have been removed from valve face.
• If the valve seat width on valve face is too
wide or too narrow, or seat is not centered,
the valve seat must be refaced.
5-12
INSPECTION AND REPAIR IENG l'-1
4. Reface:
• Valve seat
Use 10°, 45° and 60° Valve Seat Cutter.
~---,~~ -----------
Remove just enough material to achieve satis
factory seat.
When twisting cutter, apply light downward
pressure with finger tips on each end ofT-bar,
and twist one direction evenly to prevent chatter
marks.
Cut sections as follows

Section Cutter
A 10°
B 45°
c 60°
302·015
A Valve seat refacing steps:

I
!
I
0 Valve face indicates that valve seat is
centered on valve face but is too wide.
II .. Valve Seat Cutter Set Desired Result
I
10° cutter To reduce valve seat
Use
width to 1.0 mm
lightly 60° cutter (0.04 in)
~ Valve seat is in the middle of the valve

face but too narrow.
B
I Valve Seat Cutter Set Desired Result
I ··
I To achieve a uniform
I
I Use 45° cutter valve seat width of
I
I
I
1.0 mm (0.04 in)
@J Valve seat is too narrow and right up

near valve margin.
Valve Seat Cutter Set Desired Result
c 10° cutter To center the seat and

Use to achieve its width of
l 45° cutter 1.0 mm (0.04 in)
J•
I
I
I
r.
I
5-13
INSPECTION AND REPAIR I l'\.1
ENG
D @] Valve seat is too narrow and is located
down near the bottom edge of the valve
face.
Valve Seat Cutter Set Desired Result

60° cutter,
To center the seat and
Use first
increase its width.
45° cutter
5. Lap:
• Valve face
• Valve seat
NOTE:
After refacing the valve seat or replacing the valve
and valve guide, the valve seat and valve face
should be lightly lapped.
Valve lapping steps:

• Apply a fine lapping compound CD to the
valve face.
Be sure no compound enters the gap between

the valve stem and guide.
302·017
• Apply a molybdenum disulfide oil to the
valve stem.
• Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all compound.
NOTE:----------------------
To obtain the best lapping result, lightly tap the
valve seat while -rotating the valve back and
302·024 forth between your hand.
5-14
ENG
NOTE:------------
Be sure to clean off all compound from the
valve face and valve seat afte'r every lapping
operation.
• Apply the Mechanic's bluing dye (Oykeml®

302·011
to the valve face.
• Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
• Measure the valve seat width @ again. If
the valve seat width is out of specification,
reface and lap the valve seat.
VALVE SPRING
1. Measure:
• Spring free length CD
Out of specification -.. Replace.
Valve Spring Free Length Limit

(IN/EX):
35.0 mm (1.38 in)
302·005
2. Measure:
• Spring tilt CD
Tilt Limit:
2.5° or 1.6 mm (0.063 in)
3. Measure: ·
• Spring force (Installed length)
Valve Compressed Force Limit:

8.0 kg (17 .61blCD/
29mm (1.14 in)®
302 006
5-15
INSPECTION AND REPAIR IENG I\.I
A VALVE INSTALLATION
1. Lubricate
• Valve stem
• Oil seal
• Valve stem end
High-Quality Molybdenum Disulfide

Motor Oil or Molybdenum Disulfide
1 - -... Grease.
2.1nstall:
B
• Valve Q)
• Oil seal®
• Valve spring@
• Valve spring seat® (Upper)
• Valve retainer®
Use the Valve Spring Compressor.
[A] INTAKE
rnJ EXHAUST
Valve Spring Compressor:

YM-1253, 90890-01253
3. Check:
• Valve sealing
Leakage at valve seat -+ Reface, relap or
replace valve.
Refer to "VALVE SEAT".
Valve seat checking steps:

• Pour a clean solvent Q) into the intake and
exhaust ports.
• Check the valve sealing, there should be no
leakage at the valve seat®.
Relapping steps:
• Disassemble head parts.
• Repeat lapping steps using fine lapping
compound.
• Clean all parts thoroughly.
• Reassemble and check for leakage again
using solvent.
• Repeat steps as often as necessary to effect
a satisfactory seal.
5-16
INSPECTION AND REPAIR IENG l'-1
6.1nspect:
• Rocker arm shaft support hole
We ar/Pitti ng/Scratches/Biue discoloration
-+ Replace.
7. Measure:
• Rocker arm shaft support inside diameter
Use a Bore Gauge CD .
Out of specification --. Replace.
Rocker Arm Shaft Support

Inside Diamet er:
t--;w
12.00 - 12.14 mm
(0.472 - 0.478 in)
Rocker Arm Shaft-Rocker Arm
Shaft Support Clearance:
Limit: 0.24 mm (0.0094 in)
CAMSHAFT
1.1nspect:
• Cam lobes
Pitting/Scratches/Blue discoloration
• Replace.
2. Measure:
• Cam lobes
Use Micrometer.
B 'Out of specification __. Replace.
Cam Lobe Cam Lobe

""A " "B"
29.16 -29.28 mm 24.11 - 24.22 mm
Intake
(1.148 - 1.153 in) (0.949- 0.954 in)
29.20 - 29.32 mm 24.15 - 24.25 mm

Ex h aust
(1.1 50 - 1.154 in) (0.951 - 0.955 in)
3 . Measure:
• Camshaft bearing surface diameter®
Use a micrometer.
Out of specification --. Replace camshaft.
• Camshaft pivot inside diameter:
Out of specification - Replace crankcase
cover and/or crankcase.
5-18
ENG
Camshaft Bearing Surface Diameter:
15.90- 15.99 mm
(0.625 - 0.630 in)
Camshaft Pivot Inside Diameter:
16.00- 16.05 mm
(0.630 - 0.632 in)
GEARS
1.1nspect:
• Gear teeth
Blue Discoloration/Pitting /Wear
-. Replace.
CD camshaft
®Crankshaft
®Balancer shaft
CYLINDER AND PISTON

1.1nspect:
• Cylinder and piston walls
Vertical scratches-+ Rebore or replace
cylinder and piston.
2. Measure:
• Piston-to-cylinder clearance
Piston-to-cylinder clearance measurement

steps:
First step:
• Measure the cylinder bore "D" with a
cylinder Bore Gauge.
NOTE=-----------
Measure the cylinder bore "D" in parallel to
and at right angles to the crankshaft. Then, find
the average of the measurements.
3()4 001 Cylinder Bore "D":

75.00 - 75.02 mm
(2.953 - 2.954 in)
< limit: 75.05 mm (2.955 in)
Taper Limit ..T,.:
0.15 mm (0.006 in)
Out of Round limit "R'":
0.15 mm (0.006 in)
D =Maximum Diameter
T =(Maximum D 1 or D 2 ) -
(Maximum D 5 or D 6 )
5-19 (Rev. 6/99)

INSPECTION AND REPAIR ENG I l"\.1
R = (Maximum D 1
D3 or D5 )
, -
(Minimum D2 , D4 or D6 )
• If out of specification, rebore or replace the

crankcase assembly and replace the piston
and piston ring as a set.
Second step:
• Measure the piston skirt diameter "P" with a
micrometer.
CD 5 mm (0.20 in) from the piston bottom edge
~ Piston Outside Diameter "P"
74.96- 74.98
307.001 Standard
(2.953 in)
Oversize 1 75.25 mm (2.963 in)
• If out of specification, replace the piston

and piston rings as a set.
Third step:
• Calculate the piston-to-cylinder clearance
w~th fo{lowing formula:
Piston-to-cylinder Clearance =
Cylinder Bore "C"-
Piston Skirt Diameter "P"
• If out of specification, rebore or replace the

crankcase assembly and replace the piston
and piston ring as a set.
~
Piston-to-cylinder Clearance:
0.03 - 0.05 mm
(0.0012 - 0.0020 in)
< Limit: 0.10 mm (0.0039 in) >
PISTON RING AND PIN

Piston Ring
1. Measure:
• Side clearance
Use the Feeler Gauge CD.
Out of specification --. Replace piston and/
or rings.
5-20
NOTE:-------------------------
ENG I"-'
Decarbon the piston ring grooves and rings
before measuring the side clearance.
~
Side Clearance
Standard Limit
Top 0.03 - 0.05 mm 0.07 mm
Ring (0.001 - 0.002 in) (0.003 in)
2nd 0.03 - 0.07 mm 0.09 mm
Ring (0.001 - 0.003 in) (0.004 in)
2. Position:
• Piston ring
Into cylinder.
NOTE:-----------------------
Insert each ring, one at a time, into the cylinder, and
push it approximately 20 mm (0.8 in) into the cylin
der. Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
3. Measure:
• End gap
Use a Feeler Gauge CD
Out of specification --.. Replace rings as set.
~
End Gap
Standard Limit
Top 0.2-0.4 mm 1.0mm
Ring (0.008- 0.016 in) (0.04 in)
Y-415
2nd 0.2- 0.4mm 1.0mm
Ring (0.008- 0.016 in) (0.04in)
Oil 0.2-0.7 mm 1.3mm
Ring (0.008 - 0.028 in) (0.05 in)
Piston Ring Oversize

• Top and 2nd piston ring
Oversize top and middle ring sizes are
stamped on top of ring.
Oversize 1 0.25 mm(0.0098 in)

Oversize 2 0.50 mm(0.0197 in)
5-21
• Oil control ring
I l'-1
ENG
Expander spacer of bottom ring (oil control
ring) is color-coded to identify sizes.
Size Color
Oversize 1 White
Oversize 2 Blue
t
Piston Pin
1. 1nspect:
• Piston pin
Blue discoloration/Grooves -+ Replace
then inspect lubrication system.
2. Measure:
• Outside diameter® (Piston pin)
Outside Diameter (Piston Pin):

17.995- 18.000 mm
(0.7085 - 0.7087 in)
3. Measure:
• Piston pin-to-piston clearance
Out of specification -+ Replace piston .
Piston Pin-to-Piston Clearance =

Bore Size (Piston Pin)@
Outside Diameter (Piston Pin) ®
Piston Pin-to-Piston Clearance:

0.004 - 0.020 mm
(0.0002 - 0.0008 in)
< limh: 0.07 mm (0.003 in) >
5-22
ENG
Crankshaft Runout
1. Measure:
• Crankshaft assembly width @.
Out of specification -+ Replace crankshaft.
Crankshaft Assembly Width @:

109.65 - 110.05 mm
(4.317 - 4.333 in)
• Crankshaft deflection @
Use V-blocks and Dial Gauge.
Crankshaft Deflection @:
0.05 mm (0.002 in)
• Connecting rod big end side clea rance@.

Out of specification -+ Replace connecti ng
72mm 49mm rod.
(2.83 in) (1.93 in )
Big End Side Clearance @:
0.2 - 0.5 mm (0.008 ... 0.020 in)
Crank Pin Outside Diameter

1. M easure:
• Crank pin outside diamete r <!)
Use a micrometer.
Crank Pin Outside Diameter:

31.95 - 31 .97 mm
(1.258 ... 1.259 in)
Crank Pin Round or Taper Limit:
0.03 mm (0.0012 in)
Connecting Rod Bearing Clearance

1.Ciean:
• Crankshaft
• Connecting rod and cap
• Connecting rod bearings
5-23
2.1nstall:
IENG l'-1
• Connecting rod bearings
into connecting rod and cap.
NOTE=-------------
Be sure to align the bearing end projection with
the notches of the connecting rod and cap.
3 .Attach :
• Plastigage ®
Onto the crank pin.
Plastigage ®
VU-33210
4 . 1nstall:
• Connecting rod
Connecting rod cap.
NOTE:-----------------------
Be sure the mark on both components align to
form perfect character. Plastigage should be go·
from rod cap to rod seam.
5 . Lubricate:
• Connecting rod bolt threads
Molybdenum Disulfide Grease or Oil
6. Tighten:
• Connecting rod cap nut
NOTE:-------------
Do not turn connecting rod until clearance
measurement has been completed .
Tighten to full torque specification without

pausing. Apply continuous torque between 3.0
and 3.8 m•kg. Once you reach 3.0 m•kg, DO NOT
STOP TIGHTENING until final torque is reached.
If tightening is interrupted between 3.0 and 3.8
m•kg, loosen nut to less than 3.0 m•kg and start
again.
5-24
INSPECTION AND REPAIR IENG l'\.1
Connecting Rod Cap:
38 Nm (3.8 m • kg, 27 ft • lb)
7. Remove:
Use care in removing.
8. Measure:
• Width of plastigage ® CD
Out of specification -+ Replace bearings
and/or replace crankshaft if necessary.
Connecting Rod Bearing Clearance:

0.020 - 0.050 mm
(0.0008 - 0.0020 in)
limit: 0.1 mm (0.004 in)
Connecting Rod Bearing Selection

• Numbers used to indicate crankpin size are
stamped on crank web CD.
~ Size
31.961-31.970 mm
1
(1.2583- 1.2587 in)
31.952-31.961 mm
2
(1.2580 - 1.2583 in)
• Connecting rod is numbered "0" or "1";

numbers are in ink, on the rod @.
~ Size
35.012 - 35.024 mm
0
(1.3784- 1.3789 in)
35.000 - 35.012 mm
1
(1.3780- 1.3784 in)
NOTE:-------------------------
This number is the match mark.
5-25 (Rev. 6/99)

INSPECTION AND REPAIR IENG l'\..1
...----------------, 1. Subtract rod size number from crank pin
number to select.
~ Color CD Part No.
0 Brown J38·11656-00
1 Black J38-11656-1 0
2 Blue J38-11656-20
5-26
ENGINE ASSEMBLY AND ADJUSTMENT IENG l'-1
ENGINE ASSEMBLY AND ADJUST
MENT
ENGINE BRACKET
1.1nstall:
• Oil level switch
• Engine bracket
Oil Level Switch Holding Screw:

10 Nm (1.0 m • kg, 7.2 ft • lb)
Y-365
Bracket Holding Bolt:
39 Nm (3.9 m • kg, 28 ft • lb)
CRANKSHAFT, CAMSHAFT AND BALAN

CER SHAFT
1. Install:
• Crankshaft
• Tappets (Exhaust G)/Intake @)
NOTE=------------------------
Be sure the tappets are positioned correctly.
Y-360
2.1nstall:
• Camshaft CD
• Balancer shaft ®
NOTE:-----------------------
Aiign the hole in the camshaft gear with the
punch mark on the crankshaft cam gear. Align
the punch mark on the balancer shaft gear with
the inkstamp mark on the crankshaft balancer
gear.
Y-367
5-27
ENGINE ASSEMBLY AND ADJUSTMENT
I l"--1
ENG
1.1nstall:
• Piston rings
onto the piston using a piston ring expander.
NOTE=------------------------
Be sure to install the rings so that manufacturer's
marks or numbers are located on the top side of
the rings. Oil the pistons and rings liberally.
2.1nstall:
• Connecting rod ®
• Piston pin ®
• Piston pin clip CD
(onto piston@)
NOTE=-------------------------
• Install the piston with the arrow mark ® on
the piston head pointing toward left of the
"Y" mark@.
• Always install new piston pin clips CD.
3.1nstall:
• Connecting rod bearings CD
Into connecting rod® and cap ®.
NOTE=------------------------
Be sure to align the bearing end projection ®
with the notches of the connecting rod and cap.
• Connecting rod bolts®

Into connecting rod ® .
4. Lubricate: .
~ Molybdenum Disulfide Grease
5-28
-~~~~~~~~~ENG I~! ENGINE ASSEMBLY AND ADJUSTMENT .
CRANKSHAFT,BALANCERSHAFT,ANDCAMSHAFT
_ ,._ _
CD Crankcase
® Balancer shaft
@ Crankshaft
@Tappet
@Camshaft
@ Oil level switch
(/) Oil drain plug
5-29
ENGINE ASSEMBLy AND ADJUSTMENT
PISTON, CONNECTING ROD, AND CRANKCASE COVER
IENG I~ I
CD Top ring @ Connecting rod bearing
® 2nd ring ®Rod cap
@ Oil ring @ Splashed plate
(1) Piston ([j) Dip stick
@ Piston pin @Filler cap
@ Piston pin clip @ Crankcase cover
(j) Connecting rod @Gasket
@Nut
@ Rod cap bolt
A CRANKCASE COVER TIGHTENING

SEQUENCE:
Y-370
38 Nm (3.8 m • kg, 28ft· lb)
14
124 Nm (2.4 m·kg, 17 ft·lb) ~
5-30 (Rev. 6/99)

5. Oil li bera lly :
IENG'"-'
• Pist on
• Rings
• Cylinder
• Piston Pin
6. Set:
• Piston ring ends
NOTE:-----------------------
M ake su re the ends of the oil ring expander does
not overlap.
CD TOP RING
® OIL RING (LOWER RAIL)
@ OIL RING (UPPER RAIL)
@2ND RING
@ ARROW MARK
7 . Install:
• Piston/Connecting rod
into cylinder using a piston ring compres
sor.
NOTE: -----------------------
The arrow ma rk on the piston should face toward
~·/
CD the front of the engine (push rod side).
Piston Ring Compressor:

YU-33294
\ .
8. 1nstall:
• Connecting rod cap CD (with bearing)
• Splash plate ®
• Connecting rod cap nuts @
NOTE:------------------------
Aiign the joint marks on the connecting rod and
cap.
Connecting Rod Cap Nut:

38 Nm (3.8 m • kg, 28 ft • lb)
5-31 (Rev. 6/99)

ENGINE ASSEMBLY AND ADJUSTMENT IENG l'\.1
9- Align the hole in the camshaft gear with the
punch mark on the crankshaft cam gear.
Align the punch mark on the balancer shaft
gear with the inkstamp mark on the crank
shaft balancer gear.
NOTE:-----------------------
Do not turn the crankshaft in this position until
the rocker arms are installed.
CRANKCASE COVER
1. Install:
• Dowel pins ®
• Gasket (New) G)
2. Install:
• Crankcase cover G)
NOTE:------------------------
Follow numerical number shown in photo.
~ Crankcase Cover Bolts:

~ 24 Nm (2.4 m • kg, 17 ft • lb)
Y-357
FLYWHEEL
tapered portion of crankshaft and flywheel
with a non-oily solvent.
2. Install:
• Pickup coil ®
NOTE:------------------------
Insert the pickup coil grommet completely into
the crankcase.
3. Install:
• Woodruff key G)
• Flywheel
• Washer
• Spring washer
• Nut
5-32
ENGINE ASSEMBLY AND ADJUSTMENT I ENG 1~1
4. Tighten:
• Flywheel securing nut
Use the primary Sheave Holder G).
Flywheel Securing Nut:

75 Nm (7.5 m ·kg, 54ft •lb)

YS-1880-A, 90890-01701
PRIMARY SHEAVE
1.1nstall:
Use the Primary Sheave Holder.
Refer to CHAPTER 4 "PRIMARY
SHEAVE - INSTALLATION" section.

85 Nm (8.5 m • kg, 61ft •lb)
CYLINDER HEAD
1. Install:
• Dowel pins
• Gasket (New) CD
• Cylinder head ®
• Bolts
NOTE=------------------------
The swelling side of the gasket CD should face
upward.
IAJ UPWARD
NOTE:-------------------------
Tighten the bolts in sequence as shown and
torque the bolts in two stages.
Bolt (Cylinder Head):

28 Nm (2.8 m • kg, 20 ft • lb)
[ID LONGER BOLT
2.1nstall:
• Rocker-arm-shaft supporter CD
Supporter Holding Bolt:
10 Nm (1.0 m • kg, 7.2 ft •lb)
5-33
FLYWHEEL
ENGINE ASSEMBLY AND ADJUSTMENT I l'-1
ENG
<DGrommet
® Pick up coil
@ Woodruff key
@Flywheel
@ Spring washer
®Nut
75 Nm (7 .5 m· kg, 54 ft·lb)
5-34
ENGINE ASSEMBLY AND ADJUSTMENT I
ENG I'\..]
3.1nstall:
• Push rods CD
NOTE:------------
• Be sure the push rod is positioned correctly.
• The hollow end® of the push rod should face
upward.
• Be sure the push rod is placed correctly onto
the tappet @ .
IAJ UPWARD
4.1nstall:
• Rocker arm (Intake) CD
• Rocker arm shaft®
• Rocker arm (Exhaust) @
5. Adjust:
• Valve clearance
Refer to CHAPTER 2 " VALVE CLEA
RANCE ADJUSTMENT" section.
Valve Clearance (Cold):

Intake and exhaust:
0.1 mm (0.004 in)
G. Install:
• Gasket (New)
• Cylinder head cover G)
• Spark plug
Bolt (Cylinder Head Cover):

10 Nm (1.0 m • kg, 7.2 ft •lb)
Spark Plug:
20 Nm (2.0 m • kg, 14ft • lb)
AIR SHROUD
1. Install:
• Air shroud (Side) CD
Bolt (Air Shroud - Side):
8 Nm (0.8 m • kg, 5.8 ft • lb)
LOCTITE®
Y-345
5-35
ENGINE ASSEMBLY AND ADJUSTMENT IENG l'-1
CYLINDER HEAD AND ROCKER ARM
Q) Cylinder head cover
® Rocker arm (Exhaust)
® Rocker arm (Intake)
@ Rocker-arm-shaft support
® Rocker arm shaft
® Push rod
(j) Cylinder head
® Gasket
VALVE CLEARANCE: (COLD)

A (Intake and Exhaust)
0.1 mm (0.004 in.)
CYLINDER HEAD TIGHTENING

8
SEQUENCE
5-36
2. Install:
IENG l"--1
•Air shroud (Front) CD (With ignition
coil)
Bolt (Air Shroud - Front):

8 Nm (0.8 m· kg, 5.8 ft·lb)
LOCTITE®
Y-344
3. Install:
• Air shroud (Rear) ®
• Oil delivery hose CD
Screw (Air Shroud - Rear):

8 Nm (0.8 m· kg, 5.8 ft·lb)
LOCTITE®
4. Connect:
• Oil delivery hose®
• Crankcase breather hose ®
• Plug cap CD
Y-342
STARTER-GENERATOR
1. Install:
• Starter-generator ®
• Bolts and nuts CD®
• V-belt@
Y-341
2. Adjust:
• Belt tension®
Refer to CHAPTER 3 "STARTER BELT
Starter Belt Tension ® :

8-12mm/10kg
(0.31 - 0.47 in/22 lb)
5-37
ENGINE ASSEMBLy AND ADJUSTMENT I I"-I
ENG
Belt Tension Bolt-Nut:
14 Nm (1.4 m • kg, 10ft • lb)
Holding Bolt-Nut:
53 Nm (5.3 m • kg, 38ft • lb)
REMOUNTING ENGINE
Reverse the "ENGINE REMOVAL" procedure.
1. Install:
• Engine (With bracket)
• Mounting nuts
Engine Bracket Mounting Nut:

35 Nm (3.5 m•kg, 25 ft·lb)
NOTE:-----------------------
Do not "twist" engine mounts when tightening
mounting nuts. This can cause vibration and/or
noise.
2. Install:
• Muffler stay (with throttle cable) ®
3. Adjust:
• Engine bracket tensioner cable <D
Refer to CHAPTER 2 "ENGINE BRACKET
Engine Bracket Tension Free Play:

2 mm (0.08 in)
4. Install:
• Muffler assembly (with new gasket @l
• Muffler mount bolts ®
• Exhaust pipe holding nuts <D
• Carburetor
5. Tighten:
• Bolts/Nuts/Screws
Exhaust flange Nut CD :

20 Nm (2.0 m· kg, 14 ft·lb)
1---::o~ Muffler Holding Bolt®:
14 Nm ( 1.4 m· kg, 10 ft· lb)
Carburetor Holding Nut:
6 Nm (0.6 m· kg, 4.3 ft·lb)
Spark Plug:
20 Nm (2.0 m·kg, 14 ft·lb)
5-38
6. Connect:
ENG l'\.1
• Throttle cable
• Choke cable
• Fuel hose
7 . Adjust:
• Free play (Throttle cable 2)
Refer to CHAPTER 2 "THROTTLE
CABLE ADJUSTMENT" and "CHOKE
Free Play (Throttle Cable 2 ):

0.5 mm (0.02 in)
1.0 mm (0.04 in)
8. Fill:
• Crankcase
Refer to CHAPTER 2 "ENGINE OIL
REPLACEMENT" section.
Recommended Oil:
YAMALUBE 4-cycle oil or
does not go below
2·c (35.F): SAE 20W40]
0.9 L (1 .0 US qt, 0.19 Imp gal)
Oil Capacity:
1.1 L (1.16 US qt, 0.241mp gal)
NOTE:-------------------------
Service SE, SF, or SG. Engine oils labeled
"Energy Conserving II" are recommended.

engine.
5-39
cARBURETION lcARsl f I
CHAPTER 6
CARBURETION
CARBURETOR ................................................. 6-1

SECTION VIEW .......................................... 6-2
REMOVAL ................................................... 6-4
DISASSEMBLY ........................................... 6-4
INSPECTION ............................................... 6-5
ASSEMBLY ................................................. 6-6
INSTALLATION .......................................... 6-7
_____________ c_A_R_eu_R_e_ro_R_I~R~~~
CARBURETION
CARBURETOR SPECIFICATIONS
CD Cable housing clamp Main jet (M.J.) #102.5
® Pilot screw (P.S.) Main air jet (M.A.J.) 02.5
@Throttle stop screw Pilot jet (P.J.) #60
@ Main jet (M.J.) Pilot air jet (P.A.J.) 01.2
@Main nozzle Throttle valve (Th.V.) #120
®Float Valve seat (V.S.) 01.2
(j) Float chamber cover By-pass (1) (B.P.-1) 00.6
By-pass (2) (B.P.-2) 00.7
® Cover holding bolt By-pass (3) (B.P.-3) 00.9
® Float needle valve
By-pass (4) (B.P.-4) 00.6
@ Pilot jet (P.J.) Pilot outlet (P.O.) 01.0
Pilot screw (P.S.) 1 turn out
Float height (F.H.) 14.5 mm (0.57 in)
CHOKE CABLE FREE PLAY:

A
1.0 mm (0.04 in)
:: o
THROTTLE CABLE FREE PLAY:

0.5 mm (0.02 in)
FLOAT HEIGHT (F.H.):
Yo373A
6-1 (Rev. 6/99)
--------------------------------
SECTION VIEW
lcARsl f cARBUREToR I
Main Metering System
Q) Main nozzle ®Throttle valve A ¢:1 AIR

® Main air jet @Pilot jet
8 9 M IXTURE
@ Choke valve
@ Pilot air jet
®Float
@ Bypass hole
c
• FUEL
@Main jet
(f) Cover holding bolt
@ Float chamber cover
6-2
_ _ _ _ _ _ _ _ _ _ _ _ _ _c_A_R_s_u_RE_T....:o_R
Float System
lcARBI f I
G) Main nozzle
®Float
A ¢:J AIR
® Float chamber cover
® Cover holding bolt B ¢J MIXTURE
® Needle valve
®Valve seat
(J) Fuel inlet
c
• FUEL
6-3
CARBURETOR ICARBI •
REMOVAL
1. Remove:
Refer to CHAPTER 5 "ENGINE RE
MOVAL- CARBURETOR" section.
If the throttle valve is disassembled, a repair kit

must be installed as screws are clinched and will
damage shaft if removed.
DISASSEMBLY
1.Remove:
• Cover holding bolt CD
• Gasket®
• Float chamber cover @
• Rubber gasket ®
Y-375
2. Remove:
• Main jet CD
• Float pin®
~~~-~ltll~t~i. ----------
Float pin is staked on one end. When driving
out float pin, use pliers, side cutters or a small
punch on opposite end of staking. Use care
not to break the float stanchions
Y-377
3. Remove:
• Float CD
• Float needle valve ®
• Main nozzle (located in center of float
chamber)
Y-378
4. Remove:
• Pilot jet CD
• Throttle stop screw® (with spring)
• Pilot screw® (with spring)
6-4 (Rev. 6/99)

--------------~-R_B_u_R_~_o_R_~AR~·~
INSPECTION
1. 1nspect:
• Carburetor body
• Fuel passage
Contami nation · ~Clean .
NOTE:-----------------------
• Use a carburetor cleaner (such as acetone) for
cleaning.
• Blow out al l passag es and jets with com
pressed air.
A WARNING
Carburetor cleaners are extremely flammable.
• Keep sparks and flames away fro'T' work area.
• Follow all cleaner manufacturer's warnings
and instructions.
• Never use gasoline as a cleaning agent.
2. 1nspect:
• Float CD
Y·380 Y-381 Damaged - Replace.
NOTE: -----------------------
Be su r e that st opper t ab @ is 90° t o f l oat
bracket@.
• Rubber gasket ®
Damaged/Torn - Replace.
• Needle va lve ®
Wear - Replace.
• Valve seat
Wear/Damage -+ Replace the carburetor
body.
3. 1nspect:
• Throttle stop screw CD
• Pilot screw ®
• Pilot jet @
Wear/Damage/Corrosion - Replace.
4.1nspect:
• Throttle valve <D
Wear/Damage - Install kit.
• Choke va lve ®
Wear/Da mage -+ Replace carburetor body.
5. Check:
• Choke valve f ree m ovement
Sticking - Replace parts.
6.1nspect:
• Main jet CD
• Main nozzle ®
• Pilot jet®
Contamination • Clean/Replace.
NOTE=- - - - - - - - - - - -
v-385 Blow out the jets w ith com pressed air.
6-5
--------------~-R_B_U_R_H_O_R_~AA~~~
ASSEMBLY
Reverse the "DISASSEMBLY" procedures.
NOTE:-----------
Before reassembling, wash all the parts with a
carburetor cleaner (such as acetone).
A WARNING
• Keep sparks and flames away from work area.
and instructions.
• NEVER use gasoline as a cleaning agent.
1. Install:
• Pilot jet CD
• Throttle stop screw® (with spring)
• Pilot screw@ (with spring)
Y-379
NOTE:---------------
See page 2-13 for pilot screw and throttle stop
screw settings.
2. Install:
• Main nozzle
• FloateD
• Float pin
Y-378
3. Measure:
• Float height
Float Height (F.H.):

14.5 mm (0.57 in)
Measurement and adjustment steps:

• Hold the carburetor in an upside down
position.
• Incline the carburetor at 60 - 10· (so that
the float valve does not compress as a result
of float weight).
• Measure the distance from the inside of the
gasket sealing surface of the carburetor body
to the top of the float.
6-6 (Rev. 6/99)

cARBUREToR jcARsl f I
NOTE:----------------------
The float should be just resting on, but not
depressing, the spring loaded inlet needle.
• If the float height is not within specification,

inspect the valve seat and needle valve.
• If needle valve rubber seat or body is worn,
or if spring is damaged or sticking, replace
needle valve.
v.a86 • If valve seat is worn, replace carburetor.
• If both are fine, adjust the float height by
bending the float tang <D on the float.
~~~~~~~~-----------
Do not move float stopper tab to adjust float
level.
• Recheck the float height.
4. Install:
v-387 • Main jet <D
5. • New rubber gasket

• Float chamber cover
• Cover holding bolt
INSTALLATION
1.1nstall:
• Carburetor

6 Nm (0.6 m • kg, 5.3 ft • lb)
6-7
I I
ELECTRICAL
--------------------------------------------
iii I ELEC
CHAPTER 7
ELECTRICAL
ELECTRICAL FOR G14-A

G14-A WIRING DIAGRAM ..................................7-1
ELECTRICAL COMPONENT
LOCATIONS .........................................................7-2
ELECTRICAL COMPONENTS .......................... 7-3
STARTING AND CHARGING SYSTEM .......... 7-5
TROUBLESHOOTING ................................ 7-7
• THE STARTER DOES NOT TURN ......... 7-7
• THE BATTERY IS NOT CHARGED ...... 7-11
STARTER GENERATOR ........................... 7-13
SOLENOID RELAY ................................... 7-20
VOLTAGE REGULATOR .......................... 7-21
IGNITION SYSTEM ....................................... 7-23

TROUBLESHOOTING .............................. 7-25
• NO SPARK OR WEAK SPARK ............. 7-25
SIGNAL SYSTEM .......................................... 7-29

• THE OIL LEVEL INDICATOR
LIGHT DOES NOT COME ON ............. 7-31
• THE BACK-UP BUZZER DOES
NOT OPERATE ..................................... 7-34
ELECTRICAL FOR G14-E

G14-E WIRING DIAGRAM ................................7-37
ELECTRICAL COMPONENTS ........................ 7-39
STARTING AND RECHARGING SYSTEM .... 7-40
TRACTION MOTOR ................................. 7-50
MOTOR CONTROLLER ............................ 7-57
I
SOLENOID RELAY ..................................... 7-63
SIGNAL SYSTEM ......................................... 7-64

TROUBLESHOOTING ............................. 7-66
C)
...
..a
I
)>
COLOR CODE
@@:1--e - - , B ............. Black R ............. Red ~
L. ............. Biue P ............. Pink 2;!
® 0=:=00=:---+---e Y .............Yellow
G ............. Green
9l
O .............Orange
Br ............ Brown
B/R .......... Black/Red
RJW ......... Red/White
z
C)
c
)>
@F?l--B~R W/B .........White/Biack
W/R .........White/Red C)
REV~R~P-----.J @) :lJ
)>
®~ Rm------88--1 s: m
r-
~ Br~Br t il Ill m
n
-1
:a
Br
R I • I
RrN
-
n
)> m
r-
-...J
....
I B
.,
r- m
~
0 :lJ
:a 0
CD Ignition coil
®Buzzer
@ Back switch
® Accelerator switch
@ Main switch
®Relay
@ Starter generator
® Voltage regulator
@ Oil level gauge
@Rotor
-.®~ ~®
ut ~
'
y C)
I
)>
)>
....
,a:.
r-
"TT
0
:lJ
Q
...
..a
®TT. ~ n rh®
@Pilot lamp (12V, 3.4W) ®Pick-up I
(!)Battery @)Ignitor )>
® Body ground
@Fuse (10A)
~
~ 'f -m
r-
m
0
Y-58 -
IJ
ELEcTRICAL FoR G14-A IELecl iii I
ELECTRICAL COMPONENT LOCATIONS
CD Main switch
® Accelerator stop switch
@ Ignition coil
@Spark plug
@ Ignitor unit
® Pickup coil
(f) Rotor
@ Voltage regulator
® Starter-generator
® Solenoid relay
QD Battery (12V)
@Fuse
@Oil level switch
® Oil level indicator light
@ Back switch
@ Back-up buzzer
/
.,.,..------ '
I \
\
' ..... ______ , /
I
,..------....
II '
\
' ______
I I
\ ., I
/
9 3 4
7-2
ELECTRICAL FOR G14-A IELECIIiii I
ELECTRICAL COMPONENTS
G) Solenoid relay @ Battery plus lead clamp
®Pilot lamp @) Starter/generator
@ Main switch ®Battery
@ Accelerator stop switch
@ Oil level switch
®Wire harness assembly, fuse
(J) Back-up buzzer
@ Earth lead wire
7-3
ELEcTRicAL FoR G14-A IELEcl iiiil
CD Pickup coil
@Flywheel
® Ignition coil
(!) Ignitor unit
@ Starter/generator belt tensioner
7-4
en
;
~
@(§>---- B----. COLOR CODE
B ............. Black R ............. Red
z
C)
L .............. Biue P .............Pink
)>
®Q=:~:~
Y .............Yellow O .. ,..........Orange
G .............Green Br ............Brown 2
c
• FWD~
® -~-- B =ffiffi=
: : R
9 B/R .......... Black/Red
R/W......... Red/Whi.te
W/B .........White/Black
W/R .........White/Red
n
::z:
)>
- REV R p _----.J :a
@) -2
C)
@~:'~, +II ·. , ... ·. II I

C)
en
<
Br
~
m
@1 : _1 I ~ I ,... l
R
B
I •.
~1m
r-
-..1
u, m
~
® :a
c;
)>
r-
<D Ignition coil @Relay "T1
®Buzzer ® Starter generator 0
@ Back switch @ Voltage regulator :a
@ AcCelerator switch @ Oil level gauge C)
@ Main switch
@Pilot lamp (12.V, 3.4W)
@Rotor
®Pick-up
,.•
..a
(!) Battery · ®Ignitor )>

@Fuse (10A) ® Body ground ,;
-m
r-
m
-n
I
ELECTRICAL FOR G14-A IELECI iii I
STARTING AND CHARGING SYSTEM COMPONENTS
CDMain switch
® Starter-generator
® Solenoid relay
@ Battery (12V)
@Fuse
/
,------ '
( \
\
\ ...... ______ ., I
I
,---- -.-...
II ' \
I
\
..... ______ ., /
I
I
7-6
ELECTRICAL FOR G14-A IELECI iiii I
TROUBLESHOOTING
THE STARTER DOES NOT TURN
Procedure
Check:
1. Battery 6. Solenoid relay
2.Fuse 7. Wiring connection
3. Main switch
4. Accelerator stop switch
5. Starter-generator
NOTE:----------------------------------------------------------
• Remove the following parts before troubleshooting.
1) Seat
2) Service lid
3) Drink holder insert.
• Use the following special tools in this troubleshooting.
Pocket Tester: Hydrometer:

YU-3112-C, 90890-03112 YU-03036, 90890-03036
1. Battery
• Check the battery condition. INCORRECT
Refer to CHAPTER 2 "BATTERY INSPEC-
TION" section.
Specific Gravity:
1.260 at 2o·c (68.F) • Refill battery fluid.
Voltage: • Clean battery termi nals.
12V • Recharge or replace battery.
~CORRECT
2.Fuse NO CONTINUITY
• Remove the fuse.
• Connect the Pocket Tester (Q x 1) to the
fuse.
• Check the fuse for continuity. I Replace fuse.
l
~ CONTINUITY
*
7-7
ELEcTRICAL FoR G14-A IElEcj iii I
3. Main switch
• Disconnect the main switch coupler from
the wireharness.
main switch.
Tester(+) Lead -+ Red Lead CD

Tester (-) Lead -+ Brown Lead®
nx1
E21 .-rrl ·2~

(
8 A
~/A Br
t9~ 9 -
l \..._..... }
• Turn the main switch to "ON", UCHECK" and

UOFF".
• Check the main switch for continuity.
Switch Good
position condition Bad condition
BAD CONDITION
OFF X 0 X 0
CHECK
ON 0
X 0
X
X
X
0
0
I
l
o: Continuity x : No continuity Replace main switch.
I
~ GOOD CONDITION
• Disconnect the accelerator stop switch leads
from the wireharness.
• Connect the Pocket Tester (Q x 1) to the accel
erator stop switch.
Tester(+) Lead -+ Brown Lead CD

Tester(-) Lead .... Red/White Lead ®
7-8
• Push the accelerator pedal.
ELECTRICAL FoR G14-A IELecjlii I
• Check the accelerator stop switch for continu-
ity.
Accelerator Pedal Good Bad BAD CONDITION

Position Condition Condition
Push 0 0 X X
Free X 0 0 X
0: Continuity x : No continuity IReplace accelerator stop switch.
~ GOOD CONDITION
5. Starter-generator *A WARNING
• Connect the battery positive terminal CD • A wire for the jumper lead must have at least
and starter-generator terminal F2 ® using
the equivalent capacity of the battery lead or
the jumper lead®*·
the jumper lead may bum.
• Connect the battery negative terminal ®
• This check is likely to produce sparks, so be
and starter-generator terminal A 1 ® using
sure that no flammable gas or fluids are in the
the jumper lead®*·
vicinity.
• Check the starter-generator operation.
I
FAULTY
I
~
I
~- ----- ---J
,
l
Repair and/or replace starter-generator.
~OK
6. Solenoid relay
• Disconnect the solenoid relay leads (Red/
White, Black).
• Connect the battery positive terminal CD and
solenoid relay lead (Red/White)® using the
jumper lead @ .
• Connect the battery negative terminal® and
solenoid relay lead (Black) ® using the
jumper lead ®.
• Check the starter-generator operation.
7-9
ELECmiCAL FOR G14-A IELECI iii I
FAULTY
r-----J
,
I
I
I
i
Replace solenoid relay.
~ OK
7 . Wiring connection
• Check the entire starting system for connec
tions.
Refer to "STARTING AND CHARGING SYS
TEM DIAGRAM" on page 7-5.
7-10
ELEcTRicAL FoR G14-A jELEcl iliii j
THE BATTERV IS NOT CHARGED I
Procedure
Check:
1. Battery
2. Charging voltage
3. Charging coil resistance
4. Wiring connection
NOTE:---------------------------------------------------------
1) Seat

VU-3112-C, 90890-03112 VU-03036, 90890-03036
1. Battery
Refer to CHAPTER 2 "BATTERY IN SPEC-
TION" section .
Specific Gravity:
1.260 at 2o·c (68.F) • Refill battery fluid.
12V • Recharge or replace battery.
~ GOOD CONDITION
2. Charging Voltage
• Connect the Pocket Tester (DC20V) to the
battery.
Tester(+) Lead ...... Battery Positive Terminal

Tester(-) Lead ...... Battery Negative Terminal
7-11
ELECTRICAL FoR G14-A IELecl iii I
14.5- 15.5 v. *A WARNING
Be sure the drive belt is removed when starting
the engine. The speed limiter will not function,
so you must regulate engine speed with the
throttle.
• Remove the drive belt.

• Start the engine and accelerate to about MEETS SPECIFICATION
2,500 r/min.*
• Measure the charging voltage.
Charging Voltage:
14.5- 15.5V at 2,500 r/min I Replace battery.
I OUTOF
.... SPECIFICATION
3. Charging coil resistance

• Disconnect the starter-generator thin leads
(Red, Green).
starter-generator thin leads.
Tester(+) Lead -+ Red Lead

Tester (-) lead -+ Green lead OUT OF SPECIFICATION
• Measure the charging coil resistance.
~ c
Charging Coil Resistance:
4.5 - 5.5Q at 20· C (68.F)
l
I Repair and/or replace starter-generator. I
n MEETS
"'(7 SPECIFICATION
4. Wiring connection POOR CONNECTION
• Check the entire starting system for con

nections.
Refer to "STARTING AND CHARGING SYS
TEM DIAGRAM on page 7-5.
I Correct.
l -------
~CORRECT
Repair and/or replace voltage regulator.
7-12
ELEcTRicAL FoR G14-A IELEcliii I
STARTER-GENERATOR
Q) Brush cover @Terminal NOTE=------------------------
® Bearing
@ Brush holder
@Yoke
@ Bearing holder
* The drai n slot in the brush cover having a drain
slit must face downward.
@ Brush-spring @ Bracket (Puller side)
@ Woodruff key
® Armature assembly
(]) Brush
® lead wire
® Bracket (Brush side)
7-13
ELEcTRicAL FoR G14-A IELEcj iii I
Removal
1. Remove the seat
2. Disconnect the battery negative lead.
3.Remove:
• Air cleaner case CD
Refer to CHAPTER 2 "ENGINE BRACKET
ADJUSTMENT'' section.
4. Disconnect:
• Starter-generator lead to relay (Red) CD
• Starter-generator lead to neg battery post
(Black)
• Start-generator lead to fuse (Black)
• Starter-generator charging coil leads (Red,
Green)@
Y-329
5. Attach:
• Primary Sheave Holder to primary sheave.

YS-1880-A, 9089~01701
6. Loosen:
• Pulley nut (starter-generator) while holding
primary sheave in place.
7. Remove:
• Bolts and nuts CD, CV
• V-belt @
• Starter-generator@
Y-341
Disassembly
1.Remove:
• Pulley nut
• Washer
• Belt pulley
• Woodruff key
7-14
ELEcTRICAL FoR G14-A IELEcllilill
2. Remove:
• Brush covers
• Lead connecting screws CD
Hold brush holder tabs in place with pliers when

removing stubborn lead connecting screws to
avoid twisting tabs.
Y-393
3.Remove:
• Brush CD
Remove it while pulling up the brush
spring® with a spring puller (made from
steel wire) ®or a bent paper clip.
Do not pull wire lead of brush. Use care when

removing brushes, they are easily damaged.
4.Remove:
• Bolts CD
5. Separate the yoke, armature and bracket
(brush side).
6 . Remove:
• Screws CD
7. Separate the bracket (pulley side) and
armature assembly.
Inspection .
1 . Clean the interior of the yoke and brackets
with compressed air.
2.1nspect:
...
• Outer surface (yoke and brackets)
--
'~
Y-397
7-15
ELecTRICAL FoR G14-A IELEcliiii I
3.1nspect:
• Yoke
EEJ
0
0.005-
0.007Q Defects__,. Replace.
Yoke inspection steps:

• Connect the Low Reading Ohmmeter to the
yoke terminal F1, F2.
• Connect the Pocket Tester to the charging coi I
leads (Red, Green).
• Measure the field coil resistance (Series and
Shunt).
~
Low Reading Ohmmeter:
YU-91026, 90890-03064
Pocket Tester:
YU-3112-C, 9089Q-03112
~
Field Coil Resistance:
Series (f1- F2):
0.005 - 0.007Q at 2o·c (68.F)
Shunt (Red - Green):
4.5 - 5.5Q at 2o·c (68.F)
• If the resistance is incorrect, replace the

yoke.
4.1nspect:
• Commutator (Outer surface)
Hold the armature in a vise CD between
copper or aluminium plates® .
Dirty __,. Clean with #600 grit emery
cloth®.
Hold armature lightly between padded vise jaws

to avoid damaging armature.
5. Measure: ·
• Commutator (Diameter)
Out of specification --. Replace.
Measure the diameter of the commutator
as shown.
Wear Limit (Mimimum Diameter):

39 mm (1.54 in)
7-16
ELECTRICAL FoR G14-A IELEcl iliii I
6. Measure:
A CORRECT
• Mica CD (Insulation depth)
(between commutator segments)
Out of specification -+ Scrape mica to
proper limits.
Use a hacksaw blade ® that is ground to
fit.
Mica Undercut @:
Limit: 0.3 mm (0.012 in)
B INCORRECT
NOTE:-------------------------
• The mica insulation ofthe commutator must be
undercut to ensure proper operation of the
commutator.
• Carefully clean between the segments after the
above steps.
1 Mil or more on 7 .Inspect:

• Armature coil (insulation/continuity)
Defects-+ Replace armature.
Armature coil inspecting steps:

• Connect the Pocket Tester for continuity
check CD and insulation check® .
• Measure the armature coil resistances.
~
Pocket Tester:
YU-3112-6, 90890-03112
~
Armature Coil Resistances:
Continuity Check CD :
on at 2o·c (68.Fl
Insulation Check ® :
More than 1M.Q at 2o·c (68.Fl
• If the resistance is incorrect, replace the

armature.
8. Check:
• Bearing movement
Rotate with fingers.
Roughness/Wear-+ Replace.
Y·399
7-17
ELECTRICAL FoR G14-A IELEcl iii I
Bearing replacement steps:
• Remove the bearing CD with a bearing puller
®.
• Install the new bearing.
Do not strike the outer race CD or balls of

the bearing. Contact should be made only
with the center race ® .
©PRESS
Y-114
9. Measure:
• Brush length
Out of specification -~ Replace.
Minimum Brush Length @:

16 mm (0.63 in)
CD Wear indicator
Assembly
Reverse the "Disassembly" procedure.
Y-115
1. Measure:
• Brush spring force
Use a spring scale CD.
Pull the scale and check reading as the
I I
.. I
brush spring just comes off the brush.
Brush Spring Force:

300-500 g (10.6- 17.6 oz)
7-18
ELECTRICAL FoR G14-A IELEcliiii I
Installation
1.Adjust:
• Starter belt tension
Refer to CHAPTER 2 "STARTER BELT
Starter Belt Tension:

8- 12 mm/10 kg
(0.31- 0.47 in/22 lbJ
2.Tighten:
• Bolts and nuts G), ®
Belt Tension Bolt-Nut CD:
14 Nm (1.4 m • kg, 10ft • lb)
Starter Holding Bolt-Nut ® :
53 Nm (5.3m • kg, 38ft •lb)
Y-400
3. Tighten:
• Pulley nut
Tighten it white holding the primary sheave
with Primary Sheave Holder.
Pulley Securing Nut:

50 Nm (5.0m • kg, 35ft • lb)

Y8-1880-A, 90890-01701
7-19
ELEcTRicAL FoR G14-A IELEcl iiiii I
SOLENOID RELAV
Function
The solenoid coil, when activated by closing the
engine stop switch, closes the solenoid contacts,
thus providing the starter with cui·rent.
It also acts as a safety device, preventing the
vehicle from abruptly starting when the main
switch is operated.
Inspection
1. Remove:
• Seat
• Drive belt
2. Turn the main switch to "ON" G).
3. Check:
• Solenoid relay (Clicking)
Press the accelerator pedal to close the
engine stop switch.
If clicking - Check for continuity between
the two contact posts with Pocket Tester,
while the solenoid is activated. If there is no
continuity, replace the relay.
Not clicking - Measure coil resistance in
solenoid.
4. Disconnect:
• Solenoid coil leads (Black, Red/White)
5. Measure:
Y-422
• Coil resistance
Use the Pocket Tester®.
Out of sp~cification .... Replace.
Within specification .... Inspect starting
circuit.
Refer to "TROUBLESHOOTING" section.
Pocket Tester:
VU-3112-C, 90890-03112
Solenoid Coil Resistance:

21n ± 10% at 20· C (68. F)
Y-116
7-20
ELEcTRicAL FoR Gt4-A
6. Check:
IELEcl iiii I
• Connection of leads to main solenoid termi
nals.
Looseness -+ Tighten.
Terminal Nut:
6 Nm (0.6 m • kg, 4.3 ft • lb)
7. Replace:
Y-401
• Drive belt
Removal
1. Disconnect:
• Battery positive lead
• Leads to solenoid terminals
2. Remove:
• Solenoid relay
Installation
1 . 1nstall:
• Solenoid relay CD
2.Connect:
• Lead from starter-generator (Red)
• Leads to solenoid coil (Black, Red/White)
• Battery negative lead (Black)
VOLTAGE REGULATOR
Generator Voltage Inspection
1. Remove:
• Drive belt
Refer to CHAPTER 2 "DRIVE BELT
2. Connect the Pocket Tester (DC20V) to the
battery.
Pocket Tester:
VU..3112-C, 90890-03112
7-21
ELEcTRicAL FoR G14-A IELEcllili I
3. Start the engine and accelerate to about
2,500 r/min.
4. Measure:
• Generator voltage
Out of specification --. See page 7-11 for
troubleshooting.
Generator Voltage:
14- 15V
Y-402
CD Voltage regulator
NOTE:-----------------------
The voltage regulator is solid state and non-
adjustable. Refer to page 7-11 "THE BATTERY IS
NOT CHARGED" for troubleshooting procedures.
7-22
-
C)
2
=t
COLORCOQE 0
-..
@@>-s - - B .............Black R ..... .,....... Red 2
- L. ............. Biue P ............. Pink en
0===00==---+--. <
Y .............Yellow O .............Orange
~
G .............Green Br ............ Brown
® B/R .......... Black/Red
&)R- B~R <D

<==u . R/W ......... Red/White
W/B .........White/Black
m
3:
REV ~ R~P----' @)
®~ RrN--AB--1
l_2j-- Br~Br----...w-~·:.____~---+---+-
RrN
®I B I I~ I I m
"";-J r
N
(,)
B m
~
® :a
~
-.®rnlJt
y
r-
G) Ignition coil
®Buzzer
@Relay
® Starter generator ~ "TI
0
~@ .
® Back switch ® Voltage regul~tor :a
@ Oil level gauge C)
@ Accelerator switch
@ Main switch ® Rotor ,.
..a
®T T. ~ n ~@
@Pilot lamp (12V, 3.4W) ®Pick-up I
(J) Battery @ Ignitor )>

@Fuse (10A) ® Body ground
A~ 'r m
r
m
Y-58 -n
I
ELEcTRICAL FoR G14-A IELEcl iii I
IGNITION SYSTEM COMPONENTS
CD Main switch
@ Ignition coil
@Spark plug
@ Ignitor unit
® Pickup coil
(J) Rotor
@ Battery (12V)
@Fuse
/
,.,.------ '
I \
\
\ ..... ______ .,I
I
,-------..
II ' \
I
' ....____ __ ,/
)
2 3
7-24
TROUBLESHOOTING
NO SPARK OR WEAK SPARK.
Procedure
Check:
1. Spark plug 4. Ignition coil resistance
2. Ignition spark gap 5. Pickup coil resistance
3. Spark plug cap resistance 6. Wiring connection
NOTE:--------------------------------------------------------
1) Seat
• Use the following special tool in this troubleshooting.
Pocket Tester: Dynamic Spark Tester:

YU-3112-C, 90890-03112 YM-34487, 90890-03144
1. Spark plug
• Check the spark plug condition.
• Check the spark type.
• Check the spark plug gap.
Refer to CHAPTER 2 "SPARK PLUG INS-
PECTION" section.
INCORRECT
Standard Spark Plug:
~
BPR2ES or BPR4ES
Spark Plug Gap:

I
l
0.7 .. 0.8 mm (0.028 .. 0.032 in) Repair or replace spark plug.
I
~CORRECT
7-25
2. Ignition spark gap
• Disconnect the spark plug cap from spark
plug.
• Connect the Dynamic Spark Tester CD as
shown.
(g) Spark plug cap
@spark plug
• Turn the main switch to "ON".
• Check the ignition spark gap. MEETS SPECIFICATION

• Start engine, and increase spark gap until
misfire occurs.
It:==========;,
jj,.
Minimum Spark Gap:
6.0 mm (0.24 in) I Ignition system is good.
I OUT OF SPECIFICATION
. . ORNOSPARK
7-26
ELECTRICAL FOR G14-A I c liiiii I
ELE
3. Spark plug cap resistance
• Remove the spark plug cap.
• ConnectthePocketTester(Qx 1k)tothespark
plug cap.
lnx I lK
___.... - §+
l I'i>
J
<
OUT OF SPECIFICATION
• Check the spark plug cap for specified
~
resistance.
Spark Plug Cap Resistance:

I
l
3.75- 6.25 kQ at 20" C (68. F)
n MEETS
Replace spark plug cap.
I
~SPECIFICATION
4. Ignition coil resistance
• Disconnect the ignition coil coupler from

the wireharness.
• Connect the Pocket Tester to the ignition
coil.
Primary Coil [A] : Secondary Coil [ID :

Tester(+) Lead -+ Red/White Lead Tester(+) Lead -+ Red/White Lead
Tester (-) Lead -+ Orange Lead Tester(-) Lead -+ Spark Plug Lead
0
nx 1
R/W
7-27
eLEcTRICAL FoR G14-A IELEcl iii I
• Measure the primary and secondary coil re-
sistances.
~ l
Primary Coil Resistance:
2.6n ± 20% at 20· c (68. F)
Secondary Coil Resistance:
11.9kn ± 20% at 20· c (68. F) I Replace ignition coil.
I
BOTH MEET
SPECIFICATIONS
5. Pickup coil resistance
• Disconnect the pickup coil coupler from the

wireharness.
pickup coil terminal.
Tester(+) Lead ~ White/Red Lead

Tester(-) Lead ~ White/Black Lead
- n x 100
[2]
~~~ 9~i
'f- J
• Measure the pickup coil resistance.
~
Pickup Coil Resistance:
3500 ± 20% at 20· C (68. F)
(White/Red -White/Black) I ~--
Replace pickup coil.
~
n MEETS
SPECIFICATION
6. Wiring connection POOR CONNECTION
Check the entire ignition system for con

nections.
Refer to "IGNITION SYSTEM DIAGRAM" on
page 7-25. ICorre~t.
l -----.....,
~CORRECT
I
Replace ignitor unit.
7-28
tn
C5
z
)>
CO~ORCODE r-
@@>-a - - . . B ...:.........B!ack R ........\.... Red.,,,. tn
L .............. Bt.ue P ......... :'.._.Pink' ,. _ <
®0=:=00=:~
Y ......... :;...Yellow o ..,........:.orange tn
G ............. Green Br ............Brown -f
m
@F:1+-s~R
<91 B/R .......... Black/Red
RM/.....:•.. Red/WI:lite
W/B ........ ;White/Black,
W/R ........ .White/Red .
3:
REV ~ R-01S--P ------1

@
@f0>=l--_MY~I
~ Br~Br -'i •II II I
MY
":-'
m
rg r
8 m
(")
-f
::u
-
~
CD Ignition coil
®Buzzer
@ Bac.k switch
@Relay
@) .Starter generator
@Oil level gauge
MY .:L _
. If ~ · ~ .
rn-
® 8~G - ~y
B B
.,r
0
::u
....C)
'@ ...
til@
@Main switch @Rotor
~ F}
B
@Pilot lamp (12V, 3.4W) @Pick-up
® lgnitor
@) A G '
CZ> Battery )>
I .. ·. · 1 y
® Body ground I I,
~ ~
@,Fuse (1 OA)
..... fl--bL, m
r
m
(")
Y·58
I
ELEcTRICAL FoR G14-A IELEcl iiiii I
SIGNAL SYSTEM COMPONENTS
G) Main switch
@ Ignitor unit
® Battery (12V)
@ Fuse
@ Oil level switch
® Oil level indicator light
® Back switch
® Back-up buzzer
/
..,..------ '
( \
\
\ ..... ______ .., I
I
,..----- ........
I '
I \
I
' ..... ______ ,./
J
7-30
ELECTRICAL FOR G14-A IELECIIiill
TROUBLESHOOTING
THE OIL LEVEL INDICATOR LIGHT DOES NOT COME ON
Procedure
Check:
1. Bulb 4. Voltage to lamp
2. Bulb socket 5. Wiring connection
3. Oil level switch 6. Lamp check
NOTE=--------------------------------------------------------
1) Seat
2) Drink holder insert

YU-3112-C, 98090-03112 YU-03036, 90890-03036
1. Bulb
• Remove the bulb.
bulb.
nx1
[2]
<@9
-" l J NO CONTINUITY
I
l
• Check the bulb for continuity. Replace bulb.
I
~ CONTINUITY
2. Bulb socket
• Disconnect the indicator light leads (Green,
Yellow) .
leads.
Tester(+) Lead ~ Green Lead

Tester(-) Lead ~ Yellow Lead
7-31
ELEcTRICAL FoR G14-A IELEcj iii I
nx1
NO CONTINUITY
• Check the bulb socket for continuity. IReplace bulb socket.

l
~ CONTINUITY
3. Oil level switch

• Disconnect the oil level switch lead.
• Connect the Pocket Tester (.Q x 1) to the oil
level switch lead (Black).
Tester (+) lead -. Black lead

Tester (-) lead • Ground (Engine body)
• Turn the main switch to the "Check" position
(halfway between "off" and "on").
• Check the oil level switch for continuity.
• Drain the engine oil.
Refer to CHAPTER 2 "E NGINE OIL RE-
PLACMENT" section.
• Check the oil level switch for continuity.
Oil level Good condition Bad condition BAD CONDITION
Full
Empty
X
0
X
X
0
X
0
0
I
l
o: Continuity x : No continuity Replace oil level switch.
I
~ GOOD CONDITION
4. Voltage to lamp
NO VOLTAGE
n I Replace ignitor unit. - - - - - - - - .

~ GOOD CONDITION
7-32 (Rev. 6/9~ 1

ELECTRICAL FoR G14-A IELEcl iii I
*
~ POOR CONNECTION
• Check the connections of the entire signal

system.
Refer to signal "SIGNAL SYSTEM WIRING I
l --------.
Correct the connectio_n_._ _ _ _ _.......
DIAGRAM" on page 7-33.
~CORRECT
6. Lamp check
• Turn the main switch to "CHECK" to verify

repairs are satisfactory.
I••••••••••••
BULB DOESN'T LIGHT
..
I Recheck wiring connections.
7-33
ELEcTRICAL FoR G14-A IELEcliiii I
THE BACK-UP BUZZER DOES NOT OPERATE I
Procedure
Check:
1. Battery
2.Fuse
3. Buzzer switch
5. Back-up buzzer
NOTE:------------------------------------------------------
1) Seat

YU-3112-C, 90890-03112 YU-03036, 90890-03036
1. Battery
Refer to CHAPTER 2 "BATTERY IN SPEC-
TION" section.
Specific Gravity:
1.260 at 20· C (68. Fl • Refill battery fluid.
12V • Recharge or replac e battery.
~ CORRECT
2.Fuse NO CONTI NUITY
• Remove the f use.
fuse.
• Check the fuse for continuity. I
Replace f use.
l
~ CONTINUITY
*
7-34
ELECTRICAL FOR G14-A IELECI iiii I
3. Buzzer switch
• Disconnect the buzzer switch coupler.
buzzer switch coupler.
Tester(+) Lead _,. Red Lead

Tester (-) Lead _,. Pink Lead
I p I R (< ~
n x,
9@~
t J
• Turn the shift lever "FORWARDnand

"REVERSE" position.
• Check the buzzer switch for continuity.
lever position Good Bad BAD CONDITION

condition condition
FORWARD
REVERSE 0
X X
X
0
X
0
0
I
l
0: Continuity x : No continuity Replace buzzer switch.
I
~ GOOD CONDITION
4. Back-up buzzer
• Disconnect the back-up buzzer leads.
• Connect jumper leads to the back-up buzzer
leads (Black, Pink) and battery.
0
8 -c:::::M-J
P~- 7
/
I
/b-7 e <±>I
I
I
I
FAULTY
/ r---J
~
I
l
• Confirm the back-up buzzer sounds. Replace back-up buzzer.
I
~OK
* 7-35
ELEcTRICAL FoR G14-A IELEcl iiiii I
• Check the entire signal system for connec
tion.
Refer to "WIRING DIAGRAM" section.
7-36
-...
C)
I
m
:E
:0
® ® CD ® 2C)
®
~~
@
n~
'
fW
g~
P R
Y/8
y
FFON
Y VIS
G) Back switch
-
0
)>
C)
® ~ ~
RIY R RIW 8
~
®Buzzer
::D
)>
"TT @Diode (B)
8/R
8 p
@Diode (A)
3:m
B B•
@ Main switch
r-
So
R
(!)Fuse (10A)
m
(")
@Battery ~
® Receptacle
@l Throttle sensor
®Controller
@Motor
-
:a
( ")
)> m
r-
~
""" I
@ Shift switch
@ Limit switch .,
r- m
(')
0 -1
COLOR CODE
B ............. Black
:a n
::D
®
L. ............. Biue
G ............. Green
Y .............Yellow
...
C) l>
ora. ,r-
• 0
at~@@~ R ............. Red m ::D
([i)
P ............. Pink
Br ............Brown
W ............White
B/R .......... Biack/Red
Y/B .......... Yellow/Biack
-...
C)
I
m
® R/Y .......... Red/Yellow
R/W ......... Red/White -m
r-
m
Y·59 -n
I
ELEcTRICAL FoR G14-E IELEcj iii I
G) Main switch
® Accelerator switch
@ Buzzer switch
@ Back-up buzzer
® Forward-reverse switch
@ Traction m otor
(I) Cut-off switch
@ Speed controller
® Throttle sensor
@)Charging receptacle
@Fuse
@Diodes
@ Solenoid relay
® Batteries (6V x 6)
®
@ @
F1 s
R F2
@ @
/ ------- ....
I '
I )
\ I
'------""'
7-38
ELEcTRICAL FoR G14-E IELEcliiiii I
CD Receptacle @ Wire harness
®Relay assy @Clamp
@Rectifier @) Battery fitting plate
@Buzzer ® Fitting screw
®Wire harness @Wire lead
®Wire harness @)Accelerator stop switch
(J) Battery charger ® Main switch
@Fuse (lOA)
J N41 00-5200
1-39 (Rev. 6/99)

0
~
~
2
G)
® CD )>
2
c
::g
CD Back switch m
®Buzzer
n
::1:
® @ Accelerator switch
@Diode (B)
)>
::g
®Diode (A)
@ Main switch
(J) Fuse (1 OA)
-2
G)
G)
@Battery
0
I I @
® Receptacle
® Throttle sensor
®Controller
<
0
-flm
~
A
6 I ~1ownR
FORW •AD I
~~~~~"JI~I
~ ~
@ Motor
@ Shift switch
® Limit switch
m r-
S: m
~
::g
COLOR CODE
B ............. Black
c=;
)>
L. .............Biue
@ G ............. Green
Y ............. Yellow
.,r-
0
(f;t~@©E~~~ R ............. Red
P ............. Pink
::g
C)
,.
~
Br ............ Brown ...a
W ........... .White I
(jJ) B/R .......... Black/Red m
®
© Y/B .......... Yellow/Black
R/Y .......... Red/Yellow
R/W ......... Red/White
-
m
r-
m
Y-59 -n
I
ELEcTRICAL FoR G14-E
STARTING AND RECHARGING SYSTEM COMPONENTS
IELecl iii I
CD Main switch
@Forward-reverse switch
@ Traction motor
(j) Cut-off switch
® Speed controller
® Throttle sensor
® Charging receptacle
@Fuse
@Diodes
@Solenoid relay
® Batteries (6V x 6)
®
(Q) (Q)
F1 s
R F2
(Q) (Q)
,-------,
I '
I
\ ...... ______., I
;
7-41
ELECTRICAL FOR G14-E IELECI iiiii I
TROUBLESHOOTING
• The motor does not turn • Poor low speed • Jerky running
• Bad acceleration • Poor power • Abrupt starting
• Low speed
NOTE: ------------------------------------------------------
1) Seat
2) Service lid
3) Access panel
4) Drink holder insert
• Use the following special t ools in t his troubleshooting.

YU-3112-C, 90890-03112 YU-03036, 90890-03036
1. Battery INCORRECT
• Check the battery condition.
Specific Gravity:
1.260 at 20°C (68°F)
~--
• Refill battery fluid.
Voltage: • Clean battery termi na ls.
6V (x 6) • Recharge or replac e battery.
~ CORRECT
NO CONTINUITY
2. Fuse
• Connect t he Pocket Tester (Q x 1) to t he fuse.
• Check the fuse for continuity.
I
Repl ace fuse.
l ------ .......
~ CO NTINUITY
7-42
ELEcTRicAL FoR G14-E IHEel iii I
3. Diode check
• Remove the diode A (Red/Yellow, Red) and
the diode B (Red/White, Black).
• Connectthe PocketTester(Qx 1)totwo posts.
• Check each diode.
[E
9®9 @
~ :..:...-
Y· 117
BAD CONDITION
Good
Pocket tester connecting point
·-----.
condition
(+)Red H Black
CD
®
®
CD
0
X
IReplace diode.
0: Continuity X: No continuity
~ GOOD CONDITION
4. Main switch
• Disconnect the main switch couplerfrom the
wireharness.
• Connect the Pocket Tester (Q x 1) to the main
switch coupler (Red, Brown).
Tester(+) Lead _. Red terminal CD

Tester H Lead --. Brown terminal®
nx 1
7-43
ELECTRICAL FOR G 14-E I c Iiii I
ELE
• Turn the main switch to "ON" then to "OFF". BAD CONDITION
• Check the main switch for continuity.
Sw itch Good Bad condition ~-------...

position
ON
condit ion
0 X X 0
I Replace main switc h.
OFF X X 0 0
0 : Contin uity X : No continuity
~ GOOD CONDITION

• Disconnect the accelerator switch leads.
accelerator switch leads (Brown, Red/White).
Test er (+I Lead -~ Brown Lead

Tester(-) Lead • Red/ White Lead
• Push the accelerator peda l. BAD CONDITION

• Check the accelerator switch for continuity.
Accele rator
Pedal posit io n
Good
condition
Bad condition
I
l
Replace accelerator stop switch.
Push 0 X X 0
Free X X 0 0
0 : Continuity X: No continuity
~ GOOD CONDITION
7-44 (Rev. 6/99)

ELEcTRicAL FoR G14-E IELEclliiiilii I
6. Solenoid relay
solenoid relay terminals.
• Disconnect the solenoid relay coupler.
• Connect the battery positive terminal CD and
solenoid relay terminal (Red/White)® using
the jumper lead®*.
• Connect the battery negative terminal® and
solenoid relay termina l (Black) ® using the
jumper lead®*.
BAD CONDITION
__
• Check the solenoid relay for continuity.
Good Bad condition ----~...;;.._ __,

condition J Replace solenoid rela_y _. _ _ _ _ __,
Connect
0 X X 0
the battery
Disconnect
X X 0 0
the battery
~ GOOD CONDITION
7. Shift switch
• Disconnect the cut-off switch lead.
• Connect the Pocket Tester (Q x 1)to the cut-off
switch leads (Yellow, Yellow).
Tester (+) Lead - Yellow/Black Lead

Tester (-) Lead - Yellow lead
7-45
ELEcTRicAL FoR G14-E IELEcl iii I
• Turn the shift lever "FORWARD", neutral, and

"REVERSE" position. BAD CONDITION
• Check the shift switch for continuity.
Good Bad
Lever
Condition condition I Replace shift switch.
FORWARD
0 X X 0
OR REVERSE
Neutral X X 0 0
~ GOOD CONDITION
8. Throttle sensor
• Turn the main switch to "OFF".
• Remove the throttle sensor coupler.
• Connect the Pocket Tester (.Q x 1k) to the
throttle sensor coupler.
Tester (+I Lead - • Blue and White terminal

Tester H Lead -+ Green terminal
*NOTE:
ED ~
The ohmmeter needle sho uld move smoothly
from about on to about 1k.Q when accelerator
_§@ .2_
l
1_7 pedal is depressed. Jumpy needle movement
indicates a faulty TPS and w ill cause erratic run-
ning conditions.
~
Throttle sensor resistance INCORRECT
Blue-Green: 1kQ :t 20o/o
~------...
White-Green: O.Q
• Slowly depress the accelerator pedal*.

If the accelerator rod Iength is good, re-
~
Throttle sensor resistance place throttle sensor.
White-Green: 0 -+ 1kQ :t 30%
n MEETS
~ SPECIFICATION
* 7-46
ELEcTRicAL FoR G14-E IELEcj iii I
9. Traction motor check
• Jack up the rear wheels and block the front
wheels.
• Connect the battery positive terminal <D and
*A WARNING
traction motor terminal A1 ® using the • A wire to the jumper lead must have
jumper lead®*. at least the equivalent capacity of the
• Connect the battery negative terminal@ and battery lead or the jumper lead may
traction motor terminal A2 ® using the bum.
jumper lead®*. • This check is likely to produce sparks,
• Check the traction motor operation. so be sure that no flammable gas or
fluids are in the vicinity.
• This test will make the motor run at
., full speed.
I
I
I
I
I
FAULTY
l
I
I
I
.J
/
"-------,.
~I
I
I
®
IRepair and/or replace traction motor.
{!,. OK
10. Controller check

• Before checking the controller, turn the main
switch "OFF".
• Discharge the controller condenser for 30 sec-
onds*.
r~ l+nt.oll"
*
NOTE:----------
Use a jumper lead with 1kQ resistance.
• Turn the main switch uON".

• Turn the shift lever to "F"
• Check the solenoid relay for output voltage.
Tester(+) Lead -+ Solenoid relay output

terminal
Tester (-) Lead _. Ground
• Slightly push the accelerator pedal.
7-47
ELECTRICAL FoR G14-E IELEcl iii I
INCORRECT
t
Check solenoid relay again and wiring
Y-1 18 harness.
Solenoid relay output:

36V
• Check the traction motor for output voltage.
Tester(+) lead -+ A2 terminal

Tester H lead -+ Ground
• Slightly push the accelerator pedal.
Traction motor output voltage:

Y·1 19
l
Check shift switch, traction motor and
36V wiring harness again.
• Remove the controller coupler.

• Check the controller power source voltage.
Tester(+) lead • Brown terminal

Tester H lead -+ Ground
mL
~
...
Wiring
harness OUT OF SPECJFICATION
l
I Check wiring harness.
Controller input voltage:
36V
• Check the cut-off switch for resistance.
7-48
ELEcTRicAL FoR G14-E IELEclliiii I
Tester (+) lead - • Yellow terminal
Tester(-) lea d ~ Yellow/Black terminal
ED
c-@1_
l J w
__.,;
B
I
l
Replace cut-off switch.
~
Cut-off switch resistance:
Shift lever F•R position: OQ
Shift lever neutral position:ooQ NOTE:
Before checking the controller output
• Check the controller for o utput voltage.
voltage, connect the c o ntroller cou pler.
• Remove the throttle sensor coupler from
controller.
Tester(+) lead ~ Blue terminal

Tester (-) lead ~ Green terminal
ED
19@9
-{ l J
~Cont•oll" ...
~
Output voltage:
Blue-Green : 5V
• Connect t he throttle sensor coupler.
• Depress the accelerator pedal.
If traction motor moves, OK. I Replace controller.
~ OK
BAD CONDITION
• Check the wiring harness for damage.
Ref er to "START IN G A ND RECHARG IN G
SYSTEM WIRING DIAGRAM" on page 7-45.
I
l
Replace wiri ng harness.
7-49
TRACTION MOTOR SPECIFICATIONS
CD Front bracket Model 58C58JB56184
®Armature assembly
@ Stator assembly Voltage 36VDC
@Brush set Rated output KW/HP 1.9 KW 2.5 HP (30 min.)
@ Brush holder Performance
@ Brush holder screw Current 62A
(J) Bracket Voltage 36V
@Grommet Torque 8.7Nm
(0.87 m • kg,
6.3 ft • lb)
Revolution 3,300 r/min
Weight 16.5 kg (36.4 lb)
BRUSH LENGTH: COMMUTATOR DIAMETER:

A Limit: 14.5mm (0.57 ini C Wear limit:
Standard: 34.3 mm (1.35 in) 66.55 mm (2.62 in)
BRUSH SPRING FORCE:
New brush:
B 720 - 1,080 g (24.3 - 39.2 oz)
Worn brush:
450 g (15.2 oz)
7-50
ELECTRICAL FOR G14-E I ElECI iiii I
Removal
1. Remove:
• Access panel
• Seat
2. Disconnect
• Negative cable to motor controller.
• Negative lead to battery pack.
3. Disconnect:
• All four leads
from the motor terminals.
4. Remove:
• Motor securing bolts <D
5. Remove:
• Traction motor
7-51
ELEcTRICAL FoR G14-E IELEcl iiili I
6. Remove:
• Bolts
• Bracket G)
Y-407
7. Remove:
• Bolts
• Brush holder G)
NOTE:-----------------------
Leave brush leads attached to yoke while check-
ing brush length.
8. Check:
• Brush length
Minimum Brush Length:

14.5 mm (0 .57 in)
9. Remove:
• Armature CD
Y-410
7-52
ELECTRICAL FOR G14-E IELECI iii I
Inspection
1 _Clean the interior of the yoke and bracket
with compressed air_
2.1nspect:
• Outer surface
Cracks/Damage _. Replace.
A 3. Measure:
• Insulation resistance (Yoke !AI and bracket
[ID)
Use a 500 volt insulating resistance tester.
Defective _. Replace.
CJ CJ
Insulation Resistance:
More than 1MQ at 20· C (sa· F)
u"" = = = = == = =
II
Y-120
4. Measure: ·
• Field coil resistance
Use the Low Reading Ohmmeter_
Out of specification _. Replace.

0.005 - 0.0064 Q at 20° C (68° F)
7-53 (Rev. 6/99)

ELECTRICAL FOR G14-E
5.1 nspect:
I ELECI iii I
• Com mutator (Outer surface)
Hold the armature in a vise CD and copper
or aluminium plate® .
Dirty -+ Clean with #600 grit emery
cloth@.

6. Measure:
• Com mutat or (Diameter)
Out of specification - • Replace.
Measure t he diam eter of the commutat or
as shown.
Wear Limit (Mimimum Diameter):

66.55 mm (2.62 in)
Y-411
A CORRECT 7. Measure:
Out of specification - • Scrape mica to proper
limits.
Use a hacksaw blade® that is ground to fit.
Mica Undercut @ :
Limit: 0.25 mm (0.0098 in)
8 INCORRECT
NOTE=------------------------
• The m ica insu lation of the comm utat or must be
undercut to ensure prope r operation of t he
commutat or.
• Carefully clean between the segments after the
above steps.
8. Measure:
• A rmature coil resistance
Use the Low Reading Ohmmeter.
Armature Coil Resistance:

0.0228 ... 0.0232 Q at 20° C (68° A

YU-91026, 90890-03064
7-54
....------------------. 9. Check:
Roughness/Wear - Replace.

®.
Do not strike the outer race ® or balls of

the bearing. Contact should be made only
with the center race @ .
B [g PRESS
10. Install:
• Armature coil
into the brush holder.
11. Measure:
Use a spring scale G).
Out of specification _. Replace
Brush Spring Force:

New brush: 720 - 1,080 g
(24.3 - 36.5 oz)
: ' " " '' i limit: 450 g (15.2 oz)
\
CD
7-55
ELECTRICAL FOR G14-E IELECI iii I
Assembly
1. Install armature G) into yoke while spreading

apart brushes.
i~P
·"'*~< ..... ''" ·····•··· ,::;= - - - - - - - - - - -
When installing armature into yoke, use care not
to damage brushes.
Y-410
2.1nstall:
• Bracket CD
• Bolts
Installation
Motor Securing Bolt CD :

(Upper)
6 Nm (0.6 m • kg, 4.3 ft • lb)
1. Connect:
• Motor terminal leads
Y-405
2. Connect:
• Negative·cable to motor controller
• Negative lead to battery pack
3. Install:
• Seat
• Access panel
7-56
ELEcTRicAL FoR G14-E IELEcl iii I
MOTOR CONTROLLER
2? Motor control unit
Throttle sensor
rnJ To
[A]
~~"~
T Batte ry ( Negative)
o Traction motor A2
~ Throttle bracket ~ To Buzzer
v:v Return spring [Q] To Solenoid rela
® Circlip [E) To Wireharness y
® Pedal crank pin [£) To Throttle sensor
(j) Cover
®Joint rod
p;l
(): l®
7-57
CONTROLLER SYSTEM
ELEcTRicAL FoR G14-E IELec! iii I
CD PWM (Pulse Width Modulation) (j) Traction motor
control circuit ® FET (Field Effect Transistor)
®Throttle sensor ® Solenoid relay
@ Slow-start circuit @Battery
@ Electric current control circuit (j]) Controller unit.
(Current limiter)
@ Safeguard circuit
@ FET driving circuit
-®
1
I
r--------L --------
~~
-------,
I
I
r-- ...J
1 -t
-
-=®
I
I
I
I ® CD @
I
I
t
®
L - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ___ J
FEATURES
• Maintenance free due to solid state, sealed construction
• Soft starting and smooth operating (infinitely variable speeds)
• Current limiter to prevent motor burning
• Solenoid relay protection circuit to prevent relay chattering damage when climbing by an excessive
discharge of the battery.
7-56
ELECTRICAL FOR G14-E IELECiiii I
FUNCTION
..,..-,
I
\ 1. PWM control circuit
I I
I I FD In the partial open range, the FET controls the
I - oN motor speed with fast repeating "ON" and "OFF"
I
\ ......,. hf --- OFF switching .
In this case, while the FET is "ON" (time t), the
current 10 is on to traction motor; while FET is in
"OFF" (time T-t), the current IF is on to traction
motor through FD (Field Diode).
Consequently, in the partial open range, the bat
tery current IDwill be reduced, because the motor
current IM is compounded with 10 and If.
IM = lo+ It
2. Throttle sensor
(!)
The throttle sensor transfers a pulse (determined
~ Full close by the movement of the accelerator pedal) to the
controller.
Q)
u
c
...
~
(/)
(/)
Q)
Full open
a:
Acceleration range
G .......... Green
.--------o B (+5V) W .......... White
B ........... Blue
<>--- - - - W --. Pulse (V)
' - - - - - - o G (g round)
7-59
ELEcTRICAL FoR G14-E IELEcliiii I
3 . Principle of PWM driving circuit
Full close
!_jc___ _ __
- ~------------------ Pulse
• Time
!I
u.. ~==========· OFF
Partial range (low)
!I
ON
Partial range (high) Q)

Cl
~ ~ ---·-
- Time
- r- - ....- ,....... ....- ....- ON
OFF
Full open ..---8

w --~-~~ ----- -------------- ~ulse
! L.----~
.=--------Time
~1-----------0N
u.. L - - - - - - - - - ----OFF
CD PWM IC Chopping Wave
7-60
ELECTRICAL FOR G14-E IELECiiiii I
4. Slow-start circuit
Full open When the accelerator pedal is depressed briskly,
the slow-start ci rcuit prevents the car from start
...
0 ing too quickly.
.....
...ro
~Q)
Q>C)
Uc:
Uco
<( ...
Close Time
In t his case, the slow-start circuit delays the

accelerator pulse by 0.6s.
Q)
Ill
:::1
a..
Time
Q)
C)
co
::
0
>
_____ J
Time
C)
c:
·:;
-
·.:
'"0
1-
w
u..
....
Time
7-61
ELECTRICAL FOR G14-E IELecl iii I
5. Electric current control circuit (Current limiter)
The current limiter keeps the traction motor and
controller from burning out due to a too large
current when the traction motor locks.
6. Safegaurd circuit
1) Spark Contact Protection (Cut-off switch)
• The current is on after the solenoid relay is
on.
• FET is forced off when the shift lever is
moved from forward or reverse position.
2) Low-Voltage protection
• FET is turned off by force if the battery
voltage becomes 1OV to prevent relay chat
tering damage by an excessive discharge of
the battery.
3) Thermal protector
• The FET is forced OFF, when the FET tem
perature reaches 100"C.
• When the thermal protector cuts in, stop
and let it cool for a while, then start again.
7-62
ELEcTRicAL FoR G14-E IELecliii I
SOLENOID RELAY
1. Remove:
• Seat
2. Turn the main switch to "ON".
3. Check:
• Solenoid relay (clicking sound)
Press accelerator pedal to close the
accelerator stop switch.
If clicking - Check for continuity between
the two contact posts with Pocket Tester
while the solenoid is activated. If there is no
continuity, replace the relay.
If not clicking - Measure coil resistance in
solenoid.
4. Check:
• Solenoid relay (no clicking sound)
Disconnect solenoid leads.
Measure coil resistance use the Pocket Tester.
Pocket Tester:
YU-3112-C, 90890..03112
Y-116

56.2 - 68.&1 at 20" C (68. F)
Installation
1. Install:
• Solenoid relay
2.Connect:
• Leads
Nut (Terminal):
6 Nm (0.6 m • kg, 4.3 ft • lb)
7-63
-
rJ)
C)
2
)>
,....
rJ)
<
rJ)
® @ -t
m
~~ 31:
1~,1 ~
~ CD Back·switch
@ B!JZZer
A/Y R RIW 8 (GS
lltfWI
@)Diode (B)
• I I I I I T I @ Dioqe (A)
@ Main switch
(!)Fuse ·(1 OA)
@Battery
® Receptacle ·
® ThrottiEl sensor
-
®Controller
@) @Motor
m
,....
";-' S F2 F1 R @) Shift ~witch m
~ I FORWARD I ® Limit switch (")
~~~~A~:(J t-- -t
1-
COLOR CODE
::0
B ............. Biack
~
,....
L ..............Biue
G ............. Gree.n .. .
Y .............Yellow ·
.,
0
R ............. ~ed ::D
P .............Pink_ • C)
Br ............Brown ..A
w ............White ~
I
B/R ......... ,Black/Red m
Y/B ..........Yeflow/Biacl<
RIY ...... .'... Red!)'allow
R/W ......... RedJWhite ,...m
m
n
I
)
ELECTRICAL FOR G14-E I
ELECI iii I
SIGNAL SYSTEM COMPONENTS
Q) Main switch
@ Buzzer switch
® Back-up buzzer
@Fuse
@ Batteries (6V x 6)
@ @
F1 S A2 S2 A1
R F2
@ @ @ @ @
..,.--- --- .....

I/ '\
I
\
, _______ _,/
I
I
/-------,
CJ I
I
\ ....... ______, I
'
)
7-65
TROUBLESHOOTING
ELEcTRicAL FoR G14-E IELEcl iiiii I
THE BACK-UP BUZZER DOES NOT OPERATE
Procedure
Check:
1. Battery
2.Fuse
3. Buzzer switch
4. Back-up buzzer
NOTE:--------------------------------------------------------
1) Seat

VU-3112-C, 90890-03112 VU-03036, 90890-03036
1. Battery
Refer to CHAPTER 2 "BATIERY INSPEC-
~-------------
TION" section.
Specific Gravity:
1.260 at 20·c (68.F) • Refill battery fluid.
6V (x 6) • Recharge or replace battery.
..,£!, CORRECT
2.Fuse NO CONTINUITY
fuse.
• Check the fuse for continuity. IReplace fuse.
l --------------t
..,£!, CONTINUITY
7-66
ELECTRICAL FoR G14-E IELEcliiii I
3. Buzzer switch
• Disconnect the buzzer switch leads.
• Connect the Pocket Tester (Q x 1} to the
buzzer switch leads (Red, Pink}.
Tester(+) lead -+ Red lead

Tester (-} lead -+ Pink lead
• Turn the shift lever "FORWARD" and

"REVERSE" position.
• Check the buzzer switch for continuity.
Lever Good Bad BAD CONDITION

Position condition condition
FORWARD
REVERSE
0: Continuity
X
0
x : No continuity
X
X
0
X
0
0
I
l
Replace buzzer switch.
~ GOOD CONDITION
4. Back-u p buzzer
• Disconnect the back-up buzzer leads.
• Connect jumper leads to the back-up buzzer
leads (Black, Pink) and battery (36V).
/r=p
0
a~J
P~- 7
/ / u7 e <t>
I
'
1
FAULTY
l
/ r---J
tf____tJ
• Confirm the back-up buzzer sounds. I Replace back-up buzzer.

I
~ OK
* 7-67
ELEcTRICAL FoR G14-E IELecl iii I
• Check the entire signal system for connec
tion.
Refer to "SIGNAL SYSTEM WIRING DIA
GRAM" on page 7-69.
7-68
CHAPTER 8
TROUBLESHOOTING
TROUBLESHOOTING FOR G14-A/G14-E .........8-1

SUSPENSION AND STEERING ................. 8-1
TROUBLESHOOTING FOR G14-A .....................8-2

TROUBLESHOOTING CHART ................... 8-2
ENGINE ....................................................... 8-3
ELECTRICAL ............................................... 8-4
STARTER- GENERATOR .......................... 8-4
TROUBLESHOOTING FOR G14-E ..................... 8-5

TROUBLESHOOTING CHECKING
PROCEDURE ........................................... 8-5
ELECTRICAL ............................................... 8-6
TRACTION MOTOR ................................... 8-8
IS G1 ?
THRTBDL
TROUBLESHOOTING FOR G14-A/G14-E
-------------------------------------------------
I
TROUBLESHOOTING
TROUBLESHOOTING FOR G14-A/G14-E
SUSPENSION AND STEERING
Condition Possible Cause Correction

HARD OR ERRATIC 1.1ncorrect tire pressure. Inflate t ires to recommended pressures.
STEERING 2.1nsufficient or incorrect lubrication. Lubricate as required.
3. Suspension, steering or linkage parts Repair or replace parts as necessary.
damaged or misaligned.
4.1ncorrect front wheel alignment. Adjust wheel alignment angles.
5. 1ncorrect steering gear adjustment. Adjust steering gear.
6. Sagging springs. Replace shock absorber
PLAY OR LOOSENESS 1. Steering wheel loose. Inspect splines and repair as necessary.
IN STEERING lighten steering wheel nut.
2. Steering linkage or attaching parts Tighten, adjust, or replace faulty com-
loose or worn. ponents.
3. Pitman arm loose. Inspect shaft splines and repair as neces-
sary. Torque attaching nut and lock in
place with lock washer plate.
4. Steering gear attaching bolts loose. Tighten bolts.
5. Loose or worn wheel bearings. Adjust or replace bearings.
6. Steering gear adjustment incorrect or Adjust gear or replace defective parts.
parts badly worn.
WHEEL SHIMMY OR 1. Incorrect tire pressure. Inflate tires to recommended pressures.
VIBRATION 2. Wheels, tires, or brake drums out-of- Inspect parts and replace unacceptable
round. out-of-round parts.
3.1noperative, worn, or loose shock Repair or replace shock absorbers or
absorbers or mounting parts. mountings.
4. Loose or worn steering or suspension Tighten or replace as necessary.
parts.
5. Loose or worn wheel bearings. Adjust or replace bearings.
6.1ncorrect steering gear adjustments. Adjust steering gear.
7. Incorrect front wheel alignment. Correct front wheel alignment.
TIRE WEAR 1. 1ncorrect tire pressure. Inflate tires to recommended pressures.
2. Failure to rotate ti res. Rotate tires.
3. Brakes grabbing. Adjust or repair brakes.
4.1ncorrect front wheel alignment. Align front wheels.
5. Broken or damaged steering and sus- Repair or replace defective parts.
pension parts.
6. Wheel runout. Replace faulty wheel.
7. Excessive speed on turns. Make driver aware of condition.
CAR PULLS TO ONE 1.1ncorrect tire pressure. Inflate tires to recommended pressures.
SIDE 2. Front tires with uneven tread depth, Install tires of same construction and
wear pattern, or different design. reasonably even tread depth and wear
pattern.
3. 1ncorret front wheel alignment. Align front wheels.
4. Brakes dragging. Adjust or repair brakes.
5. Pulling due to uneven tire construe- Replace faulty tire.
tion.
8-1
TROUBLESHOOTING FOR G14-A ~~~¥~ ? I
TROUBLESHOOTING FOR G14-A
TROUBLESHOOTING CHART
POOR LOW SPEeD PERFORMANCE POOR MIDRANGE OR HIGH SPEED

PERFORMANCE
I I
... "' ... ... ~ "' ... "' ~
Plugged gas tank "" Spark plug fouled Carburetor dirty Dirty air filter
vent [Replace) [Clean as necessary) [Clean or replace)
[Clean or repair)
~ ~
! Weak spark _I_ Brake drag
Choke on [Check ignition coil] Incorrect fuel level [Readjust brakes)
[Choke off) and TCI circuit [Adjust)
. ,..
l .
Incorrect ignition .. ,.. Low compression
Fuel pump faulty timing
Clogged main jet [Check engine ]
[Repair) [Replace TCI unit)
[Clean] components
,..
l
Governor
... misadjusted
Clogged pilot jet
Pilot screw [Adjust)
[Clean)
[Adjust as
necessary ]
l
Carburetor dirty
[Clean as necessary)
l
Incorrect fuel level
[Adjust)
l
Air leak
[Repair com-]
ponent
8-2
TROUBLESHOOTING FOR G14-A IJ~¥~1 ?•
ENGINE

ENGINE WILL NOT 1. Weak battery. Test battery specific gravity.
START Recharge or replace as necessary.
2. Corroded or loose battery connec- Clean and tighten battery connection.
tions. Apply a coat of grease to terminals.
3. Faulty starter. Repair starter-generator.
4. Moisture on ignition leads and spark Wipe leads and cap clean and dry.
plug cap.
5. Faulty ignition circuit leads. Replace any cracked or shorted leads.
6. Open or shorted primary ignition cir- Trace primary ignition circuit and repair
cuit. as necessary.
7. Faulty coil. Test and replace if necessary.
B. Incorrect spark plug gap. Set gap correctly.
9.1ncorrect ignition timing. Replace TCI unit.
10. Dirt or water in fuel line or carbure- Clean lines and carburetor. Replace fi lter.
tor.
11. Carburetor flooded. Check fuel passages for contamination.
12 .Incorrect carburetor float setting. Adjust float level -check seats.
13. Faulty fuel pump. Install new fuel pump.
14. Carburetor percolating. No fuel in Measure f loat level. Check bowl vent.
the carburetor.
ENGINE STALLS 1. Incorrect choke adjustment Adjust choke.
2. Pilot screw mixture too lean or too rich. Adjust carburetor.
3. Incorrect carburetor float setting. Adjust float setting.
4. Leak in intake manifold Inspect intake manifold gasket and re-
place if necessary.
5. Incorrect ignition wiring. Install correct wiring.
6. Faulty coil. Test and replace if necessary.
ENGINE LOSS OF 1. 1ncorrect ignit ion timing. Replace TCI unit.
POWER 2. Dirty or incorrectly gapped spark Replace plug and set gap.
plug.
3. Dirt or water in fuel line, carburetor Clean lines, carburetor and replace filter.
or filter
8-3
ELECTRICAL
TROUBLESHOOTING FOR G14-A ~~~~~ ? I
STARTER DOES NOT 1. Weak battery. Test battery specific gravity.
TURN Recharge or replace as necessary.
2. Corroded or loose battery connec- Clean and tighten battery connections.
tion. Apply a coat of grease to terminals.
3. Open or shorted solenoid coil circuit. Trace solenoid coil circuit and repai r as
necessary.
4. Faulty solenoid relay. Test and replace if necessary.
5. Faulty main, or accelerator stop Replace switches if necessary.
switches.
GENERATOR DOES NOT 1. Corroded or loose battery connec- Clean and tighten battery connections.
CHARGE tions. Apply a coat of grease to terminals.
2. Faulty starter-generator. Repair starter-generator.
STARTER-GENERATOR

STARTER DOES NOT 1. Brushes are off commutator. Adjust properly or replace.
TURN 2. Starter-generator terminals are loose Tighten or clean.
or corroded.
3. Leads are broken. Check for breaks at bend or joint. Re-
place or repair leads.
4. Field coil is open. Repair or replace at a service shop.
5. Armature coil is open. Repair or replace at a service shop.
STARTER TURNS 1. Terminals are loose or corroded. Retighten or clean.
SLOWLY 2. Leads are nearly broken or connec- Check for any defect of leads at bend
tions are faulty. or joint. Replace leads or repair con-
nections.
3. Mechanical problem inside motor. Check.
STARTER IS NOISY 1. Bolts are loose. Retighten.
2. Starter-generator has foreign matter Clean motor interior.
inside.
3. Bearings are faulty. Replace.
4. Bearings contain foreign matter. Replace.
5. Bearings need grease. Replace.
BEARING HEAT 1. Bearings are faulty or lack grease. Replace.
EXCESSIVE 2. Improperly installed. Adjust, replace if necessary.
POOR MOTOR 1 . Load exceeds specification. Adjust load to spec.
PERFORMANCE 2. Armature is out of round . Repair or replace at service shop.
3. Brushes are worn beyond limits. Replace.
4. Commutator is excessively rough. Smooth with sandpaper (#500 - 600).
5. High mica segment. Recondition at service shop.
6. Commutator is dirty with oil or dust. Clean with a cleaner, and dry cloth.
7. Armature coil is shorted or broken. Repair or replace at service shop.
VIBRATION 1. Starter-generator installed loosely. Retighten.
2. Starter-generator turns irregularly. Repair or replace at service shop.
8-4
_THRTBGLI_
TROUBLESHOOTING FOR G14-E IS ? 1
_
TROUBLESHOOTING FOR G14-E

TROUBLESHOOTING CHECKING PROCEDURE
• Motor does not run • Poor low speed

• Jerky running • Bad acceleration
• Poor power • Hasty starting
• Low speed • Abrupt starting
..._s_A_TT
_ E_R_v c_o_N_D_IT_Io_N
.......
c_H_Ec
_K____ ___.I-+ Refer to page 7-42
OK
~
...._F_u_s_E_c_H_E_c_K_ _.........,....,.._ _ _ _ _ ___.I-+ Refer to page 7-42
OK
..._o_l_
o _o _
E_c_H_
Ec_K
_________ __.I-+ Refer to page 7-43
OK ~
..._M_A_I_N_s_w_lr_c_H_c_H_E~C~K....,.._ _ _ _ ____.I ... Refer to page 7-43
OK ~
..._A_c_c_E_L_
ER
_A_:r_o_R_s_r_o_P_s_w_l_rc_ H
____ __.I-+ Refer to page 7-44
OK ~
L-s_o_L_E_N_O_ID_R_EL_A_v_c_H~E~C-K_ _ _ _ ____.I-+ Refer to page 7-45
OK {>-
l_s
.. _H_I_Fr_
sw _ lr_c_H_c_H_E_c....
K.......---------~-+ Refer to page 7-45
OK {>-
L-T_H_R_o_n_LE_sE_N_s_o_R~CH~E_c_K_ _ _ _ _......I-+ Refer to page 7-46
OK ~
L-T_R_A_c_r_lo_N_M_o_r_o_R_C~H~E_c_K_ _ _ _ _......I-+ Refer to page 7-47
OK {>-
..._c_o_N_T_R_O_L_LE_R_CH_E_C~K=-------.....1-+ Refer to page 7-47
OK {>-
..._w_IR_IN_G
_ c_
o _N_N_E_
c_r l_
o _N_c_H_E_
c_K_ _ _ _...... I-+ Refer to page 7-49
8-5
TROUBLESHOOTING FOR G14-E ~~~~~ ?
ELECTRICAL
Should any one of the troubles (1 to 8) below 4. When the acceleration becomes rough,
occur, it is advisable to check for the possible uneven or jerky.
cause in the order specified. 5. The car abruptly starts off the moment
1.1f batteries tend to discharge much faster the main switch is set to "ON" position.
than specified after being charged pro 6. The car abruptly stops.
perly. 7. The car's top speed slows.
2. When the car does not move. 8. The motor does not stop when the accelera
3. When the car moves forward but not back tor pedal is released.
ward, or it moves backward but not forward.
CHECK ITEMS
1. If batteries tend to discharge much faster then normal after being charged properly.
A. Batteries, charger and charging circuit

1) Check battery terminals for tightness or corrosion.
2) Check the battery electrolyte level.
3) Check the specific gravity of battery electrolyte.
4) Check battery cells for damage.
5) Check the charging circuit for loose connections, broken wires, or separated connections.
6) Check whether the battery charger output is adjusted correctly, and that proper A. C. voltage (115 Volts,
15 Amp) exists at the battery charger A.C. connection.
7) Check that the charging receptacle is tightly connected to the charger plug.
8) Check the charge cord for damage.
9) Check battery capacity with a discharge tester.
B. Solenoid control circuit and traction motor circuit

10) Check the solenoid control circuit and traction motor circuit for loose connectors. (Check for loose connectors
on the speed controller, solenoid relay and traction motor.)
11) Check the solenoid relay for dirty, burned or worn-contact points.
12) Check he traction motor for worn brushes, misaligned brushes, or dirty commutator.
C. Parts other than circuits

13) Check the brake for proper play. (Check if the brakes are dragging.)
14) Check whether the throttle position sensor is properly adjusted.
15) Check whether the tire pressure is low.
[Tire pressure: 137 kPa (1.4 kgf/cm2, 20 psi) G14-El
108 kPa (1.1 kgf/cm2, 16 psi) G14-Al
16) Check for excessive wheel bearing friction.
17) Check the differential for oil leakage or malfunction.
18) Check whether the operation of controls is correct. Except when low speed operation is necessary, the car
should be run with the accelerator pedal fully depressed as much as possible to minimize power consumption.
2. When the car does not move.
1) Check whether the batteries are discharged.

2) Check the battery posts and battery terminals for loose or separated connections, or corrosion.
3) Place the main switch in the "ON" position and step on the accelerator pedal to check whether a click is heard.
If no click, check the solenoid relay, main switch, accelerator stop switch, cut-off switch and charging
receptacle.
4) Check traction motor, for loose or separated connections.
5) Check the traction motor for worn or separated brushes, or dirty commutator. Also check the armature
circuits for broken wires or shortcircuit.
8-6
TROUBLESHOOTING FOR G14-E _THRTBGLI_
IS ?I _
CHECK ITEMS
3. When the car moves forward but not backward, or it moves backward but not forward.
• Check the forward-reverse switch

1) Check the operation of the forward-reverse switch. Check the motor circuit for loose or separated connections.
2) Check the contact of the forward-reverse switch.
4. When the acceleration becomes rough, uneven or jerky.
1) Check for loose or separated connections between the speed controller and solenoid relay.
2) Check for loose terminal.
3) Check the throttle sensor.
5. The car abruptly starts off the moment the main switch is set to the " ON" position.
1) Check the engine stop switch and solenoid relay for stuck contact points.
2) Check for stuck accelerator pedal.
6. The car abruptly stops. Refer to Item 2 or 3 above.
7. The car's top speed slows.

1) Check the batteries for sulfation and discharge capacity.
Check the battery electrolyte level and charged condition.
2) Check the batteries, speed controller and traction motor for loose connections.
4) Check for wires shorted or separated at connections.
5) Check the traction motor for worn or separated brushes, or dirty commutator.
8. The motor does not stop even when the accelerator pedal is released.
• The motor stops if the main switch is placed in the OFF position:
1) Check the engine stop switch.
• The motor does not stop even if the main switch is placed in the OFF position:
2) Check the solenoid relay for stuck contact points.
3) Check the engine stop switch for stuck contacts.
4) Check the main switch.
8-7 (Rev. 6/99)

TROUBLESHOOTING FOR G14-E ~~~¥a ? 1
TRACTION MOTOR

MOTOR DOES NOT 1. Brushes are off commutator. Adjust properly or replace.
TURN 2. Motor terminals are loose or corrod· Tighten or clean.
ed.
3. Leads are broken. Check for breaks at bend or joint. Replace
or repair leads.
4. Field coil is open. Repair or replace at a service shop.
5. Armature coil is open. Repair or replace at a service shop.
MOTOR TURNS 1. Terminals are loose or corroded. Retighten or clean.
SLOWLY 2. Leads are nearly broken or connec- Check for any defect of leads at bend
tions are faulty. or joint. Replace leads or repair
connections.
3. Mechanical problem inside motor. Check.
MOTOR IS NOISY 1 . Bolts are loose. Retighten.
2. Motor has foreign matter inside. Clean motor interiqr.
3. Bearings are faulty. Replace.
4. Bearings contain foreign matter. Replace.
5. Bearings need grease. Replace.
BEARING HEAT 1. Bearings are faulty or lack grease. Replace.
EXCESSIVE 2.1mproperly installed Adjust, replace if necessary.
POOR MOTOR 1 . Load exceeds specification. Adjust load to spec.
PERFORMANCE 2. Armature is out of round. Repair or replace at service shop.
3. Brushes are worn beyond limits. Replace.
4. Commutator is excessively rough. Smooth with sandpaper (#500 - 600).
5. High mica segment. Recondition at service shop.
6. Commutator is dirty with oil or dust. Clean with a cleaner, and dry cloth.
7. Armature coil is shorted or broken. Repair or replace at service shop.
VIBRATION 1. Motor installed loosely. Retighten.
2. Motor turns irregularly. Repair or replace at service shop.
8-8
~~~~~~~~~SPEc!~,~
CHAPTER 9
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................... 9-1
MAINTENANCE SPECIFICATIONS
FOR G14-A ..................................................... 9-2
ENGINE ....................................................... 9-2
TRANSMISSION ........................................ 9-5
CHASSIS ..................................................... 9-6
ELECTRICAL ............................................... 9-8
FORG14-E ................................................... 9-11
TRANSMISSION ...................................... 9-11
CHASSIS ................................................... 9-11
ELECTRICAL ............................................. 9-13
TIGHTENING TORQUE .................................. 9-16

ENGINE (FOR G14-A) ............................... 9-16
CHASSIS ................................................... 9-17
POWER TRAIN ......................................... 9-17
ELECTRICAL ............................................. 9-18
GENERAL TORQUE SPECIFICATIONS ... 9-19
DEFINITION OF UNITS ............................ 9-19
LUBRICATION POINT AND GRADE

OF LUBRICATION ..........................................9-20
CABLE/WIRE ROUTING ..................................9-21

FOR G14-A ....................................................9-21
FOR G14-E .....................................................9-23
WIRING DIAGRAM ............................................9-25

FOR G14-A ....................................................9-25
FOR G14-E .....................................................9-26
GENERAL sPECIFICATioNs lsPEcl P?'l
SPECIFICATIONS
GENERAL SPECIFICATIONS
~ m G-14-A G14-E
Model Code JN3 JN4

Frame Serial Number JN3-100101 - JN4-1001 01 -
Dimensions:
Overall Length 2385 mm (9.39 in) f-
Overall Width 1200 mm (47.2 in) f-
Overall Height (Steering height) 1190 mm (46.8 in) f-
Height of Floor 300 mm (11.8 in) f-
Wheelbase 1629 mm (64.1 in) f-
Tread:
Front 870 mm (34.3 in) f-
Rear 980 mm (38.6 in) f-
Min. Ground Clearance 97 mm (3.8 in) f-
Weight:
Dry Weight (without battery) 300 kg (661 lb) 254 kg (560 lb)
Performance:
Maximum Loading Limit 250 kg (550 lb) f-
Maximum Speed 19-24 km/h (12-15 mph) f-
Starter Generator Red Zone 4,000 r/min -
Cranking Speed Appx. 800 r/min -
Motor Red Zone 5500 r/min
Minimum Turning Radius 3.0 m (118 in) f-
Seating Capacity 2 persons f-
Hill Climbing Ability 30° on pavement 15° on pavement
9-1
MAINTENANCE SPECIFICATIONS FOR G14-A lsPECI ~?I
MAINTENANCE SPECIFICATIONS FOR G14-A
ENGINE
Item G14-A
Description:
Engine Type Forced air cooled 4-stroke OHV gasoline
Number of Cylinder Single
Displacement 300 cm3
Bore x Stroke 75 x 68 mm (2.95 x 2.68 in)
Compression Ratio 8.1: 1
Compression Pressure (at sea level) Standard:
1,250 kPa (12.5 kg/cm2, 178 psi)
Minimum:
1,000 kPa (10.0 kg/cm2, 142 psi)
Maximum
1,400 kPa (14.0 kg/cm2, 199 psi)
Starting System Starter
Ignition System T.C.I.
Lubrication System Wet sump
Cylinder Head:
Combustion Chamber Volume (With spark 41.0 - 41.8
plug)
Head Gasket Thickness J * 0.2 mm (0.008 in )
~-t*
Cylinder:
Material Cast iron sleeved aluminum (crankcase)
Bore Size 75 mm (2.95 in)
Taper/Limit 0.02 mm (0.0008 in)/0.15 mm (0.006 in)
Out of Round/Limit 0.02 mm (0.0008 in)/0.15 mm (0.006 in)
Piston:
Piston-to-Cylinder Clearance 0.03- 0.05 mm (0.0012 - 0.0020 in)
<Limit> < 0.1 mm (0.004 in) >
Oversize: 1 0.25 mm (0.01 in)
2 0.50 mm (0.02 in)
Piston Pin Outside Diameter 17.995- 18.000 mm (0.7085- 0.7087 in)
Piston Pin-to-Piston Clearance 0.004- 0.020 mm (0.0002 - 0.0008 in)
<Limit> < 0.07 mm (0.003 in) >
Piston Ring:
Top Ring:
Type I1-- -.I
II B Plain
2.0 x 3.2 mm (0.079 x 0.126 in)
Dimensions (B x T) T
End Gap (Installed) 0.2- 0.4 mm (0.008- 0.016 in)
<Limit> < 1.0 mm (0.04 in) >
Side Clearance (Installed) 0.03- 0.05 mm (0.0012- 0.0020 in)
<Limit> < 0.07 mm (0.0028 in) >
Engine Oil:
Recommended Oil YAMALUBE 4 cycle oil or SAE10 W30 type
SE, SF, orSG
Oil Change Quantity 1.0 U.S. qt (0.9 L, 0.19 Imp gal)
Oil Capacity 1.16 U.S. qt (1.1 L, 0.241mp gal)
9-2
MAINTENANCE SPECIFICATIONS FOR G14-A lsPECI.SO~I
Item G14-A
2nd Ring:
Type Plain (Taper face)
Dimensions (B x T) 2.0 x 3.2 mm (0.079 x 0.126 in)
<Limit> < 1.0 mm (0.04 in) >
Side Clearance 0.03 - 0.07 mm (0.0012 - 0.0028 in)
< Limit> (Installed) < 0.09 mm (0.0035 in) >
Oil Ring:
Small End Bearing:

Type None
Big End Bearing:

Type Plain bearing
Crankshaft:
Crankshaft Assembly Width "A" 109.65- 110.05 mm (4.317- 4.333 in)
Crankshaft Deflection "B" 0.05 mm (0.0020 in)
Connecting Rod Big End Side Clearance "C" 0.2- 0.5 mm (0.008- 0.020 in)
Crank Pin Outside Diameter 31.95-31.97 mm (1.258- 1.259 in)

Crank Pin Type Solid crankshaft
Crank Bearing Type (Left) x Q'ty #6307 c3 x 1 pc
Crank Bearing Type (Right) x Q'ty #6306 c3 x 1 pc
Crank Oil Seal Type (Left) x Q'ty SD 35 50 8 x 1 pc
Crank Oil Seal Type (Right) x Q'ty SD 30 45 8 x 1 pc
Camshaft:
Drive Method Gear drive
Cam Cap Inside Diameter 16.00 - 16.05 mm (0.630- 0.632 in)
Camshaft Outside Diameter 15.90- 15.99 mm (0.626- 0.630 in)
Shaft-to-Cap Clea rance 0.01 - 0.05 mm (0.0004- 0.0020 in)/
<Limit> <0.15 mm (0.0059 in)>
9-3
MAINTENANCE SPECIFICATIONS FOR G14-A ISPECI9'?1
Item G14-A
Cam Dimensions:
Intake "A" 29.16-29.28 mm (1.148- 1.153 in)
11811
24.11 - 24.22 mm (0.949 - 0.954 in)
"C" 5.16- 5.28 mm (0.203- 0.208 in)
Exhaust "A" A 29.20-29.32 mm (1.150- 1.154 in)

"B" 24.15 - 24.25 mm (0.951 - 0.955 in)
"C" 5.20 - 5.32 mm (0.205 - 0.209 in)
f----8-
Rocker Arm/Rocker Arm Shaft:

Arm Inside Diameter 12.00- 12.04 mm (0.472- 0.474 in)
Shaft Outside Diameter 11.90 - 11.99 mm (0.469 - 0.472 in)
Arm-to-Shaft Clearance 0.01 - 0.07 mm (0.0004- 0.0028 in)
Valve, Valve Seat, Valve Guide:

Valve Clearance (Cold) IN. 0.1 mm (0.004 in)
EX. 0.1 mm (0.004 in)
Valve Dimensions:
)\
~ad~
"A"
bB" be" ~
Face Width Seat Width
.
Margin
Thickness
"0''
"A" Head Diameter IN. 30 mm (1.18 in)

EX. 26 mm (1.02 in)
"8" Face Width IN. 2.26 mm (0.089 in)
EX. 2.26 mm (0.089 in)
"C" Seat Limit Width IN. 1.4 mm (0.055 in)
EX. 1.4 mm (0.055 in)
"D" Margin Thickness Limit IN. 0.8 mm (0.032 in)
EX. 0.6 mm (0.024 in)
Valve Spring Free Length 36.2mm

<Limit> <35.0 mm>
Spring Tilt 2.5° or 1.6 mm
Spring Force (Installed Length) 8.0 kg (29.0 mm)
Throttle Cable Freeplay:

Cable 1 0.2 - 0.5 mm (0.008 - 0.020 in)
Cable 2 0.5 mm (0.020 in)
Choke Cable Freeplay 1.0 mm (0.040 in)
Engine Tensioner Bracket Freeplay 2.0 mm (0.08 in)
9-4
MAINTENANcE sPEciFicATioNs FoR G14-A IsPEel p~I
Item G14~A
Carburetor:
Model/Maker BV26~18/MIKUNI
I.D. Mark JN3-00
Venturi Diameter (Ven. T.) 018
Main Jet (M.J.) #102.5
Main Air Jet (M.A.J.) 02.5
Pilot Jet (P.J.) #60
Pilot Air Jet (P.A.J.) 01.2
Throttle Valve (Th.V.) #120
Valve Seat (V.S.) 01.2
By~pass (1) (B.P. 1) 00.6
By-pass (2) (B.P. 2) 00.7
By-pass (3) (B.P. 3) 00.9
By~pass (4) (B.P. 4) 00.6
Pilot Outlet (P.O.) 01.0
Pilot Screw (P.S.) 1 turn out
Float Height (F.H.) 14.5 mm (0.57 in)
Engine Idling Speed * 1200 r/min
*Firing beginning point
Fuel Pump:
Manufacturer/Type MIKUNVOF-52-150 (Diaphragm)
Fuel Tank:
Recommended Fuel Unleaded regular gasoline
Fuel Rating P.O.N (#1) MIN. 87 octane
Fuel Tank Capacity 23.0 L (20.2 Imp qt, 6.1 US gal)
Fuel Tank Material/Color Polyethylene/Natura I
TRANSMISSION
Item G14-A
Transmission:
Type V-belt automatic centrifugal engagement
Primary Reduction Ratio 3.1 : 1 - 0.8 : 1
Shift r/min 3,400 r/min
Primary Spring: None
Secondary Spring:
Outside Diameter x Wire Diameter 54.5 x 4.0 mm (2.15 x 0.16 in)
No. of Turns/Free Length 8.25/100 mm (3.94 in)
Color Code Black
Twist Angle (Preload setting) 30° (B-3)
Torque Cam Angle 44deg
Sheave Center to Center Distance 270.5 mm
Sheave Off-Set 24.3mm
V-belt Width and Outer Line Length 31 x 1,010 mm (1.22 x 39.76 in)
V-belt Wear Limit 27 mm (1.06 in)
9-5
MAINTENANcE sPEciFICATioNs FoR G14-A IsPeel P~l
Item G14-A
Differential/Reduction Gear:
Secondary Reduction System Helical gear
Secondary Reduction Ratio:
Forward 11.34: 1
Reverse 15.25: 1
Differential Type Bevel gear
Lubricant/Capacity SAE 90 gear oil/800 cc (0.70 Imp qt, 0.85 US qt)
Governor:
Type Oil bath flyweight
Adjustment Screw with lock nut
Factory Speed Setting 19 km/h (12 mph)
CHASSIS
Item G14-A
Frame:
Type Ladder type pipe structure
Material/Color Tubular steel (STKM)/Yamaha Black
Front & Rear Cowling:

Type Injection Molding
Material Thermoplastic Olefin
Color Std: Ivory Delta
Opt: Kingstone Grey
Sunfast Red
Teal Green
Front Panel:
Material Thermoplastic Olefin
Color Black
Seat:
Seat cover:
Material Vinyle chloride leather
Color Ivory white
Seat Cushion:
Material Urethane foam
Bumper:
Front Polypropylene (Blow molding)
Rear Polypropylene (Blow molding)
9-6
MAINTENANcE sPECIFicATioNs FoR G14-A Is PEel P~l
Item G14-A
Steering System:
Type Worm and pin
Steering Angle (L.H.) 1.5 turn
(R.H.) 1.5 turn
Turning Radius 3.0 m (118 in)
LubricanVCapacity Grease/90 cc (3.17 Imp oz, 3.04 US oz)
Front Axle:
Type Eliot kingpin type
Toe-in/Fully Loaded 1 - 11 mm (0.04- 0.43 in)/Zero mm (Zero in)
Camber (loaded) Zero deg
Caster 7 deg
Kingpin Inclination 3 deg
Rear Axle:
Rear Wheel Axle Type Semi-floating type
Toe-in Zero mm (Zero in)
Camber Zero deg
Front Suspension:
Type Single swingarm (independent suspension)
Coil spring with hydraulic shock absorbers
(double action type)
Spring Rate 6.63 kgf/mm ± 10%
Shock Absorber Free Length 263.5 mm (10.37 in)
Damper Type Oil damper (double action/both compression and
tension)
Rear Suspension:
Type Axle type trailing arm (unit swing)
Coil springs with hydraulic shock absorbers
Spring Rate 1.83 - 6.30 kgf/mm ± 10%
Shock Absorber Free Length 315.3 mm (12.41 in)

Damper Type Oil damper (double action/Both comp. & tens.)
Brakes:
Brake System Mechanical brake linkage to individual drum
brakes on each rear wheel with self-adjusting
brake shoe.
Type of Brake Dual internal expanding shoe.
Leading/Trailing shoes (self-adjusting)
Lining Thickness Std/Min. 4 mm (0.16 in)/0.75 mm (0.029 in)
Brake Drum Inside Dia. 161 mm (6.34 in)
Linkage Adjustment (Brake Cable Free Play) 25- 30 mm (0.98- 1.18 in)
9-7
MAINTENANcE sPECIFicATioNs FoR G14-A IsPeel PfI
Item G14-A
Parking Brake:
Type Foot type; Parking brake with automatic release
Release Timing 1 mm (0.04 in)
(Bolt head round parallel to arm)
Wheel:
Tire Type (Pattern):
Front and Rear Tubeless (Sawtooth tread pattern)
Tire Size:
Front 18 x 8.50-8.00/4 PR
Rear 18 x 8.50 - 8.00/4 PR
Rim Size:
Tire Pressure: 7.00 - I -8.00
Front/Rear 108 kPa (1.1 kg/cm2, 16 psi)
ELECTRICAL
Item G14-A
Voltage: 12V Negative ground
Ignition System:
Type T.C.I.
Model/Manufacturer JN3-00/YAMAHA
Pickup Coil Resistance (Color code) 3500 ± 20% at 20·c (68.F)
(White/Red- White/Black)
Output (Min.) PEAK 15V AC at approximate cranking speed
800 r/min
Dynamic Timing 32° B.T.D.C. at 3,000 r/min
Ignition Advance Curve:

-
u
0
30
..,_:
-c
a:i 20
Cl I
E
·.;:; 10
c I
0
:~
c 0
~ 1 2 3 4 5
Engine speed (x 103 r/min)
Ignition:
Model/Manufacturer JF2-00/YAM AHA
Spark Gap 11 mm (0.43 in)/3,000 r/min
Primary Winding Resistance 2.60 ± 20% at 2o·c (68.F)
(Orange- Red/White)
Secondary Winding Resistance 11.9 kO ± 20% at 2o·c (68.F)
(High tension cord - Red/White)
Diode (Yes or No) No
9-8
MAINTENANcE sPECIFICATioNs FoR G14-A IsPEel P~l
Item G14-A
Spark Plug:
Type/Manufacturer BPR2ES or BPR4ES/NGK
Spark Plug Gap 0.7- 0.8 mm (0.028- 0.031 in)
Thread Size M14 x P1.25
Spark Plug Cap:

Type Resistor type
Resistance 3.75 - 6.25 kO at 2o·c (68.F)
T.C.I. Unit:
Model/Manufacturer JN3-00/YAM AHA
Charging · Starting/System:
Type Starter generator
Model/Manufacturer HITACHI
Starting Output 0.6kw
Charging Output 14V-15N5,000 r/min
Armature Coil Resistance 0.010- 0.0160 at 2o·c (68.F) (A1-A2)
Field Coil Resistance
Shunt Coil (Battery Charging) 4.5- 5.50 at 2o·c (68.F) (Red- Green)
Series Coil (Starting) 0.005 - 0.0070 at 20·c (68.F) (F1- F2)
Starter belt tension 8- 12 mm (0.31 - 0.47 in)/10 kg (22 lbs)
Brush Length Std/Min. 26.5 mm (0.9 in)/16 mm (0.63 in)
Spring Pressure/O'ty 300- 500 g (10.6- 17.6 oz)4 pes.
Commutator Outside Dia. 40.9- 41.1 mm (1.61- 1.62 in)
Mica Undercut/No. of Slots 0.7 mm (0.028 in)/41 pes
Voltage Regulator:
Type Transistor
Model/Manufacturer JF2-00/SHINDENGEN
Regulated Voltage (No lead) 14.3- 15.3V
Solenoid Relay:
Model/Manufacturer 586-117111/ESSEX CONTROLS
Amperage Rating 100A
Sole noid Coil Resistance (Z) Z: 1890± 10%
Resistance (X) X: OFF co
X ONOO
r------1
C c.-__ Fixed contact
z[ ~Movable
~Solenoid
contact
coil
u
Battery:
Model BCI Group 24 (12V-48AH)

Capacity RC: minimum 60 min
CCA : minimum 400A
Specific Gravity 1.260 at 20° C (68° F)
Dimension (L x W x H) 6-3/4 X 10-1/4 X 9 in
9-9
MAINTENANCE SPECIFICATIONS FOR G14-A lsPECI .>0~1
Item G14-A
Back Buzzer:
Type Piegoelectric buzzer (Intermittent)
Model/Manufacturer JNJ-00/YAMAHA
Frequency 2.4-3.6 kHz
Current Less than 25 rnA
Fuse:
Amperage x Q'ty
Neg. Fuse 10Ax 1
9-10
MAINTENANcE sPECIFICATioNs FoR G14-E jsPec! SD~I
MAINTENANCE SPECIFICATIONS FOR G14-E
TRANSMISSION
Item G14-E
Reduction Gear Ratio/Gear Type 11.96 (60/23 x 78/17) Helical
Oil Type/Capacity SAE 90 Gear oiV300 cc (0.26 Imp qt, 0.32 US qt)
CHASSIS
Item G14-E
Frame:
Type Ladder type pipe structure
Material/Color Tubular Steel (STKM)/Yamaha Black
Front & Rear Cowling:

Material Thermal Plastic Olefin
Color Std: Ivory Delta
Opt: Kingstone Grey
Sunfast Red
Teal Green
Front Panel :
Material Thermal Plastic Olefin
Color Black
Seat:
Seat cover:
Material Vinyl Chloride Leather
Color Ivory White
Seat Cushion:
Material Urethane foam
Bumper:
Front Polypropylene (Blow molding)
Rear Polypropylene (Blow molding)
Steering System:
Type Worm and Pin
Steering Angle (L.H.) 1.5 turn
(R.H .) 1.5 turn
Turning Radius 2.8 m (113 in)
Lubricant/Capacity Grease/90 cc (3.17 Imp oz, 3.04 US oz)
9-11
MAINTENANcE sPEciFICATioNs FoR G14-E IsPEel ~~I
Item G14--E
Front Axle:
Type Eliot Kingpin Type
Toe-in/Fully Loaded 1 - 11 mm (0.04- 0.43 in)/Zero mm (Zero in)
Camber (Loaded) Zero deg
Caster 7 deg
Kingpin Inclination 3 deg
Rear Axle:
Rear Wheel Axle Type Semi-floating type
Toe-in Zero mm (Zero in)
Camber Zero deg
Front Suspension:
Type Single swingarm (independent suspension)
Spring Rate 7.34 kgf/mm ± 10%
Shock Absorber Free Length 264.2±2 mm
Damper Type Oil damper (double action/both compression
and tension)
Rear Suspension:
Type Axle type trailing arm (unit swing)
Spring Rate 3.63 N/mm (3.63 kg/mm, 203/lb/in)
Shock Absorber Free Length 316 mm (12.44 in)
Damper Type Oil damper (Double action/Both Comp. & Tens.)
Brakes:
Brake System Mechanical brake linkage to individual drum
brakes on each rear wheel with self-adjusting
brake shoe.
Type of Brake Dual internal expanding shoe.
Leading/Trailing shoes (self-adjusting)
Lining Thickness Std/Min. 4 mm (0.16 in) 0.75 mm (0.029 in)
Brake Drum Inside Dia. 160 mm (6.30 in)
Linkage Adjustment (Brake cable free play) 25-30 mm (0.098- 1.18 in)
Parking Brake:
Type Foot type; Parking brake with automatic release
Release Timing
(Bolt head round parallel to arm) 1 mm (0.04 in)
9-12
MAINTENANcE sPECIFICATioNs FoR G14-E IsPEel p~I
Item G14-E
Wheel:
Tire Type (Pattern):
Front and Rear Tubeless (Sawtooth tread pattern)
Tire Size:
Front 18 x 8.50-8.00/4 PR
Rear 18 X 8.50-8.00/4 PR
Rim Size 7.00 - I- 8.00
Tire Pressure:
Front/Rear 137 kPa (1.4 kg/cm2, 20 psi)
ELECTRICAL
Item G14-E
Voltage: 36V DC, 6V Battery x 6 pes series
(locally supplied)
Traction Motor:
Model/Manufacturer H/S 58C58JB56184/GE
Rated Voltage 36VDC
Power/Horsepower 1.9 kw/2.5 hp at 3300 r/min
Current 62A
Voltage 36V
Torque 8.7 Nm (0.87 kg.m, 6.3 ft.lb)
Revolutions 3,300 r/min
Allowable Maximum Revolutions 5,500 r/min
Direction of Rotation Clockwise and counterclockwise
Brush Length-Std/Min. 34.3 mm (1.35 in)/14.5 mm (0.57 in)
Brush Spring Pressure-Max./Min. 720- 1,080 g (24.3- 36.5 oz)/450 g (15.2 oz)
Mica Undercut-Std/Min. 0.79 mm (0.031 in)/0.25 mm (0.010 in)
Armature Coil Resistance 0.0228 - 0.02320 at 20°C (68°F)
Field Coil Resistance 0.005 - 0.00640 at 20°C (68°F)
Insulation Resistance (All measurements) 1MQ
Motor Controller: FET (Field Effect Transistor} chopper

ModeVManufacturer JN4-00/YAMAH A
Solenoid Relay:
Model/Manufacturer 586-117111/ESSEX CONTROLS
Amperage Rating 100A
Solenoid Coil Resistance (Z) Z: 1890 ± 10%
Resistance (X) X: OFF oo
X ONOQ
r------1
C o-___ Fixed contact

~Movable contact
0 ~ -Solenoid coil
u
9-13
MAINTENANCE SPECIFICATIONS FOR G14-E ISPECI ~~~
Item G14-E
Shift Switch:
Voltage/Maximum Current Capacity 36V DC/300A
Movable Contact
Material Copper
Thickness-Std 3 mm (0.12 in)
Stationary Contact
Material Copper
Thickness-Std 4 mm (0.16 in)
Relay
Battery..:.. B
36V-=-
Battery: Locally supplied

Type 6V Electric vehicle deep cycle
Quantity/Connection 6 pes/Series
Minimum Recommended Output 107 minutes at 75A or 185 AH
Specific Gravity As specified by manufacturer at ao·F
Maximum Difference (at 1.200 corrected min.) 0.050
[Battery Arrangement and Terminal
Connections]
9-14
MAINTENANCE SPECIFICATIONS FOR G14-E ISPECI ,9)~~
Item G14-E
Back Buzzer:
Type Piegoelectric buzzer (Intermittent)
Model/Manufacturer JN4-00/YAHAMA
Current Less than 25 mA
Fuse:
Amperage
Plus Fuse 10A
9-15
TIGHTENING TORQUE ISPECI ~~~
TIGHTENING TORQUE
ENGINE (FOR G14-A)
Tightening torque
Part to be tightened Part name Thread size Remarks
Nm m ·kg ft·lb
Spark plug M14 x P1.25 20 2.0 14
Air shroud x Cylinder Head
Bolt M6 X P1.0 8 0.8 5.8
or Crankcase
Air shroud Cylinder 1 x 2 Pan head M6 x P1 .0 4 0.4 2.9
Cylinder Head: Bolt M8 X P1 .25 28 2.8 20
Cylinder Head Cover Bolt M6 x P1.0 10 1.0 7.2
Cylinder Head x Cylinder Head Bolt M6 x P1.0 10 1.0 7.2
Support
Valve Adjuster Locknut Nut M6 X P0.75 14 1.4 10
With oil
Connecting Rod Cap Nut M8 x P0.75 38 3.8 27 splasher
Cylinder x Exhaust Pipe Nut M8 X P1 .25 20 2.0 14

Exhaust Pipe Cover Pan head M6 x P1.0 7 0.7 5.1
Clamp &
M4 x P0.7 Tightening
Carburetor x Joint Pan head
steady
Flywheel Nut M16 X P1.0 75 7.5 54

Crankcase x Engine Bracket Bolt M10 X P1.25 35 3.5 25
Crankcase Cover Bolt M8 x P1.25 24 2.4 17
Crankcase Drain Plug Bolt 30 3.0 22
[Cylinder Head Tightening Sequence) [Crankcase Cover Tightening Sequence)
9-16
TIGHTENING TORQUE ISPECI jVfl
CHASSIS
Tightening torque
Nm m·kg ft·lb
Front Lower Arm x Frame Bolt M10 X P1.25 48 4.8 35
Rear Arm Comp. x Frame Bolt M10 x P1.25 90 9.0 65
Tie Rod x Universal Joint Nut M12 x P1.25 43 4.3 31
Tie Rod x Idler Arm or Knuckle Arm Nut M12 X P1.25 35 3.5 25
Steering Wheel x Steering Shaft Nut Nut M12 x P1.25 39 3.9 28
Pitman Arm x Idler Arm Nylon nut M16 X P1.5 Use lock
85 8.5 61
washer
Steering Gearbox x Frame Bolt M10 x P1.25 32 3.2 23

Steering Gearbox x Gearbox Cover
Bolt M5 x P1.0 7 0.7 5.1
Nut M6 X P1.0 7 0.7 5.1
Steering Shaft Adjusting Bolt x
Nut M48 X P2.0 25 2.5 18 55 mm width
Locknut
Pitman Shaft Adjusting Bolt x
Nut M8 X P1.25 15 1.5 11
Locknut
Front Hub x Knuckle Nylon nut M14 X P1.5 92 9.2 65
Front Wheel x Hub Nut M12 X P1.25 88 8.8 64
Rear Wheel Hub Nut M12 x P1.25 90 9.0 65
Brake Shoe Plate Ass'y x
Bolt M8 x P1.25 30 3.0 22
Rear Axle Housing
Shock Absorber Pivot Bolt Nylon nut M12 x P1.25 32 3.2 23
Fuel Pump Holding Bolt Bolt M6x P1.0 7 0.7 5.1
POWER TRAIN
!Tightening torque
Nm m·kg ft·lb
For G14-A
Primary Sheave x Engine Bolt 1/2-UNF 75 7.5 54
Secondary Sheave x Input Shaft Castle nut M12 x P1.25 60 6.0 43
Transmission Case x Rear Arm Bolt Max P1.25 23 2.3 17
Bolt M10 x P1.25 40 4.0 29
Transmission Case 1 x 20 2.0 14 First
Bolt M8 X P1.25
Transmission Case 2 25 2.5 18 Final
Differential Case x Ring Gear
For G14-E
Bolt M8 X P1.25 '38 3.8 27
-G
Transmission Case x Frame Bolt M10 X P1.25 40 4.0 29
Transmission Case x
Bolt M8 X P1 .25 25 2.5 18
Rear Axle Housing
Transmission Case 1 20 2.0 14 First
Bolt M8 X P1 .25
x Transmission Case 2 25 2.5 18 Final
Differential Case x Ring Gear Bolt M8 x P1.25 34 3.4 24
9-17
TIGHTENING TORQUE ISPECI .su~l
ElECTRICAl
Tightening torque
Nm m-kg ft-lb
For G14-A
Battery Hold Down x Battery Nylon Nut M6 x P1.0 2 0.2 1.4
Starter Motor Terminal x Wire Nut M6 X P1.0 6 0.6 4.3
Relay Terminal x Wire Nut M8 x P1.25 6 0.6 4.3
Battery Terminal x Wire Nut M8 x P1.25 6 0.6 4.3
For G14-E
Battery Hold Down x Battery Nylon Nut M6 X P1.0 2 0.2 1.4
Traction Motor Terminal x Wire Nut M8 x P1 .25 7 0.7 5.1
Relay Terminal x Wire Nut M8 x P1.25 6 0.6 4.3
Battery Terminal x Wire Nut M8 x P1 .25 6 0.6 4.3
Traction Motor x
Bolt M6 x P1.0 6 0.6 4.3
Transmission Case
9-18
TIGHTENING TORQUE ISPECI JP11
GENERAL TORQUE General Torque
A 8
SPECIFICATIONS (Nut) (Bolt) Specifications
This chart specifies torque for standard fasteners Nm m-kg ft-lb
with standard I.S.O. pitch threads. For torque 10mm 6mm 6 0.6 4.3
specifications for special components or assem
12 mm 8mm 15 1.5 11
blies not covered by this chart, please look in the
14mm 10mm 30 3.0 22
applicable sections of this manual. To avoid
warpage, tighten multifastener assemblies in a 17 mm 12mm 55 5.5 40
crisscross fashion, in progressive stages until full 19 mm 14mm 85 8.5 61
torque is reached. Unless otherwise specified, 22 mm 16mm 130 13.0 94
torque specifications call for clean, dry threads.
Components should be at room temperature.
[A] Distance across flatts

liD Outside thread diameter
DEFINITION OF UNITS
Unit Read Definition Measure

mm Millimerter 10 ·3 meter Length
em Centimeter 10 ·2 meter Length
kg Kilogram 10 3 gram Weight
2
N Newton 1kg x m/sec Force
Nm Newton Meter Nxm Torque
m-kg Meter Kilogram m x kg Torque
Pa Pascal N/m 2 Pressure
N/m m Newtons per Millimeter N/mm Spring Rate
L Liter
- Volume or Capacity
cm 3 Cubic Centimeter
r/min Revolution per Minute - Engine Speed
9-19
LUBRicAtioN POINT AND GRADE oF LUBRicANT lsPEcl Pfl
ENGINE
Lubrication point Lubricant type

Oil seal lips ~
0 -ring ~
Cylinder head bolt --tQ
Crankshaft bearing ~
Balancer (shaft, bearing, drive gear) ~
Connecting rod ~
Piston, piston ring, cylinder
-·ca
Camshaft, camshaft bearing ~
Valve stem ~
Rocker arm shaft ~
CHASSIS
Lubrication point Lubricant type

Wheel bearing ~
Steering knuckle ~
Primary sheave ~
Secondary sheave ~
@ - Lithium soap base grease
@- Engine oil
@- Molybdenum disulfide grease
9-20
CABLEJWIRE ROUTING ISPECI9'~1
CABLE/WIRE ROUTING
FORG14-A
CD Choke cable ® Brake cables ® Battery
® Main switch cable (j) Negative lead @ Ignition coil lead
@ Pilot lamp wire @ Positive lead @ Pickup coil lead
(!) Stop switch cable ® lead wire to starter generator ® Starter generator
@ Accelerator cable ®Plug lead
(.r~- f'l!'
~ ~ ,;_r-~ v®
no '\. 0 """
\~
v ~ 0~
~
( X I ""'
l
F
]o
X l j
~
II ~
__n,
IJ)
. 0
~
......... '-- ~
ff ~
I T •
v \
:Ft
IO 0
J,J
om
~
}\, ~r
F;
:!
!!
:~
~~
_@
...,...
' """1\ ~
~ :
!
!
c
lo
n;o
' .. :I k-~n----...J J
~
0
l*
T~ .(J)
r?; @. ~J~r1 .._/
~ ' \ ~iJ B
~
:~®1 ~CD
~ .. ~ - - 1-- ®
D ~ '?D \\ @
~P'_~
.Iii"\
...,...
~ 2_._.....--
l )l
1 []::::::: ............ ~._
~....,
~~J' ~ u =
1-
~
,-J
8~ Jl
-t
rol \ r Fl ~
9-21
cAsLE RouTING !sPEc! ~~~
<D Back-up
S I . b uzzer switch lead
® o enold relay
® Ignitor unit
@) Voltage regulator
® Back-up buzzer
®Fuse
B c
9-22
CABLE ROUTING lsPECIJl'~l
FORG14-E
CD Positive lead
® Negative lead
® Main switch
@) Batteries
® Traction motor
® Back-up buzzer
(/) Accelerator stop switch
® Solenoid relay
9·23
cABLE nour1NG lsPEcl ~~~
<D To battery (-)
® Charging receptacle
@Diodes
@ To motor (A2)
® To solenoid relay
®Switch
<!> To solenoid relay
® Speed controller
® Solenoid relay
9-24
a~
:u:u
QZ
•C)
@@>-a COLOR CODE
B ............. Biack R ............. Red ~c
)>-
L. ............. Biue P ............. Pink
!;
®0=:=00=:~
Y .............Yellow O .............Orange
~
G .............Green Br ............ Brown
<==]_ B/R .......... Biack/Red

R/W ......... Red/White
®~ B~R W/B ........ .White/Black
REV ~ R -Er0-- p-------'
@)
@[0q- Rffl ----A1r3-l
~ ar ----EJ'B- ar~~---+-----+----+---
Br Rffl
<D @I ~ I I ~ I ~ I R I • I
1\l
<11 B
~
® ~
y
z
C)
G) Ignition coil
@Buzzer
@Relay
@) Starter generator
- .®rn LV ~ c
)>
~@ '
@ Back switch ® Voltage regulator C)
@ Accelerator switch @ Oil level gauge :u
@ Main switch @Rotor )>
®TT . ~ n ~® s:
@ Pilot lamp (12V, 3.4W) @ Pick-up
(/)Battery @Ignitor
@Fuse (10A) ® Body ground
A~ y CJ)
\J
m
-0
~
Y-58
-~
(9
:u
....c;,
~
® @ ® ® CD ® m
Q~
FFON
~~
Y/8
y
~
P A Y Y/8
CD Back switch
® ~ ~
AIY A ANI 8
~
-,--,-
®Buzzer
OFF CHECK ST .. AT B<ANI 'l"l
8 p
@Diode (B)
8/ A
e. @ Diode (A)
8
e. @ Main switch
A (!) Fuse (1 OA)
@Battery
® Receptacle
®Throttle sensor
@Controller
Y/B Y 8r
@
~
@ Motor
~
@> Shift switch
1\) I @ Limit switch
0)
r-----
.. ~c~~~J
COLOR CODE
~
®
B .............Black
L. ............. Biue
G ............. Green
Y ............. Yellow
-
:::0
2
c;,
ca~@©I~ R ............. Red
P ............. Pink
Br ............ Brown
c
)>
C)
W ........... .White :::0
@ B/R .......... Biack/Red )>
@ Y/B .......... Yellow/Biack 3:
R/Y .......... Red!Yellow
® RIW ......... Red/White
en
"'tJ
m
Y-59
-0
~
-~
G11A
UTILITY CAR SERVICE MANUAL
SUPPLEMENT
FOREWORD
This Supplement Service Manual has been pre
pared to introduce new service and new data
for the G11A utility vehicle. For complete infor
mation on service procedures, it is necessary to
use this Supplement Service Manual together
with following manuals:
G14A/G14E
SERVICE MANUAL
G16A/G16E
SERVICE MANUAL SUPPLEMENT
G11A
2nd edition, June 1999
Printed in U.S.A.
P/N/ LIT-19616-00-00
(Rev. 6/99)
INTRODUCTION

YAMAHA MOTOR
AMERICA


INVOLVED!
car.
to the golf car.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
In t his revised format, the condition of a faulty component will precede an arrow symbol and the
• Bearings
Pitting/Damage -+ Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease of identifying
CD ® Symbol Identification
~~~~~~ 1 ~g!lfil """"

1
"'""
Symbols CD to ® are designed as thumb tabs
@ @ ® Periodic inspection and adjustment
lcHAsl~l I~WR~I
® Chassis
@) Power train
® Engine overhaul
"""" <ONM
® Carburetion
® ® (!) Electrical
® Troubleshooting
ENG \. lcARslfl ICON t S
"""'"
® Specifications
(f) @
IELEC Iiii IIJmal? I OCON"

"""'"
®
IsPEcIfJ'i I """"
Symbols @) to @ are used to identify specifi
@) ®
~ ~
@) Filling fluid
@ Lubricant
IC0N t1 0 ICON til
@ Special tool
@ Tightening torque
@ @
IS]
@ Wear limit, clearance
~
@ Engine speed
@ Q,V,A
10011112
"'"'""
@ @
~ ICON t l•
[01 ICONt15
Symbols @ to @ are used in the exploded

@) @
[mJ ICON t ill

a
l.
ICOH t 17
lubricant.
@ Apply locking agent
@) Apply engine oil
@) Apply gear oil
@) @) @
-1 -1 -1
@ Apply molybdenum disulfide oil
m a Q
ICOH"IIfWuil20
@ Apply lightweight lithium soap base grease
@ Apply molybdenum disulfide grease
@
....___
@ @
----- ~ ICONI211hrui2J
ii
INDEX
GENERAL (Refer to G16AIE

Service Manual ~
INFORMATION Supplement) GEN
INF
(Refer to G16AIE
PERIODIC INSPECTION Service Manual
Supplement)
AND ADJUSTMENT
(Refer to G14A, G14E ~
CHASSIS Service Manual)
CHAS
POWER TRAIN
(Refer to G16AIE
Service Manual ~
Supplement) POWR
TR
ENGINE OVERHAUL
(Refer to G16AIE
Service Manual
Supplement)
<\.
ENG
(Refer to G16AIE
CARBURETION Service Manual
Supplement)
(Refer to G16AIE
Service Manual
ELECTRICAL Supplement)
ELEC
(Refer to G14A, G14E

TROUBLESHOOTING Service Manual)
SPECIFICATIONS
iii
TABLE OF CONTENTS
CHAPTER 2 - PERIODIC INSPECTION
AND ADJUSTMENT
MAINTENANCE CHART ................. 2-1
CHAPTER 9- SPECIFICATIONS
SPECIFICATIONS .... . ................. 9-1
GENERAL SPECIFICATIONS ............. 9-1
CABLE/WIRE ROUTING for G11A ......... 9-2
TOWBAR ............................. 9-4
EMISSION CONTROL SYSTEM ........... 9-5
iv
PERIODIC INSPECTION AND ADJUSTMENT I~ Ii!!?JiI
A WARNING
Be sure to turn off the main switch and apply the parking brake when you perform maintenance
FOR G11A
C - CHECK CA - CHECK AND ADJUST R · REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
20 Rounds 125 rds 250 rds 500 rds 1000 rd s
Pre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs
Remarks Opera- 100 miles 600 mls 1200 mls 2500 ml s 5000mls
t ion 160 kms 1000 kms 2000 kms 4000kms 8000 kms
(Every (Every 6 (Every (Every (Every
month) months) year) 2 years) 4 years)
PRE Check engine oil c c c
OPER· Check air cooling duct c c c c c c
ATION Check fuel lines for leakage c c c c c c
CHECKS Check fuel level c c c c c c
Check brake pedal freeplay c CA CA CA CA CA
and adjust if necessary
Check tire pressure, tread c CA CA CA CA CA
depth, tire surface for damage
Check body and chassis for c c c c c c

damage
Check tightness of all bolts, c c c c c c
nuts, and screws
Check reverse buzzer c c c c c c
operation
Forward I Reverse shifting
Clean I Lube pedal control area CL
condition•• I Check compression
Check shock absorbers for oil c c c
leaks and damaged springs
2-1
-~~~~~~~~~-~ ANoJPI*I
1 5
PERIODIC INSPECTION AND ADJUSTMENT _ _~ _
C- CHECK CA- CHECK AND ADJUST R - REPLACE S - SERVICE CL- CLEAN AND LUBRICATE L- LUBRICATE
Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mls
tion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms
YEAR Adjust throttle cables, •• CA CA CA


damage and tension

wear or scratches

sheave bearing.

Apply battery terminal protectant s s s
Check wiring connections c c c
and insulation
Check shoe lining thickness c c c

and rear axle bearing play
Check kingpin play, seal, and CA CA CA

cap I Adjust wheel alignment
Check wheel nut tightness, c c c

front wheel bearing play

and leakage
Check operation and adjust CA CA CA

pedal stop if necessary

2 YEARS commutator for dirt

4 YEARS fuel hoses

Replace gear box oil R

Check for grease leakage; CA
adjust gearbox if necessary
2-2
GENERAL SPECIFICATIONS ISPEC IfJ f I
SPECIFICATIONS
~ m G11A
Model Code: JR31

Frame Serial Number JR3-000101
Dimensions:
Overall Length 3050 m m (120.08 in)
Overall Width 1280 mm (50.4 in)
Overall Height (Steering height) 1200 m m (47.2 in)
Height of Floor 300 mm (11.8 in)
Wheelbase 1900 mm (74.8 i n)
Tread:
Front 870 mm (34.3 in)
Rear 980 mm (38.6 in)
M in. Ground Clearance 115 m m (4.5 in)
Weight:
Dry Weight (without battery) 380 kg (837.8 1b)
Performance:
Maximum Speed 19-24 km/h (12-15 mph)
Minimum Turning Radius 3.5 m (137.8 in)
Seating Capacity 2 perso ns
Hill Climbing Ability 27° on pavement
9-1 (Rev. 6/99)

cABLE/WIRE RouTING jsPEcj fJ'j I
CABLE/WIRE ROUT ING
FOR G11A
<D Main switch wire CV Positive cable
® Pilot lamp (oil warning) wire @ Plus lead to starter generator
@ Stop switch wire ® To reverse buzzer switch
@) Accelerator cable @) Pulse hose to fuel pump
® Brake cables @ Throttle cable Z to transmission
® Negative cable @ Reverse buzzer
,..
0 0
lo
lo 0 0
l
I
1------f~'"' -
Y-845
9·2
~~~~~~~~~~~-c_Ae_L_E_Ro_u_n_NG_IsPECI ~11
CD Fuel pump pu lse hose ®Frame

® Fue l pump delivery hose ® Wire harness lead
@ Fue l hose to carburetor @ Engine stop relay
@) Relay positive cable @ Voltage regulator
® Relay lead wires @ Relay wire haness
® Relay negat ive cable @ Ground lead
CV Reverse buzzer switch @ Solenoid relay
Y·84 7
9-3
_ _ _ _ _ _ _ _ _T_ow_eA_R !sPEc! fJ CJ I
G) Towbar U-bolt torque: 23ft lb (315 kgf.cm, 3.1 Nm)
@ Centering distance= 114.5 ± 2.0 mm
Y-849
9-4
______________________ E_M_Is_s_lo_N_c_o_N_T_R_o_L_s_v_sT_E_M_,SPEC~ jU~~
EMISSION CONTROL SYSTEM COMPONENTS

CD Air cleaner
® Crankcase breather hose
@Engine
@)Carburetor
@ TCI Magneto
®Exhaust
,----~
I )
I ~
I
......--· -· - --. .....

/
/ '\
(,.... ""'"\
"• ~ ~>
n
~-
@ "
Y-844
9-5
G16A, G16E
SUPPLEMENT
FOREWORD
for the G16A/G16E. For complete information
on service procedures, it is necessary to use
this Supplement Service Manual together with
following manual:
G14A/G14E
SERVICE MANUAL
NOTE:--------------------------
This Service Manual contains information regard-
ing periodic maintenance to the emission control
system. Please read this manual carefully.
G16A,G16E
2nd edition, June 1999
Printed in U.S.A.
P/N/ LIT-19616-00-00
(Rev. 8/96, 6/99)

INTRODUCTION

YAMAHA MOTOR
AMERICA


INVOLVED!
car.
- · This message describes special precautions that must be taken to avoid damage
to the golf car.
MANUAL FORMAT
• Bearings
Pitting/Damage ---+ Replace.
EXPLODED DIAGRAM
GEN ~
INFO 0 0
""'""
~~~8! IIPJi I com
@ @ ® Periodic inspection and adjustment
lcHAsl~l IP<?Yr~l
® Chassis
@) Power train
® Engine overhaul
ICON I 3 COHM
® Carburetion
® Troubleshooting
ENG \. lcARBI f I ICON I S
""""
® Specifications
0 ®
IELEC Iiii Ilm?~l ? I ICON I 7 ICON I!
lsPEciP~I CON"
Symbols @ to @ are used to identify specifi

@) ®
~ ~
@ Filling fluid
@ Lubricant
ICON t 10 ICOfH 11
@ Special tool
@ Tightening torque
@ @
~
~
@ Engine speed
@ Q,V,A
ICON 112
!C<Jtj l 13
@ @
~ ICON I ll
[01 !OOIU15

@) @
[mJ ICON t1 8
a
..l
ICON II T
lubricant.
@) Apply engine oil
@ Apply gear oil
@ @) @
-1 -1 1 @ Apply molybdenum disulfide oil

- @ Apply wheel bearing grease
m m Q
ICON 118tluu t20
@ Apply lightweight lithium soap base grease
.....___
@ @
...__
@
--- IC0Nt21tlnlt23
ii
INDEX
~
GENERAL INFORMATION GEN
INF
PERIODIC INSPECTION
AND ADJUSTMENT

CHAS
~
POWER TRAIN POWR
TR
ENGINE OVERHAUL
ENG
CARBURETION
CARB
•
ELECTRICAL
ELEC
-
?
SPECIFICATIONS
iii
iv
TABLE OF CONTENTS
CHAPTER 1 -GENERAL INFORMATION CHAPTER 5- ENGINE OVERHAUL
ENGINE REMOVAL .................... . 5-1
GENERAL SERVICE INFORMATION ....... 1-1 PREPARATION FOR REMOVAL ........ 5-1
FRAME SERIAL NUMBER ............ 1-1 DRIVE BELT ....................... 5-2
SPECIAL TOOLS ................. . .. 1-1 PRIMARY CLUTCH .................. 5-2
AIR CLEANER CASE ................. 5-2
CHAPTER 2 - PERIODIC INSPECTION CARBURETOR ..................... 5-2
AND ADJUSTMENT WIRING AND HOSE ............ . .... 5-3
STARTER GENERATOR .............. 5-3
PERIODIC MAINTENANCE ............... 2-1 MUFFLER ............. . ........... 5-4
MAINTENANCE CHART FOR G16E .. . . 2-1 ENGINE OIL DRAIN ................. 5-5
MAINTENANCE CHART FOR G16A .... 2-2 AIR SHROUD .................. . ... 5-5
INSPECTION AND ADJUSTMENT FLYWHEEL ........................ 5-5
ENGINE (FOR G16A) ... . ................ 2-4 CYLINDER HEAD .... . .............. 5-6
AIR FILTER CLEANING .............. 2-4 ENGINE REMOVAL ................. 5-7
CARBURETOR ADJUSTMENT ........ 2-5 CRANKCASE COVER ................ 5-7
ACCELERATOR STOP SWITCH ........... 2-6 CAMSHAFT ....................... . 5-8
INSPECTION/ACCELERATOR PEDAL BALANCER SHAFT
POSITION ADJUSTING BOLT AND CRANKSHAFT . . . . . . . . . . . . . . . 5-8
HEIGHT ADJUSTMENT .. . ......... 2-6 PISTON AND CONNECTING ROD ...... 5-9
STARTER BELT ADJUSTMENT ........... 2-6 OIL SENDER AND
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . 2-7 WIRE GUIDE PLATE ....... . ....... 5-9
PRIMARY SHEAVE LUBRICATION BEARINGS . ....................... 5-9
(FOR G16A) ...................... 2-7 INSPECTION AND REPAIR ......... . .... 5-10
CYLINDER HEAD ................... 5-10
CHAPTER 3 - CHASSIS VALVE ........................... 5-10
REFER TO G14A, G14E VALVE SEAT ...................... 5-10
SERVICE MANUAL LIT-19616-00-70 ROCKER ARM .......... . .......... 5-11
PISTON RING AND PIN .. . .......... 5-11
CHAPTER 4 - POWER TRAIN CRANKSHAFT AND
POWER TRAIN FOR G16A ............... 4-1 CONNECTING ROD ............... 5-12
PRIMARY SHEAVE ..................... 4-1 ENGINE ASSEMBLY AND ADJUSTMENT . 5-14
REMOVAL .. . . . ...... . ............. 4-2 PISTON, CONNECTING ROD, AND
DISASSEMBLY ..................... 4-3 CRANKCASE COVER .............. 5-14
INSPECTION ....................... 4-3 BEARINGS ........................ 5-15
ASSEMBLY ............ . ........... 4-4 OIL SENDER AND WIRE
INSTALLATION .................... 4-5 GUIDE PLATE .................... 5-15
SECONDARY SHEAVE . . . . . . . . . . . . . . . . . . 4-6 PISTON AND CONNECTING ROD . .... 5-15
TRANSMISSION .... . ....... . ..... . .... 4-7 CRANKSHAFT, BALANCER SHAFT,
DIFFERENTIAL DISASSEMBLY ....... 4-10 AND CAMSHAFT ................. 5-17
DIFFERENTIAL INSPECTION ......... 4-11 CRANKCASE COVER ............... 5-19
TRANSMISSION DISASSEMBLY ..... 4-11 FLYWHEEL ....................... 5-20
TRANSMISSION INSPECTION ....... 4-13 CYLINDER HEAD AND
TRANSMISSION ASSEMBLY ........ 4-14 ROCKER ARM ................... 5-22
DIFFERENTIAL ASSEMBLY .......... 4-16 CYLINDER HEAD .............. . .... 5-23
INSTALLATION .................... 4-17 IGNITION UNIT . ................... 5-24
AIR SHROUD ...................... 5-25
REMOUNTING ENGINE ............. 5-25
PRIMARY SHEAVE ........... . ..... 5-26
STARTER-GENERATOR ............. 5-26
v
TABLE OF CONTENTS CONTINUED
CHAPTER 6 - CARBURETION CHAPTER 8- TROUBLESHOOTING
CARBURETOR ......................... 6-1 REFER TO G14A, G14E
REMOVAL ......................... 6-2 SERVICE MANUAL LIT-19616-00-70
DISASSEMBLY ..................... 6-2
INSPECTION ....................... 6-4 CHAPTER 9 - SPECIFICATIONS
ASSEMBLY ........................ 6-5 SPECIFICATIONS ...................... 9-1
INSTALLATION ..................... 6-8 GENERAL SPECIFICATIONS ............. 9-1
CHAPTER 7- ELECTRICAL FOR G16A FOR G16A ........................... 9-2
G16A WIRING DIAGRAM ................ 7-1 ENGINE ........................... 9-2
ELECTRICAL COMPONENTS ............. 7-2 TRANSMISSION .................... 9-5
IGNITION SYSTEM ..................... 7-4 ELECTRICAL ....................... 9-7
TROUBLESHOOTING ................... 7-5 TIGHTENING TORQUE .................. 9-8
ENGINE (FOR G16A) ................ 9-8
POWER TRAIN ..................... 9-9
CABLE/WIRE ROUTING for G16A ........ 9-10
WIRING DIAGRAM G16A ............... 9-12
vi
-
______ _
GENERAL _ _ .IIGNEFN
INFORMATION ·O .1-"..r.....o
~. I
GENERAL SERVICE
INFORMATION
FRAME SERIAL NUMBER

The machine serial number is stamped in the
location shown.
® G16A (JNS-000101-299999)
@ G16E (JNB-000101-299999)
© G16A (JN6-300101
G16E (JNB-300101
c
SPECIAL TOOLS
plete and accurate tune- up and assembly .
Using the correct special tool will help preven t
damage caused by the use of improper tools or
improvised techniques.
Y-102a
FOR PRIMARY CLUTCH SERVICE
1. Tapered clutch holder P/N YS-38518

This tool holds fixed sheave when removing
sliding sheave/slider.
Y-840
2. Clutch spider separator PIN YG 42131

This tool is used to remove sliding
sheave/spider assembly from fixed sheave.
Y-841
1-1 (Rev. 6/99)

PERIODIC INSPECTION AND ADJUSTMENT l 1~gs IhI
A WARNING
FOR G16E
C - CHECK CA - CHECK AND ADJUST R- REPLACE S - SERVICE CL- CLEAN AND LUBRICATE L - LUBRICATE
Pre 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs
Remarks orara- 100 miles 600mls 1200 mls 2500mls 5000mls
IOn 160 kms 1000 kms 2000 kms 4000kms 8000kms
(Every (Eve~6 (Eve1' (Every (Every
montll) mont s) year 2years) 4 years)
PRE Charge s s s s s s
OPER Clean battery tops, check for
ATION tightness of hold-down screws and s s s s s s
CHECKS terminals
Check brake pedal freeplay and
adjust if necessary c CA CA CA CA CA
Check tire pressure, tread depth,
tire surface for damage c CA CA CA CA CA
Check body and chassis for
damage c c c c c c
Check tightness of all bolts, nuts,
and screws c c c c c c
MONTH Check for loose or broken
connections c c c c c
Clean/lube pedal control area CL
EVERY6 Check all wire insulation for cracks
MONTHS and/or wom spots c c c c
Check shock absorbers for oil
leaks and damaged spring c c c c
Check shoe lining thickness and
rear axle bearing play c c c
Check kingpin play, seal, and cap I
Adjust wheel alignment CA CA CA
Check wheel nut tightness, front
wheel bearing play c c c
Check gear box oil level and
leakage c c c
Check operation and adjust pedal
stop if necessary CA CA CA
EVERY Replace gear box oil R
4 YEARS Check for grease leakage; adjust
gear box if necessary CA
2-1 (Rev. 8/96)

FOR G16A
PERIODIC INSPECTION AND ADJUSTMENT I~~ I~!":a I
C- CHECK CA- CHECK AND ADJUST R - REPLACE S- SERVICE CL- CLEAN AND LUBRICATE L- LUBRICATE
PRE- Check engine oil c c c
OPER- c c c c c
Check air cooling duct c
ATION
CHECKS
Check fuel lines for leakage c c c c c c
Check fuel level c c c c c c

damage
nuts, and screws
operation

condition** I Check compression

2-2
C- CHECK
CA- CHECK AND ADJUST R - REPLACE S- SERVICE CL- CLEAN AND LUBRICATE
~~~8! IWill
L- LUBRICATE
tion 160 kms 1000 kms 2000 kms 4000 kms 8000kms

YEAR Adjust throttle cables,** CA CA CA

damage and tension

wear or scratches

sheave bearing.

and insulation




and leakage


2YEARS commutator for dirt

4 YEARS fuel hoses


2-3
_____________________________E_N_G,_NE_I'~~~i§i~
INSPECTION AND ADJUSTMENT

ENGINE (G16A)
AIR FILTER CLEANING
1. Unlatch:
• Air f ilter cover clips G).
2. Remove:
• Case cap@.
• Ai r filter @.
Y-624
• Pre-filter @).
3. Clean:
• Pre-f ilter @).
Wash it wit h soap and water ® and allow it
to d ry.
• Do not apply oil to the element pre-filter;

resistance to air flow will be increased and
adversely affect the performance.
• Do not wash the air filter or use pressurized
air which will damage the element.
• Do not use filters made from any other mater
ial. Engine life will be reduced.
L-----~.:...........:~.....-~..__;L..o;..__ _ _ _ _
v._s
s2....~ • Be careful not to drop anything into the air

inlet.
4. Install:
• All components
NOTE:-----------------------
When assembling the air filter, reverse the
removal procedure.
• The pre-filter has a notch on one side. It will

only fit in the case one way.
Y-627
2-4 (Rev. 8/96)

CARBURETOR ADJUSTMENT
NOTE:-----------------------
Remove air cleaner assembly by removing two
bolts at the rear of the air cleaner, the two nuts at
the intake manifold, and the breather hose.
Remove the anti-tamper cap. If the cap is dam
aged replace it.
1. Adjust:
v-s41 • Pilot screw <D
Pilot screw adjustment steps:

• Lightly screw in the pilot screw (D.
• Back it out from its seated position .
Standard Turned Out: 1 and 1/2 turns
• Adjust mixture by turning the pilot screw 1/8

- 1/4 turn each time.
Too Lean~ Turn pilot screw counterclockwise.

Too Rich~ Turn pilot screw clockwise.
Replace the anti-tamper cap once the pilot screw

is adjusted.
2. Adjust:
• Throttle stop screw ®
Throttle stop screw adjustment steps:

• Screw out the throttle stop screw ® to clear
the throttle arm.
Y-542
• Slowly screw in the throttle stop screw ®
until it is lightly touching the throttle arm,
then give it another 1/ 4 turn.
Standard Turned In: 1/4 turn
Do not use any other setting or adverse perfor

mance will result.
3. Make sure gaskets are clean and not dam

aged. Replace if necessary.
4. Install air cleaner case.
Air Cleaner Intake Manifold Nuts and

Air Cleaner Case Bolts:
6.5 N•m (65 kgf•cm, 5 ft•lb)
Attach the breather hose firmly to the air cleaner

case or engine damage may result.
2-5 (Rev. 6/99)

____________________________E_N_G_IN_el'~~~~~
ACCELERATOR STOP SWITCH

POSITION ADJUSTING BOLT HEIGHT
ADJUSTMENT
1. Rem ove:
• Service lid
2. Inspect:
• Stop switch
Dirt deposits--+ clean.
Unsm ooth movem ent--+ Replace sw itch.
3. Measure:
• Adjusting bolt height @ .
Out of specif ication --+ Adjust.
Accelerator Pedal Position Adjusting

Bolt Height @:
18.00 - 18.40 mm (0.708 - 0.720 in)
0
Y-127
STARTER BELT ADJUSTMENT
Refer t o G14 Chapter 2, "STARTER BELT INSPEC
TION " and not e t he following points f or G16A:
Belt tension adjustment steps:
• Loosen t he :tw.Q large 12 mm f lange bolts G)

th at secu re the st arter gen e rat or to its
mount bracket.
• Loosen the lower tensioner lock nut ® .
• Loosen adjuster bolt lock nut @ .
• Turn adjuster bo lt @) in to increase belt ten
sion, out to decrease tension.
• Tighten t he two 12 mm flange bolts G).
Starter Generator Bracket Bolt:

60 N•m (6 .0 m•kg, 43 ft•lb)
• Tighten lower tensioner lock nut @ .
Lower T ensioner Lock Nut:

21 N•m (2.1 m•kg, 15 ft·lb)
• Tig hten adjuster lock nut @ .
Adjuster Lock Nut:

6.5 N•m (65 kfg•cm, 5 ft-lb)
• Rech eck belt tension . Re-adjust if neces

sary.
2-6
___________________________ Po_w_E_R_TR_A_tN_I 1~~~~~
POWER TRAIN
PRIMARY SHEAVE LUBRICATION
(FOR G16A)
1. Lubricate:
• Primary sheave bushings
Recommended Grease:
Molybdenum disulfide grease
Grease Amount:
Three shots (Manual grease gun)
Three seconds (Automatic grease
gun)
2. Inspect:
• Remove sheave cap bolts CD and inspect
weights and rollers.
Worn -+ Replace.
• Lubricate with teflon spray
Y-544
2-7 (Rev. 8/96)

I~ I
COMPONENT~TROL ~
EMISSION co EMISSION CONTROL SYSTEM IIANDJSP
SYSTEM . .
CD Air cleaner
® Crankcase
. breath er hose
@ Engme
®Carburetor
® TCI Magneto
®Exhaust
/
,...,--· ·
-
Y·B44
2-8 (Rev. 8/96)

NOTES
2-9
______ _
POWER _
TRAIN _ IPOTWRR-~
FOR G16A _ ~-
-
POWER TRAIN
POWER TRAIN FOR G16A

PRIMARY SHEAVE
CD Fixed sheave ® Washer, plain @ Pin, dowel
® Drive belt ® Weight @ Washer, plain
® Sliding sheave @ Shim, thrust ® Slider
@) Grease nipple ® Bolt @ Bolt
® Plug @ Nut, self-locking @) Cap
® Bushing @ Spider
(!) Oi l seal @ Collar, roller
, y~
DRIVE BELT WIDTH
NEW: r;=B ~
A 31 mm(1.22in.) -
WEAR LIMIT: \ /
27 mm (1.06 in.) \ 1
/
~~.~
/;
-·· --·~ .-1-0_N_m-----.
102Nm
10.2 kg • m
75ft •lb
Y·718
4-1 (Rev. 8/96)

REMOVAL
1. Remove:
• Seat
• Primary sheave cap bolts CD
Y-544
2. Attach
• Primary sheave holder ®

YS-1880-A, 90890-01701
3. Remove:
• Bolt (primary sheave) @
4. Attach:
• Primary sheave puller @)

YG-1876, 90890-01876
5. Remove:
When removing the sheave, tighten the
sheave puller @)
Y-785
• Slide drive belt off.
• Starter belt.
4-2 (Rev. 8/96)

----------~POTWRR~oI
POWER TRAIN FOR G16A _

DISASSEMBLY
~-
1. Attach:
• Spider removal tool CD
Spider Removal Tools:

VG-42131 G) Spider Separator
VS-38518 ® Tapered Clutch Holder
2. Remove:
• Sliding sheave @ from fixed sheave using
the spider removal tools (spider has right
hand thread).
• Lift off sliding sheave @ with spider still
attached
NOTE:-----------------------
• Use a heat gun to lightly heat spider to free-up
the locking agent.
DO NOT overheat, damage to the slider could
occur.
• Leave tapered clutch holder tool installed in
fixed sheave for assembly.
3. Separate spider from sliding sheave.

• Note position of plain washer @) between
slider and sheave.
4. Remove:
• Sliders
• Plain washers
• Roller collars
• Dowel pins
• Nuts
• Bolts
• Thrust shims
• Weights
INSPECTION
1. Inspect:
• Weights CD
Unsmooth operation/Damage-+ Replace.
• Bolts ®
• Thrust shims (not shown)
• Sliders@
• Dowel pins @)
• Roller collars and washers ®
Wear/Scratches/Damage-> Replace.
Y· 7BB • Oil seals@
• Plain washer <V
4-3 (Rev. 8/96)
POWER TRAIN FOR G16A IPO~~I
ASSEMBLY
Reve rse the "DISASSE M BLY" procedure.
NOTE:-----------------------
Apply LOCTITE® to the weight nuts and threa ds
of the spider.
Weight Bolt Nut:

8.5 N•m (85 kgf•cm, 6 ft•lb)
NOTE:------------------------
Use Teflon g rease to inst all rollers and sliders.
1. Grease the bushing and oil seal lips inside of

the sliding sheave.
2. Position:
• Weig hts toward inside of sheave.
• Spider
Into sliding sheave.
• Plain washer between slider and sheave.
3. Instal l:
• Sliding sheave CD
Onto fixed sheave.
• Check position of plain washe r @ between

spider and sliding sheave.
CAUTION
DO NOT damage or deform the oil seal lips dur
ing installation.
4. Tighten usi ng spider removal tools@.
Spider/ Sheave Assembly:

102 N•m (10.2 m•kg, 75 ft•lb)
4-4 (Rev. 8/96)

POWER TRAIN FOR G16A IPO~f§l
INSTALLATION

tapered portion of crankshaft and primary
sheave using a non-oily solvent.
2. Install:
• Sheave securing bolt
Lightly tighten the bolt in this step.
3. Check:
• Sliding sheave operation
Push and pull the sliding sheave by hand.
Unsmooth operation -+ Reassemble prima
ry sheave.
4. Attach:
• Primary sheave holder G)

YS-1880-A, 90890-01701
5. Tighten:
• Bolt (primary sheave)®

75 N•m (7.5 m•kg, 54 ft•lb)
6. Install:
• Primary sheave cap and bolts G)
Primary Sheave Cap Bolts:

8.5 N•m (85 kgf em, 6 ftolb)
• Drive belt®
Refer to G14 SERVICE MANUAL, CHAPTER
2 "DRIVE BELT INSPECTION" section.
• Starter belt
Y·543
Refer to Chapter 2, "STARTER BELT
ADJUSTMENT".
4-5
POWER TRAIN FOR G16A IPOiJ1R~I
SECONDARY SHEAVE
CD Woodruff key ® Oil seal
® Spring seat ® Grease nipple
@ Compression spring ® Sliding sheave
@) Securing nut @ Circlip
® Washer @ Ramp shoe
® Fixed sheave @ Bolt
(J) Plastic washer
A SPRING HOLE POSITION:

Position '3'
B SPRING TWIST ANGLE:

450
SPRING HOLE POSmON:
65Nm
6.5m •kg
47ft · lb
Y·7 19
4-6
POWER TRAIN FOR G16A I~WR~I
TRANSMISSION
G) Transmission cover CDWheel gear 1 (Forward) @ Shift lever 2
® Input shaft assembly ® Wheel gear 2 (Reve rse) @ Shift cable
®Shim ® Idler gear (Reverse) @ Stopper (Oil level fill/check plug)
@) Pinion gear @ Guide collar (Dog clutch) @ Governor lever (bar, 1)
® Primary gear ® Shift bar 2 (Shift fork)
® Differential @ Shift bar 1 (Shift shaft)
8Nm
80 kgf• em 55Nm
6ft • lb 5.5kg • m
40ft • lb
25Nm
2.5kg • m 55Nm
18ft•lb ---1--.1 5.5 kg • m
40 ft•lb
23Nm
2.3 kg •m
17ft•lb
Y·720
4-7 (Rev. 6/ 99)

- _________ IPOTRWR~I
POWER TRAIN FOR G16A _ ~-
TRANSMISSION
1. Remove:
• Drive belt
• Secondary sheave
4 "SECONDARY SHEAVE" section.
3. Remove:
• Bolts G)
NOTE=------------------------
AII transmission case bolts and differential cover
bolts are 1/2 inch wrench size.
• Transmission case cover using a putty

knife.

NOTE=-----------------------
It is not necessary to remove the rear axle assem
bly in order to service the t ran smission or differ
Y-318
ential. If in-chassis service is desired, disregard
steps 9- 13.
4. Set the brake, jack up the rear of the vehicle

and place a stand under the frame. Block the
front wheel.
5. Remove rear axle wheel. See G14 SERVICE

MANUAL, CHAPTER 3 "REAR AXLE WHEEL
FOR G14E" section.
6. Remove:
• Shift lever nut G)
• Governor lever nut ®
Y-790
4-8
POWER TRAIN FOR G16A ~PO~~~
7. Remove:
• Speed limiter lever bracket bolts ((D and ® l
• Speed limiter lever as a unit
• Spring and 2 plastic washers @ (keep for
installation)
NOTE:-----------------------
If removing speed limiter lever as a unit, no
adjustment of cable is necessary when installing.
Y·553
8. Remove
• Shift cables @
• Mark shift shaft and lever for alignment
during installation ®
Y-791
9. Remove:
• Remove t ransmission mounting bolt and
nut @
Y-792
4-9
10. Remove:
• Rear arm connecting rod.
11. Support swing arm so it does not drop to t he

floor.
Y· 55 6
12. Remove:
• Bottom shock bolts <D
• Bolts ® holding the rear axle to rear arm .
Y·B2B
13. Lift transmission o ut through the rear of the

car. Place on suitable work surface.
DIFFERENTIAL DISASSEMBLY
1. Remove:
• Rear hubs
• Axles
Y-sSB Refer to G14 SERVICE MANUAL, CHAPTER
3 " REAR AXLE WHEEL FOR G14E" sectio n.
2. Remove:
• Bearing holder bolts <D
Mark bearing holders before removal so they can

be returned to thei r original position - bearing
holders are not interchangeable.
• Bearing holders @
Y·559 • Differential assembly with ring gear ® and
bea rings @)
4-10
- _________ IPOTwRRI~I
POWER TRAIN FOR G16A _
3_ Separate:
-~-
• Ring gear CD
• Differential assembly®
DIFFERENTIAL INSPECTION
1_ Inspect:
• Ring gear
• Differential gear
Y-560 Damage Wear--+ Replace
• Bearing
Pitting/Damage --+ Replace
• 0-ring
Wear/Damage--+ Replace
TRANSMISSION DISASSEMBLY
1. Measure height of transmission shift detent

screw. Screw has to be installed to the same
position.
2. Remove:
• Screw(!)
• Spring®
• Detent ball®
4-11
3_ Remove:
• Input shaft circlip CD
• Transmission case bolts ®
• Remove cover ®
• Use pry points to avoid case damage
Y-563a
Y-564
4. Remove:
• End washer CD
• Reverse wheel gear®
• Dog clutch®
• Shift fork@)
Y-565
5. Remove:
• Counter shaft with forward wheel gear CD
• End washer®
Y-566
4-12 (Rev. 6/99)

6. Remove:
• Input shaft Q)
• End washer(s) if used. ® Note thickness
and diameter of shims
End washer(s) are used as needed to establish

input shaft end play of .002-.005". Use the same
end washer(s) during installation. Do not change
end washer(s) unless crankcase is replaced.
7. Remove:
• Circlip CD
• Plastic collar ®
• Shift shaft@
Y-568
8. Remove:
• Governor shaft and oil seal CD
TRANSMISSION INSPECTION
1. Inspect:
• Bearings
Rough movement- Replace.
NOTE:-----------------------
Use a bearing puller to remove bearings. If neces
sary, use a heat gun to heat the case before
removing or installing bearings.
Do not overheat the transmission case. Damage

to the case may result.
4-13 (Rev. 6/99)

- ______ _
POWER _
TRAIN _ IPOTWRRI~iltil;-1
FOR G16A _ -~-
2. Inspect:
• Gears CD
Damage/Wear ---+ Replace
• Bearings®
Pitting/Damage ---+ Replace
• Oil Seals
Wear/Damage ---+ Replace
• Transmission case @
Cracks/Damage ---+ Replace
Y-793
3. Inspect:
• Wheel gear 1 (Forward)@)
• Countershaft ®
• Wheel gear 2 (Reverse) ®
Wear/Cracks/Damage ---+ Replace
• Dog clutch (j)
Damage ---+ Replace.
4. Inspect:
• Guide bar® and pin
• Shift fork®
• Shift shaft@
5. Inspect:
• Detent screw, spring, ball ®
Wear/Damage ---+ Replace.
6. Inspect:
• Governor lever and oil seal@
• Governor weights @
• Idler collar@
Wear/Damage ---+ Replace.
• Input shaft gearwear.
• Backing plate secure on shaft.
TRANSMISSION ASSEMBLY

1. When installing the input shaft be sure to

install the original shims (if equipped) CD.
2. Install the governor fork ® onto the governor

idler collar@ between the washer and gear.
3. Apply:
v-794 • Gear oil to all oil seals and bearings.
4-14 (Rev. 6/99)

4. Install countershaft and forward wheel gear
CD with thick, silver color thrust washer ®
The forward gear is smaller in diameter and
has a "F" marked between two of the
engagement dog slots.
Y-566
5. Install:
• Dog clutch @
• Before installing the clutch, engage the shift
fork @) with groove of the clutch @ . Then
turn the shift shaft lever to align the slot of
the shift shaft ® with pin @.
• Drive gear 2 (j) (reverse) with end washer
@. (The reverse drive gear is larger in dia
meter and has a "R" marked between two
Y·795A of the engagement dog slots.)
6. Install:
• Gasket (New)
• Transmission cover @ .
7. Tighten:
• Bolts (Transmission cover)
Tighten them in a crisscross pattern.
Transmission Cover:
First: 20 Nm (2.0 m•kg, 14 ft-lb)
Final: 25 Nm (2.5 m•kg, 18 ftolb)
4-15 (Rev. 6/99)

______ _
POWER _
TRAIN _IPOTWRR
FOR G16A _ ~- ~~
-
8. Install:
• Det ent ball @
• Spring ®
• Transmission shift detent screw CD
9. Tight en transm ission shift detent screw to

specification measured during disassembly.
Y-562
DIFFERENTIAL ASSEMBLY

1. Tighten:
• Different ial case nuts attaching ring gear CD
to differential assembly @ .
Differential Case Nuts:

55 Nm (5.5 m•kg, 40 ft·lb)
Y-560
NOTE:-----------------------
Apply LOCTITE® to the differential case nuts.
2. Tighten:
• Differential bearing holder bolts CD
Differential bearing holders @ must be installed

in their original locations. Holders and case are
marked with locating letters.
Differential Bearing Holder Bolts:

Y-797
55 Nm (5.5 m•kg, 40 ft•lb)
NOTE:------------------------
Ciean the transmission cover surface @.
3. Apply:
• RTV Quick Gasket sealant (ACC-11001-05
01) or Three bond 1215 (to t he cover sur
face and into the 10 bolt holes)
4-16 (Rev. 6/99)

4. Tighten:
• Transmission cover bolts CD thru @
• New transmission case holes are not
threaded. Bolts are self-tapping.
NOTE=---------------------
Tighten the bolts in order starting with the small
est number and torque the bolts in two stages.
Y-322 Transmission Cover Bolts:

First: 20 Nm (2.0 m•kg, 14 ft-lb)
Final: 25 Nm (2.5 m•kg, 18 ft•lb)
INSTALLATION:
Reverse the "REMOVAL" procedure. Note the
following points.
1. Install:
• Transmission mount bolt and nut
Y-558
Transmission Mount Nut:

23 Nm (2.3 m•kg, 17 ft• lb)
• Rear arm bolts®
Axle Housing - Rear Arm (2):

64 Nm (6.4 m•kg, 46 ft• Ib)
2. Install:
• Rear shock absorber pivot bolts CD
Y-799 Shock Absorber Pivot Bolt CD:

32 Nm (3.2 m•kg, 23 ft•lb)
• Rear arm connecting rod @.
Connecting Rod Nut Torque:

90 Nm (9.0 m•kg, 65 ft• lb)

3 "REAR AXLE WHEEL FOR G14E,
REMOVAL" section.
• Rear wheels
Rear Wheel:
90 Nm (9.0 m•kg, 65 ft•lb)
4-17 (Rev. 8/96, 6/ 99)

- ________ IPOTRWR~I
POWER TRAIN FOR G16A _ ~-
3. Fill:
NOTE=-----------------------
Be sure to install transmission case fill cap.
Recommended Oil:
SAE 90 gear oil
Oil Capacity:
415 cc (0.261mp qt. 0.42 US qt)
4. Connect:
• Shifting cables <D {with lever @ ) onto shaft
• Align line on shaft with dot on shift lever
• Shift lever nut
NOTE:------------------------
Aiign the match marks on the lever and shaft.
Scri be mark on shift shaft end should be in 9
o'clock position {transmission in neutral) with
Y-573 lever straight up and down.
5. Install:
• Speed limiter lever onto the governor shaft.
Make sure to install the two plastic washers
@.
• Governor lever nut
~ Governor Lever Nut:

~ 8 Nm (80 kgf•cm, 6 ft·lb)
• Speed limiter lever bolts <D and ®

• Circlip onto the input shaft.
NOTE=----------------------
If speed limiter lever was removed as a unit, no
throttle cable adjustment is necessary.
6. Adjust:
• Throttle cable free play
2 "THROTTLE CABLE ADJUSTMENT" sec
tion.
4-18 (Rev. 8/96, 6/99)

ENGINE REMOVAL ENG 1~1
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE=------------------------
It is not necessary to remove the engine in order
to remove the following components:
• Cylinder head assembly
• Carburetor
• Primary sheave
• Air shroud
• Ignition unit
• Flywheel
PREPARATION FOR REMOVAL

1_ Remove all dirt, mud, dust, and foreign mate
rial before removal and disassembly_
Y-528
2. Use proper tools and cleaning equipment.

Refer to G14 Service Manual CHAPTER 1"
SPECIAL TOOLS"
CAUTION
Make sure all traces of cleaner are removed
before engine is reassembled. Engine oil can be
adversely affected by even small amounts of
Y-529
cleaner.
NOTE=----------------------
When disassembling the engine, keep mated
parts together. This includes gears, cylinders,
pistons, and other parts that have been "mated"
through normal wear. Mated parts must be
reused as an assembly or replaced.
Y-530
3. During the engine disassembly, clean all

parts and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are correct
ly reinstalled in the engine.
4. Disconnect the battery negat ive lead.
Y-53 1
5-1
DRIVE BELT
1. Remove:
• Drive belt
4 "SECONDARY CLUTCH DISASSEMBLY"
section.
PRIMARY CLUTCH
1. Remove
• Primary clutch
Refer to CHAPTER 4 "POWER TRAIN PRI
MARY SHEAVE" section.
AIR CLEANER CASE

1. Remove
• Air cleaner
Refer to CHAPTER 2 "CARBURETO R
A WARNING
Gasoline may be present in the carburetor and
fuel system. Use care during engine removal not
to spill gasoline. Gasoline is extremely flamma
ble, and its vapors can explode if ignited.
CARBURETOR
1. Disconnect:
• Fuel hose CD
2. Remove:
• Choke cable clam p ®
3. Remove:
• Cotter pin from clevis pin ®
• Clevis pin@
• Choke cable
v-soo 4. Remove:
• Circlip@
• Cotter pin from clevis pin ®
• Clevis pin@
• Throttle cable®
5. Remove
• Carburetor assembly 0
• Three gaskets@. (Replace if damaged.)
5-2
ENGINE REMOVAL ENGI ._I _ -~ _
WIRING AND HOSE

1. Disconnect:
• Ignition lead CD
• Oi l warning level switch lead (blue) ®
2. Disconnect
• Pulser hose @from crankcase.
v-sn
STARTER GENERATOR
1. Remove:
• Seat support bolts CD
• Seat support®
• Starter generator lead wire clamp
2. Remove:
• Starter generator lower adjuster lock bolt @
Y-578
5-3
3. Remove
• Starter generator bracket mount bolts @)
• Starter generator
NOTE:-----------------------
Disconnect starter generator leads if servicing is
necessary
Y·58 1
MUFFLER
1. Remove:
• Muffler joint rivets G)
Y·583
2. Remove:
• Exhaust pipe holding nuts ®
• Muffler mount bolts @
• Muffler ® and gasket
5·4
ENGINE OIL DRAIN
Refer to G 14 SERV ICE M AN UAL, CHAPTER 2
"ENG INE OIL REPLACEMENT" secti on for com
plete instruct ions.
1. Place a proper catch container under the oil

drain p lug.
2. Rem ove d rain plug.
3. Drain engine oil completely.
AIR SHROUD
1. Remove:
• Top bolts CD
• Bottom bolt ®
NOTE:-----------------------
Bottom bo lt is accessed from und erneath t he
frame.
2. Rotate t he air sh roud ®and remove.
3. Remove TCI ignit ion unit.
Y-588
FLYWHEEL
1. Rem ove:
• Flywheel securing nut and washer
Use a Sheave Holder @)

VS-1880-A, 90890-01701
Y..£!01
5-5
__________________________eN_G_t_N_e_o_ts_A_s_s_eM_s_L_v_IENGI~I
2. Remove:
• Remove valve cover
• Air shroud
• Valve cover gasket
• Spark plug
Y-59 1
3. Place va lve at TDC compression stroke. Refer

t o G14 SERVICE MANUAL CHAPTER 2
"INSPECTION AND ADJUSTMENT ENGINE"
section.
Mark flywheel at TDC f or installation CD
Y-595
4. Remove:
• Flywheel CD
Use a 2 or 3 jaw puller @.
NOTE:------------------------
Fiywheel can be removed in the frame by remov
ing the fuel tank.
Y-590
CYLINDER HEAD
1. Remove
• Rocker shaft CD and arms ®
• Push rods (Exhaust/Intake) @
NOTE:-----------------------
Mark both push rods so they can be installed in
their original positions.
5-6
ENGINE DISASSEMBLY
2. Remove:
IENG l"-1
• Cylinder head bolts@)
• Head ® and head gasket
NOTE:-----------------------
Loosen bolt s in numbered sequence as shown.
Start by loosening each bolt 1/2 turn until all are
loose.
Y-726
ENGINE REMOVAL
1. Remove:
• Engine mount nuts underneath rear arm
2. Remove:
• Engine. Place on a suitable work space
NOTE:-----------------------
The engine weighs 21.9 kg (48.3 lbs) without the
starter.
CRANKCASE COVER
1. Remove:
• Bolts
• Crankcase cover G)
• Dowel pins®
• Gasket
Y-596
5-7 (Rev. 6/99)

CAMSHAFT
NOTE:------------------------
Before removal note alignment marks for assem
bly. The punch and paint marks on the crank
shaft align with the holes on balancer and
camshaft, indicating Top Dead Center (TDC) for
the piston.
Y-598
1. Remove:
• Cam shaft CD
NOTE:-----------------------
Before removing the camshaft, place the engine
with its left-side up to prevent the tappets from
falling out.
2. Remove:
• Intake ® and exhaust tappets @
NOTE:- - - - - - - - - - - - - - -
Mark both tappets so they can be installed in
their original guide hole.
Y-600
BALANCER SHAFT AND CRANKSHAFT
1. Remove:
• Ba lancer CD
Y-601
2. Remove:
• Connecting rod bolts ®
NOTE:-----------------------
The oi l splasher @ is part of connecting rod cap .
Remove cap with care; keep bolts with cap.
When installing connecting rod cap make sure
splasher is pointing down and arrows @) on cap
match.
• Crankshaft ®
5-8 (Rev. 6/99)
ENGINE DISASSEMBLY ENG I'\.I
1. Remove:
• Piston I connecting rod from crankca se CD
Y-603
2. Remove
• Clip ® (If replacing rod, piston or piston
pin)
NOTE:------------------------
"YAMAHA" cast on left side of connecting rod @
always faces primary clutch side of engine.
OIL SENDER AND WIRE GUIDE PLATE
1. Remove:
• Bolts CD
• Wire guide plate ®
• Oil sender switch @
Y-605
BEARINGS
1. Remove:
• Bearings CD - heat case even ly with heat
gun. Use a bearing puller ® to remove
bearings
Do not overheat the engine cases. Damage to

v-606 the cases may result.
5-9
INSPECTION AND REPAIR IENG l4t.l
For Inspection and Repair refer to the G14 Service

Manual CHAPTER 5 "INSPECTION AND REPAIR".
Note the following specifications and I or steps
that are unique to the G16A engine.
CYLINDER HEAD
Cylinder Head Warp Limit:
Less than 0.03 mm (0.001 in)
VALVE
Margin Thickness (Service limit):

Intake 1.2 mm (0.047 in)
Exhaust 1.0 mm (0.040 in)
Beveled:
No minimum*
Minimum Length (Service limit):
No minimum*
Seat Width (Valve face):
1.0 mm (0.040 in)
*If valve stem end is damaged.
replace valve.
Valve Stem/Guide Maximum

Clearance
0.037 ~ 0.064 mm 0.10mm
Intake (0.0015 ~ 0.0025 in) (0.040 in)
0.030 ~ 0.057 mm 0.10mm
Exhaust
(0.0012- 0.0022 in) (0.040 in)
Maximum Runout:
0.01 mm(0.0004 in)
VALVE SEAT
Valve Seat Width:

Std: 0.7 - 0.9 mm
(0.028 - 0.035 in)
NOTE:----------------------
The G16A only requires a 45° and a 60° cutter.
The 10° cut is not required on the G16A.
Valve Compressed Force Limit:

Intake: 7.0 kg (15.41 lb)
Exhaust: 9.0 kg (19.81 lb)
5-10
ROCKER ARM
IENG I~ I
Rocker Arm Inside Diameter:
12.00 - 12.04 mm
(0.472 - 0.474 in)
Cam Lobe Cam Lobe

"A" '-'8 "
In 32.495 - 32 .595 mm 26.029 - 26.129 mm

(1.279 - 1.283 in) (1 .024 - 1.028 in)
Ex 32.495 - 32.595 mm 26.029 - 26.129 mm

(1.279 - 1.283 in) (1 .024 - 1.028 in)
Camshaft Bearing Surface Diameter:

15.90 - 15.97 mm
(0.625 - 0.628 in)
Camshaft Pivot Inside Diameter:
16.00 - 16.05 mm
(0.630 - 0.632 in)
Clearance Limits:
0.03 - 0.15 mm (0.001 - 0.005 in)
Cylinder Bore " D":

78.00 - 78.02 mm
3.070 - 3.071 in)
<Limit: 78.05 mm (3.072 in)
Taper Limit " T" :
0.15 mm (0.006 in)
Out of Round Limit " R":
0.15 mm (0.006 in)
~Standard
Piston Outside Diameter " P"
77.96 - 77.98 (3.069 - 3.070 in)

Oversize2 78.50 mm (3.090 in)
PISTON RING AND PIN
Side Clearance
Standard Limit
Top Ring 0.04 - 0.08 mm 0.10mm
(0.0015 - 0.0031 in) (0.0039 in)
2nd Ring 0.03 - 0.07 mm 0.09mm
(0.001 - 0.003 in) (0.04 in)
5-11 (Rev. 6/99)

INSPECTION AND REPAIR IENG I'\.I
Outside Diameter (Piston Pin):

19.995 - 20.000 mm
(0.7872- 0.7874 in)

Crankshaft Runout
1. Measure:
• Crankshaft assembly width (a).
Out of specification--. Replace crankshaft.
Crankshaft Assembly Width (a):

104.0- 105.4 mm
(4.094 - 4.149 in)
• Connecting rod big end side clearance (c).

Out of specification ~ Replace connecting
rod.
Big End Side Clearance (c):

0.20 - 0.65 mm (0.008 - 0.025 in)

1. Measure:
• Crank pin outside diameter@)
Use a micrometer.
Crank Pin Outside Diameter @) :

35.97 - 35.98 mm
(1.4161- 1.4165 in)
Crank Pin Round or Taper Limit:
0.03 mm (0.0012 in)
Connecting Rod Oil Clearance

1. Clean:
• Crankshaft G)
• Connecting rod ® and cap@
2. Attach:
• Plastigage®
Onto the crank pin.
-~
~ Plastigage
YU-33210
3. Install:
• Connecting rod ®
Connecting rod cap @.
5-12
INSPECTION AND REPAIR IENG I~ I
NOTE:-----------------------
Be sure the arrows on both components align.
Plastigage shou ld be 90° from rod cap to rod
seam.
4. Lubricate:
Molybdenum DisuHide Grease or Oil
5. Tighten:
• Connecting rod bolt
NOTE:-----------------------
Do not turn connecting rod until clearance mea
surement has been completed .
Tighten to full torque specification without paus

ing .
Connecting Rod Cap Bolt:

20 Nm (2 .0 m•kg, 14 ft•lb)
6. Remove:
Use care in removing.
7. Measure:
• Width of plast igage® CD
Ou t of specification ---. Repl ace connecting
rod and/or replace crankshaft if necessary.
Connecting Rod Oil Clearance:

0 .016 - 0.046 mm
(0.0006- 0.0018 in)
Limit: 0.1 mm (0.004 in)
5-13
INSPECTION AND REPAIR IENG l'\.1
PISTON, CONNECTING ROD, AND CRANKCASE COVER
CD Top ring (J) Connecting rod
@ 2nd ring @ Rod cap
@ Oil control ring ® Dipstick
@ Piston @ Filler cap
® Piston pin ® Crankcase cover
® Piston pin clip ® Gasket
20Nm
2.0m • kg
14 ft.lb.
38Nm
3.8m •kg
27ft.lb.
26Nm
260 kgf•cm
Y·724
19 ft.lb.
5-14
~~~~~~~-E_N_G_IN_E_A_s_s_e_M_e_~~AN_o~Ao_J_u_s_r_M_EN_r_IENGI~I
INSTALLATION
BEARINGS
1. Install:
• Bearings using a press. Lubricate races and
bearings to ease assembly.
OIL SENDER AND WIRE GUIDE PLATE
1. Install:
• Oil sender @
• Wire guide plate ®
• Bolts CD
6mm Bolt:
9 Nm (90 kgf•cm, 6.5 ft•lb )
Y-605

1. Install:
• Piston rings o nto the piston using a piston
ring expander.
NOTE: -----------------------
Be sure to install the rings so that manufacturer's
marks or numbers are located on the top side of
the rings. Oil the pistons and rings liberally.
NOTE: -----------------------
• Arrow on piston top CD faces front of engine
• "YAMAHA" casting ® faces primary clutch
side of engine
• Match arrows on rod and rod cap @
• Splasher @) points to bottom of engine.
Y-605
• Always install new piston pi n clips @.
2. Install:
• Piston clip ®
3. Oil liberally:
• Piston
• Rings
• Cylinder
• Piston Pin
5-15
ENGINE ASSEMBLY AND ADJUSTMENT I ENG 1. . .1
4. Set:
• Piston ring ends
NOTE:-----------------------
Make su re the ends of the oil ring expander does
not overlap.
(1) TOP RI NG
(2) OIL RING (LOWER RAIL)
(3) OIL RING (UPPER RA IL)
(4) 2ND RING
(5) A RROW MARK
5. Install:
• Pisto n/Con n ect ing rod CD into cyli nder
using a piston ri ng compressor.
NOTE:-----------------------
The arrow mark on the piston should face toward
the front of the engi ne (push rod side).
Piston Ring Compressor:

Y-603
VU-33294
5-16
ENGINE ASSEMBLY AND ADJUSTMENT IENG I~ I
CRANKSHAFT, BALANCER SHAFT, AND CAMSHAFT
G) Crankcase
@ Balancer shaft
@ Crankshaft
@) Tappet
® Camshaft
5-17
CRANKSHAFT, BALANCER SHAFT, AND

CAMSHAFT
1. Install:
• Crankshaft CD
• Connecting rod cap @
• Connecting rod cap bolts ®
NOTE:-----------------------
Ma ke sure splasher @ is pointing down and
v-ao? arrows @) on cap match
2. Lubricate:
• Connecting rod bolt th reads
~ Molybdenum o;sulfide G•ease
Connecting Rod Bolts:

20 Nm (2.0 m•kg, 14 ftolb)
• Tappet s (Exhaust @/Intake @ )
NOTE:-----------------------
Be sure the tappets are fully installed.
3. Install:
• Balancer shaft rJ)
• Camshaft @
NOTE: ----------------------
v-aos Al ign t he ho l e in the camshaft gea r with t he
punch m ark on the crankshaft cam gear. Al ig n
the hole i n o n the balancer shaft gear w ith t he
punch mark on the crankshaft balancer gear.
NOTE:----------------------
Do not turn the crankshaft in this position until
the rocker arms are installed.
Y·596
5-18
ENGINE ASSEMBLY AND ADJUSTMENT ENG 1~1
CRANKCASE COVER
1. Install:
• Dowel pins ®
• Gasket (New)
Y-597
2. Install:
• Crankcase cover
NOTE:-----------------------
Follow the numbers for t ighten ing seq uence
shown in phot o. Bolts @ and ® are 10 mm
thread size
Crankcase Cover Bolt :

8 mm: 26 Nm (2.6 m•kg, 19 ft•lb)
10 mm: 38 Nm (3.8 m•kg, 27 ft•lb)
5-19
ENGINE ASSEMBLY AND ADJUSTMENT IENG I"-I
FLYWHEEL
CD T.C.I. unit
® Woodruff key
@ Flywheel
@) Spring washer
@ Nut
@ Bolt
11 Nm
1.1 kg· m
8ft •lb
5-20
________E_N_G_IN_E_A_s_s_EM_e_L_v_A_N_o_A_o_Ju_s_r_M_E_~_I~G~~~
FLYWHEEL
1. Remove any o il and/or g rease f rom the
t apered portion of cran kshaft and flywheel
with a non-oi ly solvent .
3 . Install:
• Woodruff key
• Flywheel
• Washer
• Spring Washer
• Nut
4. Tighten:
• Flywheel securing nut
Use t he Primary Sheave Holder G).
Flywheel Securing Nut:

75 Nm (7.5 m•kg, 54 ft•lb)

YS-1800-A, 90890-01701
Y-589
5-2 1
ENGINE ASSEMBLY AND ADJUSTMENT IENG l4t.l
CYLINDER HEAD AND ROCKER ARM
G) Cyl inder head cover
® Rocker arm (Intake)
@ Rocker arm (Exhaust)
® Rocker-arm-shaft
® Push rod
® Cylinder head
(j) Gasket
7Nm 11 Nm
70 kgf• cm 100 kgf • cm
5 ft.lb. Sft.lb .
50Nm
5.0 m • kg
5 36ft.lb.
Y·729
5-22
ENGINE ASSEMBLY AND ADJUSTMENT IENG I'\.I
CYLINDER HEAD
1. Install:
• Dowel pins
• Gasket (New) CD
• Cylinder head ®
• Bolts
NOTE:-----------------------
Y-539
CD should
The swelling side of the new gasket
face upward 0.
NOTE:-----------------------
Tighten the bolts in sequence as shown and
torque the bolts in two stages.
Bolt (Cylinder Head):

50 Nm (5.0 m•kg, 36 ft·lb)
Y·726
• Make sure piston is at TDC CD
5-23
ENGINE ASSEMBLY AND ADJUSTMENT IENG I'\.I
2. Install:
• Pushrods (Exhaust/Intake) @
• Rocker shaft CD and arms ®
3. Adjust:
• Valve clearance
2 "VALVE CLEARANCE ADJUSTMENT"
Y-593
Valve Clearance (Cold):
Intake and exhaust:
0.1 mm (0.004 in)
4. Inst all:
• Cylinder ai r sh roud
• Gasket {New)
• Cylinder head cover
• Spark plug
Bolt (Cylinder Head Cover):

11 Nm (1.1 m•kg, 8 ft•lb)
Spark Plug:
20 Nm (2.0 m•kg, 14 ft•lb)
IGNITION UNIT
1. Install:
• Ignition unit
NOTE=------------------------
Rotate f lywheel 180° to line up the 2 flywheel cut
aways w ith the ignition unit bolt holes. Install
ignition unit. Pull the unit away from t he flywheel
while tightening the two bolts.
Ignition Unit Bolt:
11 N•m ( 1.1 m •kg, 8 ft•lb.)
NOTE:-----------------------
Rotate the flywhee l magnet past the ignit ion unit
to confirm that t here is an air gap between the
magnet and ignition unit. If not, loosen the bolts
and repeat procedure.
T.C.I. Air Gap:

0.3 - 0.5 mm (0.012 - 0.020 in)
2. Install:
• Spark plug cap
5-24
~~~~~~~~E_N_G_IN_E_A_s_s_e_M_a_~_Y_A_N_o_A_o_J_u_~_M_E_N_T_IENGI~I
AIR SHROUD
NOTE:-----------------------
The ai r shroud may be i nsta lled befo re re
installing the engine in the car_
1. Install:
• Flywheel ai r shroud @
Bolt (Air Shroud -Side):

8 Nm (0.8 m•kg, 5.8 ft·lb)
LOCTITE@
Y-588
• Mounting bolts CD and ®
Y-586
REMOUNTING ENGINE
Reverse the "ENGINE REMOVAL" procedure.
1. Install:
• Engine with bolts and special washers
• Mount ing nuts
Engine Mounting Nut:

35 Nm (3.5 m•kg, 25 ft·lb)
Y-594
5-25
ENGINE ASSEMBLY AND ADJUSTMENT ENG l4t.l
PRIMARY SHEAVE
1. Install:
Use the Primary Sheave Holder.
Refer to CHAPTER 4 "PRIMARY SHEAVE
INSTALLATION" section.
~ Bolt (Primary Sheave):

~ 85 Nm (8.5 m•kg , 61 ft-lb)
STARTER-GENERATOR
1. Install:
• Seat support@ and bolts CD
• Bolts and nuts@)@
• V-belt
2. Adjust:
• Belt tension
Y-579 Refer to CHAPTE R 2 "STARTER BELT
Starter Belt Tension:

8- 12 mm /10kg
(0.31 - 0.47 in/ 22 lb)
Y·578
3. Install:
• Muffler assembly (with new gasket@))
• Muffler mount bolts@
• Exhaust pipe holding nuts @
• Crankcase pulse hose
• Ca rburetor
• Air cleaner case.
4. Tighten:
v.ss4 • Bolts/Nuts/Screws
5-26
Exhaust Flange Nut (2):

16 Nm (1.6 m•kg, 12 ft•lb)
Muffler Holding Bolts (3):
16 Nm (1.6 m•kg, 12 ft•lb)
6.5 Nm (65 kgf, 5 ft•lb)
Spark Plug:
20 Nm (2.0 m•kg, 14 ft•lb)
5. Connect:
• Throttle cable
• Choke cable
• Fuel hose
6. Adjust:
• Free play (Throttle cable)
Refer to G14 SERVICE MANUAL, "THROT
TLE CABLE ADJUSTMENT" and "CHOKE
Free Play (Throttle Cable):

0.5 mm (0.02 in)
1.0 mm (0.04 in)
7. Fill:
• Crankcase
Refer to G14 SERVICE MANUAL, "ENGINE
OIL REPLACEMENT" section.
Recommended Oil:
YAMALUBE 4-cycle oil or SAE 10W30
(H temperature does not go below
2°C (35°F): SAE 20W40l
0.9 L (1.0 US qt, 0.19 Imp gall
Oil Capacity:
1.0 L (1.16 US qt, 0.241mp gall
NOTE:----------------------
Recommended engi ne oil classification; API
Service SE, SF, or SG. Engine oil s labeled
"Energy Conserving II" are recommended.

engine.
5-27
_______________c_A_R_e_u_Re_T_Io_N_I~~·~
CARBURETION
CARBURETOR SPECIFICATIONS
CD Cab le housing clamp Main jet (M.J.) #86.3
® Pilot screw (P.S.) Main air jet (M.A.J.) 01.6
@ Throttle stop screw Pilot jet (P.J.) #61.3
@) Main jet (M.J.) Pilot air jet (P.A.J.) 00.9
Throttle valve (Th.V.) #150
® Main nozzle A Valve seat (V.S.) 01.2
®Float
By-pass (1) (B.P.-1 l 00.7
<V Float chamber cover By-pass (2) (B.P.-2) 00.7
® Cover holding bolt By-pass (3) (B.P.-3) 01.0
® Float needle valve Pilot outlet (P.O.) 01.0
@)Pilot jet (P.J.) Pilot screw (P.S.l 1-1/2 turn out
® Pipe, main bleed Float height (F.H.) FIXED 16.5- 17.5 mm
@ Drain screw (0.65 ~ 0.69 in)
110
Y-752
B THROTTLE CABLE FREE PLAY:

17.0 mm (0.67 in)
c FLOAT HEIGHT (F.H.): ~

17.0 mm (0.67 in) or 16.5-17.5 mm (0.65-0.69 in) <J7
Y·731
Y·373A
6-1 (Rev. 6/99)

____________________________
cA_R_e_u_R_ET_Io_N_IcARBI ~
I
NOTE:-----------------------
Refer to G14 SERVICE MANUAL, CHAPTER 6
"SECTION VIEW" for "Main Metering System"
and "Float System" drawings.
REMOVAL
1. Remove:
Refer to CHAPTER 5 "ENGINE REMOVAL
CARBURETOR" section.
Do not disassemble throttle valve. If throttle

valve service is required, replace the carburetor
assembly.
DISASSEMBLY
1. Remove:
• Cover holding bolt CD
• Gasket @
• Rubber gasket @)
Y-611
ll
Y-61 2
2. Remove:
• Main jet CD
• Float pin
6-2
______________c_A_R_e_u_R_~_,o_N_I~Ifl
• Float pin®
Float pin ® is staked on one end. When driving

out float pin, use a small punch on opposite end
of staking. Use care not to break the float stan
chions.
Y-614
3. Remove:
• FloatQ)
• Float needle valve®
• Main nozzle A®
NOTE:-----------------------
Do not remove the second m ain nozzle (main
nozzle B), which can be seen after nozzle A is
removed. Nozzle B is fixed, and may be cleaned
Y-61s in place if required.
Y-619
4. Remove:
• Pi lot jet <D
• Throttle stop screw ® (with spring)
• Pi lot screw@ (with spring)
6-3
____________________________c_A_R_s_u_Re_T_Io_N_IcARBI ~ I
INSPECTION
1. Inspect
• Carburetor body
• Fuel passage
Contamination ~ Clean.
NOTE:----------------------
• Use a carburetor cleaner for cleaning.
• Blow out all passages and jets with com
pressed air.
A WARNING
and instructions.
2. Inspect:
• Float eD
Damaged -> Replace.
• Rubber gasket
Damaged{rorn ~ Replace.
• Needle valve ®
Wear --> Replace.
• Valve seat
Wear/Damage -> Replace the carburetor
body.
Y-615 3. Inspect:
• Throttle stop screw @
• Pilot screw @
• Pilotjet ®
Wear/Damage/Corrosion -~ Replace
4. Inspect:
• Main jet (f)
• Main nozzle A ®
• Pilot jet
Contamination --> Clean/Replace.
Y-620
NOTE:-------------------------
Biow out the jets with compressed air.
5. Inspect:
• Throttle valve
Wear/Damage --> Replace carburetor.
• Choke valve
Wear/Damage-> Replace carburetor body.
6-4 (Rev. 6/99)

_____________________________c_A_R_s_u_RE_r_,o_N_IcARBI ~ I
6. Check:
• Cho ke v alve f ree move m ent Sticking --+
Replace parts.
ASSEMBLY
Reverse the " DISASSEMBLY" procedures.
NOTE:-----------------------
Before reassembling, wash all the parts with a
carburetor cleaner.
A WARNING

and instructions.
1. Insta ll:
• Pilot jet CD
• Throttle stop screw ® (with spring)
• Pilot screw ® (with spring)
NOTE:-----------------------
See G14 SERVICE MANUAL p age 2-13 fo r pi lot
screw and throttle stop screw setting p rocedures.
2. Adj usted:
• Throttle stop screw
~ Standard Turned In:

r61 1/4turn
• Pilot screw
Standard Turned Out:

1-1/2 t urns
6-5 (Rev. 6/99)

______________________________c_A_R_s_u_R_ET_Io_N_IcARBI
3. Install:
~ I
• Main nozzle A ®
• Float CD
• Float pin ®
Y-619
Y-6 15
Y-756
6-6
______________c_A_R_a_u_R_~_~o_N_I~~~~
3. Measure:
• Float height
Float height is preset at the factory. If out of
specification replace needle valve, float or
carburetor assembly.
Float Height (F.H.) 17.0 mm (0.67 in) or

16.5 ~ 17.5 mm (0.65 ~ 0.69 in)
Measurement and adjustment steps:

• Hold the carburetor in an upside down posi
tion.
• Incline the carburetor at 60 - 70° (so that the
float valve does not compress as a result of
float weight).
• Measure the distance from the inside of the
gasket sea ling surface of the carburetor
body to the top of the float.
NOTE=-----------------------
The float should be just resting on, but not
depressing, the spring loaded inlet needle.
• If the float height is not within specification,

inspect the valve seat and needle valve.
• If needle valve rubber seat or body is worn,
or if spring is damaged or sticking, replace
needle valve.
• If valve seat is worn, replace carburetor.
• If both are fine, replace the float.
• Recheck the float height.
4. Install:
• Main jet G)
6-7 (Rev. 6/99)

_______________c_A_R_su_R_e_T_ro_N lcARBI f I
5. Installation:
• New rubber gasket @)
• Gasket @
• Cover holding bolt <D
Y-611
INSTALLATION
1. Install:
• Carburetor
Carburetor Holding Nut and

Air Cleaner Case:
Y-575
6.5 Nm (0.65 kgf•cm, 5 ft·lb)
6-8
C)
..a
Q)
)>
~
a- CD ~
2
C)
®r=;;;t- ----Ef0t- B A
c
>
REV l8-- R ~ P
oor
C)
COLOR CODE ::I:J
B ....................Black )>
@~-
8 l
L ......................Blue 3:
~ Br Br G Br
G ................... Green
Y ................... Yellow m
r-
A ................... ... Red
P ...................... Pink
m
(")
1~--R--~-.--~=-==-=~-----~~------~~~------~
Br .................. Brown -t
W .................. .White
_ ,__,,
~ ~-- Br B/ R ......... Black/Red
Y/ B ..... Yellow/Black
-
:::0
( ")
)>
m
1- - G --1---J
RIY ·......RedlYell ow
RIW ........ Red/White .,r- r
m
'1-- - Br
0 0
:::0 -4
Br
G') :!:!
~® ~
0
.....
I
)>
CD Engine stop relay ® Relay

(7)
)> .,r
® Engine ground @) Battery 0
® Pickup @ Pilot lamp {12V, 3.4W) ::0
@) Rotor @ Main switch R C)
® Oil level gauge ~
~
@ Accelerator stop switch B 0)
®
~
® Blade fuse {10A) @ Back switch )>
(J) Voltage regu lator
® Starter generator
@ Buzzer
@ Body ground ® R G
m
~
0
Y-509
I
ELECTRICAL FOR G16A IELEC Iiii I
G) Solenoid relay (!) Fuse @ Battery
@ Pilot lamp @ Back-up buzzer @ Relay plus lead wi re
@ Main switch ® Earth lead wire @ Battery plus lead
@) Accelerator stop switch @ Engine stop relay @ Battery earth lead
® Oil level switch @ Voltage regulator @ Wire harness sub lead
® Wire harness @ St arter generator
Y·nJ.
7-2
<D T.C.I. unit
®Flywheel
® T.C.I. unit wire sub-lead
@Spark plug cap
Y·7'28
7-3
Br
<D Engine stop relay

® Eng ine ground
@ Pickup
@> Rotor
® Oil level gauge
® Blade fuse (1 OA)
® Relay
@> Battery
@ Pil~t lamp (12V, 3.4W)
@ Mamswitch
~® ~
8
®
~
@ Back switch
(J) Voltage regulator ® Buzzer
® Starter generator @ Body ground
m
~
("")
Y-509T
TROUBLESHOOTING
NO SPARK OR WEAK SPARK
Procedure
Check
2. T.C.I. un it res istance
NOTE:-------------------------------------------------------
• Also refer t o G14 SERVICE MAN UAL, CHA PTER 7, "IGNITION SYSTEM " section.
• Use the f ollowing special tools in this troubleshooting
Pocket T ester: Dynamic Spark Tester:

YU-3112-C, 90890-03112 YM-34487, 90890-03144
• Remove the spark plug cap .

• Connect the Pocket T ester (Qx 1k) to the
spa rk plug cap.
Y·753
• Check the spa rk p lug cap for specified resis
tance.
Spark Plug Cap Resistance:

4 - 6 kQ at 20' C (68' F) Replace spark plug cap.
n MEETS
""'<...7' SPECIFICATION
7-5
_______________________e_L_e_cr_R_Ic_A_L_F_o_R_G_1s_A_IELECiiii I
2. T.C.I. unit resistance
• Disconnect the T.C.I. unit coupler from the

wire harness.
• Connect the Pocket Tester to the ignition
coil.
Primary Coil 0: Primary Coil liD:

Tester(+) Lead ~ Terminal Tester(+) Lead ~ Terminal
Tester(-) Lead ~ Coil base Tester(-) Lead --. High Tension Wire
Qx1 nx 1k
Y· 8 11
Y-812
• Measure the primary and secondary coi l

resistances .
Primary Coil Resistance:
0.9- 1.5n at 20· c (68. F)
Secondary Coil Resistance:
10.5- 12.9kQ: 20o/o at 20· C (68. F)
Replace T.C.I. Unit
7-6
________________________E_L_Ec_T_R_Ic_A_L_F_o_R_G_16_A_IELECiiiil
G16A IGNITION SYSTEM TROUBLESHOOTING
ENGINE WILL NOT RUN, NO SPARK
Procedure
Check:
1. Ignition unit
2. Engine stop relay
NOTE:---------------------------------------------------------
• Use the following special tool in this troubleshooting
Pocket Tester: Dynamic Spark Tester:

YU-3112-C, 90890-03112 YM-34487, 90890-03144
1. Ignition unit
• Disconnect multi-plug from Engine Stop NO SPARK PRESENT

Relay.
• Crank the engine.
~ SPARK PRESENT
Replace Ignition Unit.
2. Engine stop relay

NO VOLTAGE
• With accelerator pedal depressed, check for
voltage at the R/W wire at engine stop relay.
~VOLTAGE
Repair R/W wire circuit.
• With ohm meter, confirm Black wire conti NO CONTINUITY

nuity from engine stop relay to ground and
to engine crankcase.
~CONTINU ITY
Repair Black wire.
7-7
-----------------.
ELECTRICAL FOR G16A
NO CONTINUITY
I Iiiiiiil
ELEC
• With ohm meter, confirm continuity of Blue
wire from relay to Ignition unit.
~CONTINU ITY
Repair Blue wire.
• R{W, Black and Blue wires correct.
Replace Engine Stop Relay
7-8
_______________________G_E_N_E_RA_L__ SP_E_C_IF_Ic_A_T_Io_N_s_ISPECI JO~I
SPECIFICATIONS
~ m G16A G16E
Model Code: J N6 JN8

Fram e Serial Number J NG-000101 - JN8-0001 01 -
Di mensions:
Overall Length 2385 m m (93.9 in) ~
Overall Width 1200 m m (47.2 in) ~
Overall Height (Steering height) 1190 mm (46.8 in) ~
Height of Floor 300 mm (11 .8 in) ~
Whee lbase 1629 mm (64. 1 in) ~
T read:
Front 870 m m (34.3 in) ~
Rear 980 mm (38.6 i n) ~
M in. Ground Clearance 97 mm (3.8 in) ~
Weight:
Dry Weight (without battery) 296 kg (653 lb) 254 kg (560 lb)
Perfo rmance:
Maximum Speed 19-24 km/h (12-15 mph) ~
Minim um Turning Radius 2.8 m (1 13 in) ~
Seating Capacity 2 pe rsons ~
Hill Climbing Ability 2JO on pave m ent 20° on pavem ent
9-1
_____________M_A_I_NT_E_N_A_N_c_E_s_P_E_ci_F_Ic_A_T_Io_N_s_F_o_R_G_1_sA
__ ISPECI)O~~
MAINTENANCE SPECIFICATIONS FOR G16A
ENGINE
Item G16A
Description
Compression Ratio 8.1 : 1
1,150 kPa (11.5 kg/cm2, 164 psi)
Minimum:
1,000 kPa (10.0 kg/cm2, 142 psi)
Ignition System TCI Magneto
Cylinder Head:
Combustion Chamber Volume (With spark
plug) Gasket Thickness

Head
~
1 *
32.6-32.8
*0.20- 0.23 mm (0.0078- 0.009 in)
Y-736
Cylinder:
Piston:
Piston-to-Cylinder Clearance 0.03- 0.05 mm (0.0012- 0.0020 in)
<Limit> < 0.1 mm (0.004 in) >
2 0.50 mm (0.02 in)
Piston Pin Outside Diameter 19.995- 20.000 mm (0.7872 - 0.7874 in)
Piston Pin-to-Piston Clearance 0.004- 0.020 mm (0.0002- 0.0008 in)
<Limit> < 0.07 mm (0.003 in) >
Piston Ring:
Top Ring
Type Barrel
Dimensions (B x T)
End Gap (Installed)
I It B
1.5 x 3.5 mm (0.059 x 0.137 in)
0.2- 0.4 mm (0.008- 0.016 in)
<Limit> 1-T-1
Y-737
< 1.0 mm (0.04 in) >
<Limit> < 0.1 mm (0.004 in) >
Engine Oil:
SE, SF, or SG
Oil Change Quantity 1.0 U.S. qt (0.9 L, 0.191mp gal)
9-2
MAINTENANCE sPECIFICATIONs FOR G16A IsPEcIfJ'i I
Item G16A
2nd Ring:
Type Taper
<Limit> < 1.0 mm (0.04 in) >
Y-738
Side Clearance 0.03- 0.07 mm (0.0012- 0.0028 in)
Oil Ring:
End Gap (Installed) 0.2 - 0.7 mm (0.008- 0.028 in)
Y-739
Small End Bearing:

Type None
Big End Bearing:

Type None
Crankshaft:
Connecting Rod Big End Side Clearance "C" 0.2 - 0.65 mm (0.008- 0.025 in)
u
Y-740
35.97- 35.98 mm (1.416- 1.417 in)

Crank Oil Seal Type (Both) x Q'ty SD 35 50 8 x 2 pc
Camshaft:
Drive Method Gear drive
Cam Cap Inside Diameter 16.00- 16.05 mm (0.630- 0.632 in)
Camshaft Outside Diameter 15.90- 15.97 mm (0.626- 0.628 in)
Shaft-to-Cap Clearance 0.03- 0.05 mm (0.0011 - 0.0020 in)/
<Limit> < 0.15 mm (0.0059 in) >
9-3
_______ M_A_I_m_e_N_A_N_c_e_s_P_ec_I_F_Ic_A_n_o_N_s_F_o_R_G_1_M_IS~CIP'I
Item G16A
Cam Dimensions:
Intake "A" 32.495- 32.595 mm (1.279- 1.283 in)
I
11811 c 26.029-26.129 mm (1.024- 1.028 in)
ucu 6.495- 6.595 mm (0.255- 0.259 in)
A
Exhaust "A" 32.495-32.595 mm (1.279- 1.283 in)
~
11811 26.029-26.129 mm (1.024- 1.028 in)
ucn 6.495- 6.595 mm (0.255- 0.259 in)
Y-741

Arm-to-Shaft Clearance 0.01 - 0.07 mm (0.0004- 0.0028 in)

EX. 0.1 mm (0.004 in)
Valve Dimensions:
1~
I Head Dia. I
~"A"--l
ba· be" ~"D'
Face Width Seat Width
Thickness
Y-742

EX. 27 mm (1.062 in)
"B" Face Width IN. 2.6 mm (0.102 in)
EX. 1.6 mm (0.088 in)
EX. 1.0 mm (0.0393 in)
EX. 1.0 mm (0.0393 in)
Valve Spring Free Length 36.2 mm

<Limit> <35.0mm>
Spring Force IN. 7.0 kg
EX. 9.0 kg

Cable 1 0.2 - 0.5 mm (0.008 - 0.020 in)
Cable 2 0.5 mm (0.020 in)
Choke Cable Freeplay 1.0 mm (0.040 in) >
9-4
MAINTENANcE sPEciFicATioNs FoR G16A jsPEcj f>'j I
Item G16A
Carburetor:
Model/Maker BV26-18-47/MIKUNI
I.D. Mark JN6-01
Venturi Diameter (Ven. T.) !2118
Main Air Jet (M.A.J.) !211.6
Pilot Jet (P.J.) #61.3
Pilot Air Jet (P.A.J.) !210.9
Valve Seat (V.S.) !211.2
By-pass (1) (B.P. 1) !210.7
By-pass (2) (B.P. 2) !210.7
By-pass (3) (B.P.3) !211.0
Pilot Outlet (P.O.) !211.0
Pilot Screw (P.S.) 1-1/2 turn out
Float Height (F.H.) 16.5- 17.5 mm (0.65- 0.69 in)
Fuel Pump:
Manufacturer/Type MIKUNI/DF-52-205 (Diaphragm)
Fuel Tank:
Fuel Tank Material/Color Polyethylene/Natural
TRANSMISSION
Item G16A
Transmission:
Secondary Spring:
Outside Diameter x Wire Diameter 59 x 4.5 mm (2.32 x 0.18 in)
No. of Turns/Free Length 7.25/100.5±1.5 mm (3.95±0.059 in)
Torque Cam Angle 37.5°
Sheave Off-Set 24.3 mm
9-5
MAINTENANCE SPECIFICATIONS FOR G16A ISPEC Iif'/ I
Item G16A
Forward 11.34: 1
Reverse 15.25: 1
Governor:
9-6
MAINTENANcE sPECIFICATioNs FoR G1sA !sPEc IP'll
ELECTRICAL
Item G16A
Ignition System:
Type T.C.I.
Model/Manufacturer JN6NAMAHA

~
cj
ci 1--
....,: 20° :.--r-
@. /
C)
c:
I
.E
:;:::: 10° I
c:
0
1/
:E
c: 'v
C)
oo
1 2 3 4
Engine speed (x 103 rpm)
Y-780
Ignition:
Primary Winding Resistance 0.9 - 1.5n ± 20% at 20°C (68°F)
(Coil base to terminal)
Secondary Winding Resistance 10.5 - 12.9 k.Q ± 20% at 20°C (68°F)
(High tension cord to terminal)
9-7
TIGHTENING TORQUE lsPEcj fJ'i I
TIGHTENING TORQUE
ENGINE (FOR G16A)
Tightening torque
Nm m·kg ft·lb
Spark Plug M14 X P1.25 20 2.0 14
Air Shroud Bolt M6 x P1.0 8 0.8 5.8
Cylinder Head Bolt M10 x P1.25 50 5.0 36
Cylinder Head Cover Bolt M6 X P1.0 11 1.1 8
Valve Adjuster Locknut Nut M5 x P0.5 7 0.7 5.1
Connecting Rod Cap Nut M8 x P1.25 20 2.0 14 With oil
splasher
Cylinder x Exhaust Pipe Nut M8 X P1.25 16 1.6 12
Exhaust Pipe x Bracket Bolt M8xP1.25 16 1.6 12
Exhaust Bracket x Rear Arm Bolt M8 X P1.25 16 1.6 12
Carburetor x Joint Nut M6 x P1.0 6.5 0.65 5
Flywheel Nut M18 x P1.5 120 12.0 87
Engine Bracket x Rear Arm Nut M8 X P1.25 26 2.6 19
Crankcase Cover, 8 mm Bolt M8 x P1 .25 26 2.6 19
Crankcase Cover, 10 mm Bolt M10 x P1.25 38 3.8 27
Crankcase Drain Plug Bolt M12 x P1.5 20 2.0 14
[Cylinder Head Tightening Sequence] [Crankcase Cover Tightening Sequence]
Y·726
9-8
_________________________T_I_G_HT_E_N_IN_G_T_o_R_a_u__
e ISPECIJU~I
POWER TRAIN
Tightening torque
Nm m·kg ft·lb
For G16A
Primary Sheave x Engine Bolt 1/2-20UNF-2A 75 7.5 54
Secondary Sheave x Input Shaft Castle nut M12 X P1.25 65 6.5 47
Transmission Case x Rear Arm Bolt M8 x P1.25 23 2.3 17
Rear Axle Housing x Rear Arm Bolt M10 X P1.25 64 6.4 46
Rear Arm Connecting Rod Nut M12xP1.50 90 9.0 65
Transmission Cover 1 and 20 2.0 14 First
Bolt 5/16-18UNF-2B
Transmission Cover 2 25 2.5 18 Final
Differential Case x Ring Gear
For G16E
Bolt M8 X P1.25 55 5.5 40 --a
Transmission Case x Traction Motor Bolt M6x P1.0 11.5 1.2 8
Bolt 5/16-18UNF-2B
Differential Case x Ring Gear Bolt M8 X P1.25 55 5.5 40 --a
9-9
cABLE/WIRE RouTING lsPEcj fJ'i I
CABLE/WIRE ROUTING
FOR G16A
CD Choke cable ® Brake cables
®Main switch wire CV Negative lead
@Pilot lamp wire ® Positive lead
® Stop switch wire ® Lead wires to starter generator
®Accelerator cable @ T.C.I. unit wire lead
~~~ ..;e. ~A
~:.!
L _I
"!) ~-
@\· ~ 0
~ E
..
h•
(
.
p& ~
'I
i®
o
-~ .
oJ\
"'l
.
. ~ , •
~.
~ 0 0 I 0
0 - • I
I
I
0 0
0
~
I
r II '
~ I
I '
'
~o'er 'I 'I
fi" II
'I
~
®
II
II
II .
. .
II
0 Il l 0
\ Ill
"'
(q
- -
"'
---"' - - =
0
.
· / ·.· ·· - fc)
:f
I
'® l~',~ "\(])~

@
: ' ;;.[ ~ \ ~t® 0
r~~~
', 8 r-"1
'l
r1 ~ f}J~
,__~ ~~
Dl ~
! I
~5-=f "" " " .,. '

o ~9Jr w 1/' ~ l;
~~I
h
• ~~ ~ 0
~~ •r~~
J -- ~na=·t_®_l~
~~
~ ;.=.=. ) ~
Frb-'"' .!flo IU ~
v-
I ll I ..
. . tt ~p
....., ..
r'-- .. ~
.... ...,.l
0 0
'--' '-"
0 0
Y·746B
9-10
G) Back-up buzzer switch lead (f) Stop relay
® Solenoid relay @ Fuel hose to fuel tank
@ Shift cables ® Fuel hose to carburetor
@) Vo ltage regulator @ Pulse hose to crankcase
® Starter generator leads @ T.C.I. wire lead
@ Fuse @ Oi l warning switch lead
Y-747
9-11
} - - - 8 _ ____.
l--- P
COLOR CODE
B .................... Black
L
L ...................... Blue
G ...................Green
Y ................... Yellow
R ...................... Red
P ...................... Pink
Br ....... ........... Brown
W ...................White
R -+-~..------,
B/R ......... Black/Red
Br
Y/B ... .. Yellow/Black
RIY ....... Red/Yellow
RIW ........ Red/White
®
<D Engine stop relay ® Relay
@ Engine ground @) Battery
@ Pickup @ Pilot lamp (12V, 3.4W)
® Rotor @ Main switch
® Oil level gauge @ Accelerator stop switch
@ Blade fuse (1OA) @ Back switch
(J) Voltage regulator @Buzzer
@ Starter generator @ Body ground
® Y-509
G19E
SUPPLEMENT
FOREWORD
for the G19E. For complete information on ser
vice procedures, it is necessary to use this
Supplement Service Manual together with fol
lowing manual:
G14A/G14E
SERVICE MANUAL
G19E
2nd edition , June 1999
Printed in U.S.A.
P/N/ LIT-19616-00-00
(Rev. 6/99)
INTRODUCTION
able, appear in future ed itions of this manual.

YAMAHA MOTOR
AMERICA

Particu larly important information in this manual is distinguished by the following notations:

INVOLVED!
car.
to the golf car.
MANUAL FORMAT
In this revised format. the condition of a faulty component will precede an arrow symbol and the
• Bearings
Pitting/Damage _..., Replace.
EXPLODED DIAGRAM
~~~~~~~ ~g!lfil
1 1
"""'" """~
® @ ® Periodic inspection and adjustment
lcHAsl~l IP<?)rl~l
@ Chassis
@) Power train
® Engine overhaul
OCON" CONN
® Carburetion
® ® (j) Electrical
lcARBI f I
@ Troubleshooting
ENG ~ """" "'""'
® Specifications
(J) ®
IEL.EC Iiii Illnfhl ? I ICON t7

"'""'
®
lsPEclp~ I
""'"
Symbols @ to @ are used to identify specifi
@) ®
~ ~
@ Filling fluid
@ Lubricant
ICOI<UUI ICQ<( t 11
@ Special tool
@ Tightening torque
@ @
~
~
@ Engine speed
@ Q,V,A
ICaolf\2 ICON t 13
@ @
~ ICC!fi t l•
[0] ICONt15

@ @
[m] ICON t il
a
J..
ICONf\7
lubricant.
@ Apply engine oil
@ @ @
® Apply gear oil
-l -l l @ Apply molybdenum disulfide oil

-
m m
Q @ Apply lightweight lithium soap base grease
..._ ---- -----

ICCINt181hNIF.!O
@ @ @
IC0Nf21thrut23
ii
INDEX
~
GENERAL INFORMATION GEN
INFO
PERIODIC INSPECTION
AND ADJUSTMENT

CHAS
(Refer to G14A, G14E ~

POWER TRAIN Service Manual) POWR
TR
ELECTRICAL
ELEC
?•
TROUBLESHOOTING
SPECIFICATIONS
iii
iv
TABLE OF CONTENTS
CHAPTER 1 -GENERAL INFORMATION SPEED SENSOR TEST .............................. 8-3
SAFETY PRECAUTIONS.................................. 1-1 SPEED SENSOR MAGNET
GENERAL SERVICE INFORMATION .............. 1-2 CHECK ..................................................... 8-3
FRAME SERIAL NUMBER ......................... 1-2 CAR HAS NO REVERSE WARNING
SPECIAL TOOLS ........................................ 1-2 BEEPER .......................................................... 8-3
BUZZER WIRING CHECK .......................... 8-3
CHAPTER 2 - PERIODIC INSPECTION AND GROUND WIRE CHECK ............................ 8-4
ADJUSTMENT THE CAR'S TOP SPEED SLOWS ..................... 8-4
MAINTENANCE CHART ............................ 2-1 CHECK BRAKE AND CHASSIS ................. 8-4
ELECTRICAL (FOR G19E) ................................ 2-2 VISUAL INSPECTION ................................ 8-4
BATTERY CHARGING ............................... 2-2 CHECK BATTERIES ................................... 8-4
48V BATTERY CHARGER .......................... 2-3 TEST THROTTLE POSITION SENSOR ..... 8-4
48V CHARGER FEATURES ....................... 2-4 CHECK TRACTION MOTOR ...................... 8-4
48V CHARGER OPERATING CAR ONLY RUNS IN ONE DIRECTION ........... 8-4
INSTRUCTIONS ..................................... 2-4 CHECK FORWARD/REVERSE
BATTERY INSPECTION ................................... 2-6 DIRECTION SWITCH .............................. 8-4
CHARGE RECEPTACLE INSPECTION ............. 2-9 CAR WON'T RUN EITHER DIRECTION,
CHARGING CIRCUIT FUSIBLE LINK ............... 2-9 SOLENOID DOES NOT CLICK ...................... 8-5
CONTROLLER CONNECTOR RESET CONTROLLER ............................... 8-5
INSPECTION ................................................. 2-9 VISUAL INSPECTION ................................ 8-5
BATTERY LOAD TESTING ............................. 2-10 CHECK BATTERIES ................................... 8-5
DISCHARGE CHARTS .............................. 2-12 FUSE CHECK ............................................. 8-5
TOW SWITCH TEST .................................. 8-6
CHAPTER 3 - CHASSIS WIRE CHECK SOLENOID TO TOW
REFER TO G14A, G14E SWITCH .................................................. 8-6
SERVICE MANUAL LIT-19616-00-70 CONTROLLER GROUND WIRE CHECK ... 8-6
SOLENOID GROUND BYPASS ................. 8-6
CHAPTER 4- POWER TRAIN WIRE CHECK- SOLENOID
REFER TO G14A, G14E TO CONTROLLER ................................... 8-7
SERVICE MANUAL LIT-19616-00-70 SOLENOID RELAY BENCH TEST ............. 8-7
CAR WON'T RUN EITHER DIRECTION,
CHAPTER 7- ELECTRICAL FOR G-19E SOLENOID DOES CLICK .............................. 8-8
G19E WIRING DIAGRAM ................................ 7-1 VISUAL INSPECTION ................................ 8-8
ELECTRICAL COMPONENT LOCATIONS ...... 7-2 CHECK BATTERIES ................................... 8-8
ELECTRICAL COMPONENTS .......................... 7-3 THROTTLE POSITION SENSOR
TRACTION MOTOR ......................................... 7-4 CHECK ..................................................... 8-8
TRACTION MOTOR ......................................... 7-5 MAIN SWITCH CHECK .............................. 8-9
REMOVAL .................................................. 7-5 ACCELERATOR STOP SWITCH
DISASSEMBLY .......................................... 7-6 CHECK ..................................................... 8-9
INSPECTION AND TESTING .................... 7-8 DIRECTION SWITCH CHECK .................. 8-10
ASSEMBLY .............................................. 7-11 SOLENOID RELAY BENCH TEST ........... 8-10
INSTALLATION ........................................ 7-12 CHECK TRACTION MOTOR .................... 8-10
MOTOR CONTROLLER .................................. 7-13 TRACTION MOTOR .... .. .. .. .. .... .. .... .. ............... 8-11
CHAPTER 8- TROUBLESHOOTING CHAPTER 9- SPECIFICATIONS

ELECTRICAL ..................................................... 8-1 MAINTENANCE SPECIFICATION FOR G19E ..... 9-1
ACCELERATION BECOMES ROUGH, ELECTRICAL .............................................. 9-1
UNEVEN OR JERKY ..................................... 8-1 CABLE/WIRE ROUTING .............. .......... .......... 9-4
VISUAL INSPECTION ................................ 8-1 WIRING DIAGRAM .......................................... 9-6
TEST THROTTLE POSITION SENSOR ..... 8-1
CAR DOES NOT SLOW ON DOWN HILL
GRADE AND/OR CAR WILL ROLL AWAY
WITHOUT SLOWING .................................... 8-2
VISUAL INSPECTION ................................ 8-2
SPEED SENSOR WIRE HARNESS
CHECK ..................................................... 8-2
v
vi
GENERAL INFORMATION I~~ 1•1
SAFETY PRECAUTIONS
A WARNING
Follow t hese safety precautions and those in
Chapte r 1 of the G14A/E SERVICE MANUAL
"SAFETY PRECAUT IONS" section (P/N LIT
19616-00-70). Exercise caution when performing
service work to prevent serious accidents.
Before performing any service related to the

speed controller, or any action requiring or allow
ing physical contact with electrical power compo
nents:
SECURE THE VEHICLE

• Block the front wheels.
• Raise both rear wheels off the ground to a free
wheeling position.
• Do not allow anyone to stand in front of or
behind the vehicle during service.
DISCHARGE THE SPEED CONTROLLER

CAPACITOR.
• Turn the main switch to the "OFF" position.
• Turn the tow switch to the "TOW" position .
When turned to "TOW", t he controller capaci
tor should discharge within 5 seconds.
• Disconnect the black wire leads at the negative
battery terminal.
• Wait 30 seconds, then attach a 48 volt test
light between the positive and negative con
troller terminals to confirm that the capacitor
is discharged (test light will not illuminate).
• If required for component testing, reconnect
Negative
controller the battery and turn on main and tow switch
terminal f or specif ic measurements after required
meters are in p lace.
Positive
controller
terminal
1-1 (Rev. 6/99)

GENERAL INFORMATION I~~ 14#1:;I
GENERAL SERVICE
INFORMATION
FRAME SERIAL NUMBER

The machine serial number plate is attached in
the location shown.
® G19E (JR1·000101N299999)
® G19E (JR1-300101N)
B
SPECIAL TOOLS
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or impro
vised techniques.
L - - - - - - - - - - - - - - - - . . ; . Y·1
..;.;;;02;;;;.,a FOR SPEED SENSOR TEST
1. Speed Sensor Test Cord
YG-42221
This tool is needed to test the traction motor
speed sensor voltage output.
Y-838
1·2 (Rev.6/99)
ELECTRICAL (FOR G19El ~~~8! 11J!l11111111
A WARNING
FOR G19E
C- CHECK CA- CHECK AND ADJUST R- REPLACE S- SERVICE CL- CLEAN AND LUBRICATE L- LUBRICATE

Remarks onera- 100 miles 600 mls 1200 mls 2500 mls 5000mls
IOn 160 kms 1000 kms 2000 kms 4000 kms 8000 kms
(Every (Eve~ 6 (Every (Every (Every
montll) mont s) year} 2 years) 4 years)
PRE- Charge s s s s s s
OPER- Clean battery tops, check for
ATION tightness of hold-down screws and s s s s s s
CHECKS terminals
Check brake pedal freeplay and
adjust if necessary c CA CA CA CA CA
Check tire pressure, tread depth,
tire surface for damage c CA CA CA CA CA
Check body and chassis for
damage c c c c c c
Check tightness of all bolts, nuts,
and screws c c c c c c
MONTH Check for loose or broken
connections c c c c c
Clean/lube pedal control area CL
EVERY6 Check all wire insulation for cracks
MONTHS and/or worn spots c c c c
Check shock absorbers for oil
leaks and damaged spring c c c c
Check shoe lining thickness and
rear axle bearing play c c c
Check kingpin play, seal, and cap I
Adjust wheel alignment CA CA CA
Check wheel nut tightness, front
wheel bearing play c c c
Check gear box oil level and
leakage c c c
Check operation and adjust pedal
stop if necessary CA CA CA
EVERY Replace gear box oil R
4 YEARS Check for grease leakage; adjust
gear box if necessary CA
2-1
ELECTRICAL (FORG19El I'~ I~J~J~I
ELECTRICAL (FOR G19E)
BATTERY CHARGING
The batteries must be charged properly before
using for the first time. This initial charge will pro
long the life of the batteries.
CAUTION
To insure maximum battery performance be sure
to:
• Charge a new battery before use.
• Maintain proper electrolyte level.
Be especially careful not to overfill the batter
ies, or allow the electrolyte level to drop
below the top of the plates.
• Do not overcharge the batteries.
Failure to observe these points will result in a
shortened battery life.
NOTE:-----------
storage.
Battery charging steps:

• Before charging: only add distilled water if
fluid is below the top of the plates, and then
add just enough to cover plates.
approximately 1/4 to 1/2 inch above the
plates and 1/4 to 3/8 inch below the level
indicator. If the fluid level is low, carefully
add distilled water. Adding distilled water
after charging prevents boil over.
• Add only distilled water after a battery has
been placed in service, never add more acid
Y-837
to batterv.
A WARNING
Battery electrolyte is dangerous; it contains
sulfuric acid and is therefore poisonous and
highly caustic.
• Avoid bodily contact with electrolyte as it

can cause severe burns or permanent eye
injury.
2-2
-~~~~~~~~~~IANDJsPI~I
ELECTRICAL (FOR G19E) _
•
_~ _
Wear protective eye gear when handling or

• SKIN· Flush with water.
• EYES- Flush with water for 15 minutes and
• Do not induce vomiting.
• Drink large quantities of water or milk, fol
low with milk of magnesia, beaten egg, or
vegetable oil. Get immediate medical atten
tion.
gas. Therefore you should always follow these
• Keep batteries away from fire, sparks, or
batteries.
REACH OF CHILDREN.
48V BATTERY CHARGER

The following is a summary of the 48V charger
features, operating instructions, LED light mon
itoring system and preferable charging recom
mendations. Do not attempt to recharge the
golf car's batteries without thoroughly reading
and understanding this section and the owner's
manual provided with the 48V charger.
2-3
ELECTRICAL (FOR G19EI l'}l'gs llhlll
48V CHARGER FEATURES
1. When the charger completes a charging cycle, an internal relay turns the charger off automatically,
preventing any additional power consumption.
2. If AC power is lost during charging and DC charging cord stays plugged into car, the charge cycle will
resume from the same point in the cycle when AC power is restored.
3. If AC power is lost after a complete charge cycle, the charger will remain off when AC power is
restored.
4. For winter or extended storage, leave the charger connected. After 2 weeks and when battery voltage
drops to 2.05 volts per cell (48 Volts), a refresh charge oycle will occur automatically.
5. The charger has reverse polarity protection.
6. If the charge cycle does not complete within 16 hours, the charger will turn off and the LED will signal
an abnormal charge cycle.
48V CHARGER OPERATING INSTRUCTIONS

1. Turn golf car main switch to off position.
2. Plug ACcord into grounded receptacle.
3. Plug DC cord into car's charge receptacle.
4. The charger will go through a self diagnostic test (each of the five LED lights will flash).
NOTE:--------------------------------------------------------
If charger fails to display the diagnostic test, check the charging circuit fusible link, located in the charge
receptacle negative lead wire. A fuse failure indicates damage and/or short circuit of the DC charge cord,
plug or the charge receptacle on the vehicle. Refer to Chapter 2, "CHARGING CIRCUIT FUSIBLE LINK".
5. When the car is ready for service, disconnect the DC outlet plug from the golf car receptacle by grasp
ing the plug body and pulling the plug straight out of the receptacle.
LED READINGS - NORMAL CHARGE CYCLE
INITIAL STAGE
LED Color illuminated Charging status
*Red "INCOMPLETE" Below 80% (less than 2.38V per cell)
*Yellow "CHARGER ON" Charging in progress.
READY STAGE
*Yellow "80% CHARGE" 80% charged, above 2.38V per cell
*Yellow "CHARGER ON" Charging in progress
FINAL STAGE
* Green "CHARGE COMPLETE" Charge complete
2-4
-~~~~~~~~~-''ANru~l~l ELECTRICAL (FOR G19E) .
LED READING • ABNORMAL CYCLE
_~ _
LED Color illuminated PROBLEM REMEDY
• Red "ABNORMAL" Charge cycle did not Check batteries. Refer to Chapter 2,
complete in 16 hours. "BATTERY INSPECTION" section.
• - • Red "ABNORMAL" Open battery cells Check open circuit voltage on each
Flashes on 2 seconds, off detected. battery. Low reading indicates
1 second open cells. Replace battery(s) as
required.
NONE: (ALL LED's off) Batteries were Reconnect and charge again.
disconnected from
charger during charge
cycle.
:t Red "ABNORMAL" AC Power to charger is 1. Check AC cord. If unplugged,

:t Yellow "80% CHARGE" off. plug it back in. If it was already
-OR- plugged in, unplug it. Restore
* Red "ABNORMAL" power to AC receptacle.
:t Red "INCOMPLETE"
2. Plug the charger into the
grounded receptacle.
NOTE=-----------------
If DC cord was left plugged
in during AC power outage, the
previous charge cycle will
continue when power is restored.
Otherwise the charge cycle will
restart from "INITIAL STAGE" cycle.
:t :t Red "ABNORMAL" Output over-current Unplug AC charger cord from

Flashes condition. (Short circuit in receptacle. Repair short circuit as
:t Yellow "80% CHARGE" charger DC cord, car's necessary.
-OR- receptacle, or battery
* :t Red "ABNORMAL" wiring.)
Flashes
:t Red "INCOMPLETE"
Preferable charging:
• Connect car to same charger every night. • Organize and store the cars so that they can
• Recharge batteries as soon after usage as be used equally.
possible. • The batteries should be charged every day if
• For the first ten rounds, new batteries should used. If they are not used and checking
go only 18 holes between charges. shows that catch-up charging is not
• A 20 minute charge between rounds helps required, they should not be charged.
extend battery life.
2-5 (Rev. 6/99)

- __________ ILANDJ~I==I
ELECTRICAL (FOR G19E) _ _~ _
BATTERY INSPECTION
A WARNING
Secure vehicle and discharge the controller
capacitor. Refer to Chapter 1, " SAFETY PRECAU
TIONS" section.
1. Remove:
• Battery leads
• Batteries
A WARNING
• Always disconnect the negative lead CD first.

• Insulate wrenches with t ape to avoid short cir
cuiting of the batteries.
®To solenoid relay.
2. Wash the battery tops, sides, and surround

ing area. Use a 100/1 mixture of water and
baking soda. Be careful not to get this solu
tio n into the batteries. After drying, coat the
battery tops with a car wax.
3. Inspect:
• Lead terminals
• Battery terminals
Co rros ion~ Clean.
Terminal cleaning steps:

• Spray the term inals wit h a mixture of baking
soda and water, then allow a few minutes
for the solution to work.
v-s9s • Rinse with low pressu re water_
• Allow t ermina ls to dry and coat with anti
corrosion spray.
4. Inspect:
• Hold-downs
Use a w ire brush.
Corrosion--. Clean with baki ng soda and
water/Replace.
After cleaning, ri nse with water. Then repaint
with a corrosion resistant paint.
2-6 (Rev. 6/99)

-----------~IANDJSP l-="'1
ELECTRICAL (FOR G19E) .

5. Check:
. !!!!!"'Z..I!!.
• Electrolyte level ®
Below level-+ Add distilled water.
@ Proper fill level - DO NOT OVER FILL!
• Before charging: only add distilled water
if fluid is below the top of the plates, and
then add just enough to cover plates.
Y·830 approximately 1/4 to 1/2 inch above the plates
and 1/4 to 3/8 inch below the level indicator
If the fluid level is low, carefully add distilled
water. Adding distilled water after charging
prevents boil over.
G) Level indicator
@Cap
@Plate
6. Inspect
• Capvent
Contamination -+ Clean.
7. Measure:
• Specific gravity
Use a Hydrometer.
Less than 1.260-+ Charge battery.
Hydrometer:
YU-03036, 90890·03036
• Check the specific gravity of each cell with a

hydrometer. If the hydrometer reading is
below the specification, additional charging
is necessary.
Temperature Satisfactory Uncorrected

Of oc Hydrometer Reading
120 48.9 1.244
110
43.3 1.248
100
37.8 1.252
90
32.2 1.256
80
26.7 1.260
Y-692
70
21 .1 1.264
60
15.6 1.268
50
10.0 1.272
40
4.4 1.276
30
-1.1 1.280
• Install the filler caps, and thoroughly wipe

off the fluid around the filler caps.
2-7
ELECTRICAL (FOR G19EI ~~~~ lm!iiil
8. Install the battery trays in place as shown.
D D
D Y-697
9. Instal l:
• Batteries
Battery Holder:
2 Nm (0.2 m • kg, 1.4 ft • lbl
10. Connect:
• Battery leads
See illustrati on
G) Forward
® To solenoid relay
@ To controller
@ Between batteries
® To receptacle
Y-$34
Terminal Nut:
6 Nm (0.6 m • kg, 4.3 ft • lb)
A WARNING
Connect the negative lead @ last.
Using a wire brush, clean both the contact sur
face of the battery terminal and lead clamp until
both have a bright metallic shine for good electri
cal contact.
Apply specially treated felt washers, an anti-cor
rosion spray, or grease, to prevent corrosion.
2-8
ELECTRICAL (FOR G19E) ~~~~ ,. . .I
CHARGE RECEPTACLE INSPECTION
A WARNING
TIONS" section.
1. Inspect
• Receptacle contacts
Damage/Loose/Burned __. Replace recepta
cle.
A WARNING
Damaged receptacle contacts can cause exces
sive resistance (heat) and lead to fire.
CHARGING CIRCUIT FUSIBLE LINK

Inspect:
• Check receptacle negative lead wi re (with
fusible link) for continuity
No co nt inu i ty --. Rep lace lead w ire and
check for source of fail ure.
Inspect:
• DC charge cord, plug, car receptac le
Dam age I Burned --.Replace
CONTROLLER CONNECTOR INSPECTION

A WARNING
TIONS" section.
1. Inspect
• Controller pins
• Fem ale connect or term inals G). Lubricate
Y -682
with lig ht mech a n ica l lube eve ry t h ree
years.
Use care when probing the female connectors

inside the wire harness controller plug. The ter
minals are easily damaged which can cause fail
ure symptoms.
2-9
-~~~~~~~~~-1 ANDJsPI~I
1
ELECTRICAL (FOR G19E) _ _~ _
Design a schedule that allows discharge testing

A WARNING on one car per day or at least every other day.
Batteries also generate explosive hydrogen Follow your plan faithfully. Test each car once
gas. Therefore you should always follow these the first year and twice each succeeding year. If
your course exceeds the national average of
250 rounds each year then your discharge test
• Charge batteries in a well-ventilated area. ing schedule must be increased accordingly.
• Keep batteries away from fire, sparks, or Consult your Yamaha service representative for
open flames (e.g., welding equipment, light help with schedule adjustments. If you start out
discharge testing an older fleet with suspicious
batteries then at least 10% (i.e. 10 cars out of
• DO NOT SMOKE when charging or handling 100) should be tested. These results will give
batteries. you a feel for your replacement battery needs.
Obtain a good quality discharge tester such as
REACH OF CHILDREN. the Lester 17770. Carefully follow the procedure
found in the Section 3 "Step by Step" Testing.
1. Battery Discharge Testing- Why
Remember that seventy minutes is the industry
The purpose of the discharge load test is to standard considered adequate for 36 holes of
determine how many minutes it will take to play but as cars enter their third and fourth
bring the total voltage of a freshly charged 48 years of service, it is normal for a few batteries
to fail. Widespread failures or lack of 36-hole
or 36 volt battery pack to 42 or 31.5 volts
performance in the second year is not normal.
respectively. This test represents the maxi
mum work or run time capability of a 48-volt Ambient temperature has an effect on dis
battery pack at 80°F to fall to 42 volts. A good charge times. When temperatures are low, dis
set of 36-volt batteries should also take charge times decrease. The chart on page 2-11
approximately 70 minutes to drop to 31.5 is helpful in predicting the effects of tempera
volts. Seventy minutes should deliver 36 ture on discharge testing.
holes of golf for most courses. A shorter time
period will indicate that one or more batteries Be sure that you do the loaded individual bat
need service or replacement. tery measurements with the battery pack fully
charged to 42 (48-volt) or 31.5 (36-volt). If you
When you are load testing, you will need a do not do this part of the test immediately after
the tester shuts off, the batteries will "recover"
load tester and a high quality digital volt
as they sit. Recovered batteries will give false
meter capable of reading at least 55 volts DC. readings. If more than a few minutes elapse
Use the voltmeter to monitor the overall volt before you do individual battery measure
age decrease of the pack and the decreasing ments, turn the discharge tester back on. Allow
voltage of each individual battery during test the tester to run until the total battery pack volt
ing. Individual batteries that decrease at a age is again approaching the shut off point
faster rate are the weaker ones. Note the (31.5 volts for 36-volt cars and 42 volts for 48-
weak batteries. The weaker batteries will volt cars). This will prevent a false "good" volt
require careful measurement after the dis age measurement from a recovered battery. Be
charge tester shuts off. Once the weaker bat certain you understand this paragraph before
teries are identified they need to be replaced
you turn your discharge tester on for the first
time. You cannot achieve accurate results with
with ones of comparable age and strength of
out a complete understanding of the testing
the remaining pack. process.
2. Battery Discharge Testing - Things to Be 3. Battery Discharge Testing "Step by Step"

Aware Of
Before you start testing do the following prelim
Non-functioning chargers (or just unplugged inary checks.
chargers) can create frustrating problems,
especially if cars are not returned to the a. Fully charge the batteries (a full
same charger every night. Look for tripped charger cycle).
circuit breakers, damaged cords and plugs. b. Inspect all cables and connections.
c. Check the water level in each cell
Battery problems may be charger induced.
and add water as necessary.
2-10 (Rev. 6/99)

ELECTRICAL IFOR G19E) I~gs lsi
d. Start the charger and let it finish 1. Record surface voltage from the discharge
charging again. tester readout panel. Record the ambient
e. Let the batteries cool for 5 minutes. temperature.
2. Turn on the discharge tester. Wait at least
A WARNING 3 minutes. If you have a bad connection
(or reverse polarity) the tester will shut off
in 3 minutes. Correct any problems.
gas. Therefore you should always follow these 3. Let the tester run until it shuts off and
precautionary measures: immediately record the surface voltage
• Charge batteries in a well-ventilated area. from the discharge tester readout. Restart
• Keep batteries away from fire, sparks, or the charger and let it run until the voltage
reaches 42 volts (48-volt car) or 31.5 volts
(36-volt car).
ed cigarettes, etc.) 4. While the tester is still connected measure
• DO NOT SMOKE when charging or handling and record each individual battery voltage.
batteries. Look over the voltage measurements you
KEEP BATTERIES AND ELECTROLVTE OUT OF just recorded. A difference of 0.5 volts
REACH OF CHILDREN. from the highest to lowest measurement
indicates a weak battery.
5. Turn off the discharge tester. Wait until
The following instructions are specifically for the fan stops and then disconnect the bat
the Lester 17770 Discharge Tester. You will tery leads.
need a thermometer, discharge tester and a
digital voltmeter for the following tests. Attach
the discharge tester, be sure to observe polari If the fan is running and you disconnect the unit
ty. Heavily coated battery terminals may not
provide good electrical connections. Clean if a spark will be produced. The chart on 2-12 is a
necessary. handy place to record your measurements.
2-11 (Rev. 6/99)

-~~~~~~~~~-~IANDJsPial ELECTRICAL (FOR G19E) . _P'ZI!!!I.
DISCHARGE MINUTES ADJUSTED FOR TEMPERATURE
Temperature (P)
80
I 75 1 10 1 65 1 60 1 55 I 50 1 45 1 40 1 35 1 30
105 105
1--
100 100 103 107

1--
95 95 98 101 105
1--
90 90 93 96 100 103 107

-
85 85 88 91 94 97 101 105
-
80 80 83 85 88 92 95 99 103
-
75 75 77 80 83 86 89 93 97 101 105
-
en 70 70 72 75 77 80 83 87 90 94 98 103
-
Q)
:::J
c
I---
65 65 67 69 72 75 77 80 84 87 91 96
~ -
Q)
Ol 60 60 62 64 66 69 71 74 77 81 84 88
....
ro -
£
u 55 55 57 59 61 63 65 68 71 74 77 81
.!Q -
0 53 55 57 60 62 64 67 70 74
50 50 52
-
45 45 46 48 50 52 54 56 58 60 63 66
-
40 40 41 43 44 46 48 50 52 54 56 59
-
35 35 36 37 39 40 42 43 45 47 49 51
-
30 30 31 32 33 34 36 37 39 40 42 44
-
25 25 26 27 28 29 30 31 32 34 35 37
r-
20 20 21 21 22 23 24 25 26 27 28 29
I---
15 15 15 16 17 17 18 19 19 20 21 22
I---
10 10 10 11 11 11 12 12 13 13 14 15
ADJUSTED DISCHARGE DISCHARGE MINUTES

MINUTES = 1-(((80-TEMP) I 100}*.64)
2-12 (Rev. 6/99)

ELECTRICAL (FOR G19E) ~~~gs lll"''llll
BATTERY DISCHARGE CHART
CAR# DATE I I

Each Battery In The Blank ,--L=;;;;:;:=:J
CAR# DATE I I

CAR# DATE I I

Each Battery In The Blank ,--L=;;;;:;:=:J
( Tester Ran Minutes J
Record test results including Individual battery voltages immediately after discharge test.
Restart the Discharge Tester after it reaches 42 volts or 31.5 volts (48 V car or 36 V car)
Immediately measure and record each battery's voltage in the boxes provided above.
2-13 (Rev. 6/99)

NOTES
2-14
-
C)
CD
1""-
R
RIY
OFF ON
L~
0
0 ® ®';0"~0
ANY
)-?® ""w
RIY
y
REV FWD
0
0
0
®
CD Main switch
® Tow/storage switch
m
§
:!:!
2
~IG0II
0 C)
@ Buzzer
RIY R ~l ~ ~ @ Directional switch c
@ DC motor 5>
18801 C)
f--:!: I
G) ~ANY~ Br J
I( Jl PJ( B (J) Controller ::0
[wYRJY[v @ Throttle sensor )>
"
ANY O
OR' ON 1-- '"""
FWI ANY RW
ANY T Br p B
WRI'Y y ® Relay 3:
R 0 8 RY~ RIY
@ Receptacle m
@ Fuse (3A) r-
RIY
RIY @ Batteries (6 x 8V) m
(")
-1
Rf\11/ ~
(")
)>
_[~~ .,
COLOR CODE r- m
r
B .... .... ..... ....... .Biack m
PJY RIB R G,--------::::: X 0 0
L .... ................. ..Biue :::D -1
B~ ~ p ::0
G ................... Green C)
110~1' 11
1 2 3 6 10 4 5
15
A1 A2
Y ................... Yellow I
-A
0
)>
t-
re fi
~~ 9
8
~rs-
EB"'EB"'EB/T'>EB/T'>EB/T'o,EB~ ® R ... ....... .. .. ...... .. .Red
P ... .... .. ........ ... ... Pink
U)
m .,r
R
Jeif I
7 "' ~
f-1------- -, 0
(P) Br ........ ..... ...... Brown ::0
a&!I I (A1) _.. (A2) I
rll:J CB~
'" ~ w....................
e 1
White C)
'o' W ~=
I 1""111 3/4REC I ......
\;:!)
'
(F2)1 B/R .......... Biack/Red
®~
I CD
m
~
MOSFET
I Y/B ...... Yellow/Biack
le 18
~®
CONTROL BOARD
I 'r'
ASSY R/Y .... .... Red/Yellow
I
1\!"
@ I
BOARD
ASSY I m
~ I I R/W ........ Red/White r-
w J ____ m
~ __§1 ® I
- ----------
(N) I
.../
('")
B (j)
Y-671
I
________________________E_L_Ec_T_R_,c_A_L_F_o_R_G_19__
E IELEcliiil
<D Main switch @ Speed controller

®Accelerator stop switch ® Throttle sensor
@Tow/storage switch @Charging receptacle
@) Back-up buzzer @Fuse
® Forward-reverse switch @Solenoid relay
® Traction motor @ Batteries (8V x 6)
([) Speed sensor ® Negative wire with charging circuit fusible link
A2 Al
© ©
© ©
F1 F2
, ------ '
I '
I
\ ...... ______ , :
I
Y-833
7-2
ELECTRICAL FOR G19E IELEC I iii I
CD Receptacle ®Wire harness @Wire lead, battery set (long)
®Relay assy ®Clamp @ Relay plus lead
@ Forward/reverse switch @) Battery f itting plate. @ Tow switch
@Buzzer @ Fitting screw @ Accelerator stop switch
®Wire harness @Wire lead @ Main switch
®Wire harness @ Wire lead, minus @Fuse (3A)
0 Battery charger @Wi re lead, battery set (short)
7-3
ELECTRICAL FOR G19E IELEC Iiiiii I
TRACTION MOTOR SPECIFICATION S

Q) Front bracket M odel 5BC58JBS6272A
® Armature assembly Voltage 48V DC
@ St ator assembly Rated output KW/ H P 2.0 KW 2.7 HP (30 min.)
@) Brush set
Perform ance
® Brush holder Current 44A
® Bracket Voltage 48V
(j) Grommet Set Torque 5.4Nm
® Speed senso r (0.54 m · kg,
® Speed sensor m agnet 3.9 lb • ft)
Revolut ion 3,650 r/ min
Weight 16.5 kg (36.41b)
BRUSH LENGTH : COM M UTATOR DIAMETER :

A Limit: 14.5 mm (0.57 in) C Wear limit:
Sta nd ard: 34.3 mm (1.35 in ) 66.55 mm (2.62 in)
BRUSH SPRING FORCE:
New brush :
B 720 - 1,080 g (24.3 - 39.2 oz)
Worn brush :
450 g (15.2 oz)
l..
'' ......
......
I --~--,
·. '--..~-j
., ® ~
( -~ jz)',,, .
~- ¥::~'~-- - - -------_J
MOTOR
~
/ ~~
,( •• \
C!J€1
11.5 Nm
115 kgf.cm
~· ~
GR!MMJ
INSERT INTO
? TRANSM ISSION
SHAFT Jj /
Mfth
M0" 4 INDICATED (1 !
(J7 ·. l
~-.______/ Y·734
7-4
________________________E_L_Ec_T_R_Ic_A_L_F_o_R_G_1_9E_IELECiiiil
TRACTION MOTOR
A WARNING
TIONS" section.
REMOVAL
1. Rem ove:
• Seat
• Service access panel
2. Disconnect:
• Negative battery lead G).
3. Disconnect:
• A ll four leads® f rom the mot or te rminals.
M ark leads fo r installation.
• Speed sensor leads @
4.Remove:
• M otor securing bolt s@).
Y-815
5. Remove:
• Traction motor.
7-5
ELECTRICAL FOR G19E I 1•1
ELEC
DISASSEMBLY
1. Mark cover for installation.
Y-635
2. Remove:
• Cover plate screw CD
• Cover plate @ .
Y-636
3. Remove:
• Speed sensor @ .
Y-816
4. Remove:
• Set screw @)
• Speed sensor magnet ®
Y-8 17
5. Remove:
• Bolts@
• Bearing holder screws (j)
• Cover@
Y- 81 8
7-6
------------------------EL_E_c_TR_I_cA_L_F_o_R_G_1_9E_IElECiiiil
Y·819
6. Remove:
• Brush holder CD
NOTE:------------------------
Pull back on spring ® w ith one screw driver @
and with other @) get under wire and pull back on
brush ® to pull it away from rotor. There are four
brushes.
• Remove brush holder bolts @.
Y-643
7. Check:
• Brush length
Length of new brush is 36 mm.
Out of specificati on ~ Replace.
Minimum Brush Length:

14.5 mm (0.57 in)
Y·644
NOTE:------------------------
Leave brush leads attached to yoke while check
ing brush length.
8. Remove:
• Armature(?).
7-7
ELECTRICAL FOR G19E IELEC Iiii I
INSPECTION AND TESTING
1. Clean the interior of the yoke and bracket
with compressed air.
2. Inspect
• Outer surface
3. Measure:
• Insulation resistance (F1 and ground, F2
and ground).
Defective -+ Replace.
Insulation Resistance:
More than 1 M ohms at 20°C (68°F)

YU-91026, 90890-03064
4. Measure:
• Field coil resistance (F1 to F2)
Out of specification --> Replace.

0.9 - 1.1 ohms at 20°C (68°F)
5. Measure:
• Armature coil resistance (Armature and
brushes installed)
(A1 to A2)
Armature Coil Resistance:

0.0228 - 0.0232 ohms at 20°C (68°F)
Y~49
6. Inspect:
• Commutator (Outer surface)
Hold the armature in a vise CD and copper
or aluminum plate@.
Dirty-+ Clean with #600 grit emery cloth @.

Y·707
7-8
ELECTRICAL FOR G19E IELEC I iii I
7. Measure:
• Commutator (Diameter)
Measure t he diameter of the commutat or
as shown.
Wear limit (Minimum Diameter):

66.55 mm (2.62 in)
A CORRECT 8. Measu re:

Out of specification -+ Scrape mica to prop
er limits.
Use a hacksaw blade ® that is ground to
f it.
Mica Undercut (3):
Limit: 0.25 mm (0.0098 in)
8 INCORRECT
NOTE:-----------------------
The mica insulat ion of the commutator must be
undercut to ensure proper operation of the com
mutator.
Carefully clean between the segments after t he

above steps.
9. Check:
Roughness/Wear -+ Replace
Y-709
7-9
ELECTRICAL FOR G19E IELEC IIii I

@.
Do not strike the outer race @ or balls of the

bearing. Contact should be made only with the
Y-7 10 center race @).
[g) PRESS
10. Install:
• Armature coil
into the brush holder.
Y-711
11. Measure:
Use a spring scale G).
Out of specification - • Replace
Brush Spring Force:

New Brush: 720- 1,080 g
Y-712 (24.3 - 36.5 oz)
Limit: 450 g (15.2 oz)
7-10
ELECTRICAL FOR G19E IELEC Iiii I
ASSEMBLY
Note the followi ng points.
1. Install:
• Arm ature CD
When installing armature into yoke, use care not

to damage brushes.
2. Reposit ion brush springs @. Use the screw

d rivers @ and @)to position bru sh@.
NOTE:-----------------------
When installing cover, install a pilot screw (8-32 x
1-1/4") ® fi rst to hold the bearing retainer. Pull
u p on p i l ot sc rew 0 an d inst al l screw @.
Remove pilot screw and install second screw.
Y-822
7-1 1
ELECTRICAL FOR G19E I liiiiil
ElEC
INSTALLATION
1. Connect:
• Motor terminal leads CD
• Tachometer leads®
Motor Securing Bolt: (Upper)

5 Nm (0.5 m•kg, 3.6 ftolb)
Y-632
2. Connect:
• Negative battery lead @.
3. Install:
• Seat
Y-823
7-12
ELECTRICAL FOR G19E I 1•1
ELEC
MOTOR CONTROLLER
<D Motor control unit ~To Battery (Negative)
® Throttle sensor liD To Solenoid relay (Positive)
@ Throttle bracket IQl To Traction motor A2
@) Return spring @To Traction motor A1
® Throttle arm ~To Traction motor F2
® Circlip [E] To Traction motor F1
(J) Pedal crank pin
@ Cover
® Joint rod
Y-735
7-1 3
TROUBLESHOOTING FOR G19E ~~~~ ? I
ELECTRICAL TROUBLESHOOTING
Shou ld any one of the troubles below occur, it is
advisable to check for the possible cause in the
order specified.
Before performing any tests in this chapter, reset

the Controller as follows:
1. Turn main switch "OFF" and Tow switch <D
to "Tow" position. Wait 30 seconds.
2. Turn main switch "ON", and Tow switch to
"RUN" position.
Test the reported malfunction. If the problem is
now corrected, the controller needed to reset
internally. There are two potential causes of this
condition.
1. The user operated the tow switch without
Y-£7s allowing the system to reset. Educate the
user that the tow switch is to be used by ser
vice personnel only for vehicle towing or long
term storage.
2. If this kind of ma lfunction occurs more fre
quently, there may be a fault caused by a
poor or intermittent wire connection.
A WARNING
capacitor. Refer to Chapter 1, "SAFETY PRECAU
TIONS" section.
ACCELERATION BECOMES ROUGH,

UNEVEN OR JERKY
VISUAL INSPECTION
1. Check for loose or separated connections
between the speed controller and solenoid
relay.
2. Check for loose terminals and connections.
TEST THROTTLE POSITION SENSOR

3. Test the throttle position sensor. Refer to
page 8-8, "THROITLE POSITION SENSOR
CHECK".
8-1
_ _ _ _ _ _ _ _ _ _T_R_o_u_e_LE_s_H_o_o_TI_N_G_F_o_R_G_19_E IJM~I ?I
CAR DOES NOT SLOW ON DOWN
HILL GRADE AND/OR CAR WILL
ROLL AWAY WITHOUT SLOWING
VISUAL INSPECTION.
1. Check the speed sensor connector pins G).
A. If OK, go to step 2.
B. If not OK, repair.
SPEED SENSOR WIRE HARNESS CHECK

2. Disconnect the speed sensor harness connec
tor. Using a voltmeter, test t he wire ha rness
side red and black wires for voltage supply of
Y·687 5 VDC ± 10%. (Touch voltm eter red (+)probe
to harness red wire, black (-) probe to har
ness black wire.)
A. If OK, go to step 5.
B. If no voltage, go to step 3.
3. Us ing an oh m meter or sel f powered test

light, check the continuity of the red, green
and b lack w ires from the speed sensor con
nector to the controller.
CAUTION
ure symptoms.
A. If not OK, repair wi ring.

B. If OK, reset the controller with tow switch
again and perform step 3 again. If still no
voltage, replace controller.
4. Using a voltmeter, test controller termi nal pin

numbers 15 (positive) and 16 (negat ive) for
voltage supply of 5 VDC ± 10%.
A. If OK, reconnect controller connector and
go to step 5.
B. If no voltage, reset t he controller with tow
switch again and perform step 3 again. If
st ill no voltage, replace controller.
8-2
TROUBLESHOOTING FOR G19E ~~~~ ? I
SPEED SENSOR TEST

5. Using an analog voltmeter, check the speed
sensor output using the test cord (YG-42221 ).
I
~ Speed Sensor Test Cord:
.~ YG-42221
• Block the front wheels. Raise one rear

wheel off the ground using a jack and
stand.
• Attach test cord between harness and sen
sor leads.
• Touch voltmeter red (+) probe to test cord
green wire, b l ack(-) probe to test cord
black wire.
• Slowly rotate the rear wheel and check for
a voltage reading that swings from zero
VDC up to 5 VDC ± 10%.
A. If OK, replace controller.
B. If not OK, go to step 6.
SPEED SENSOR MAGNET CHECK

6. Remove the three screws ho lding the speed
sensor into the traction motor end cap.
Check the magnet ® on the shaft for foreign
material.
A. If contaminated, clean, reinstall and per
form step 5 again.
B. If step 5 fails again, replace sensor, mag
net or traction motor as required.
Y-690
NOTE:-----------------------
Be sure to verify the rollaway feature (including
buzzer) is operating before releasing the car to
the customer.
CAR HAS NO REVERSE WARNING

BEEPER
BUZZER WIRING CHECK

1. Check for power and ground at buzzer con
nector G), with F/R switch in reverse.
A. If both are present, replace buzzer.
B. If no power is present , check the f use,
tow switch and wiring. Repair as needed.
C. If no ground is present, go to step 2.
Y-688
8-3
TROUBLESHOOTING FOR G19E IJM~I ?I
GROUND WIRE CHECK
2. Check t he continuity of the black wire f rom
contro l le r te rminal 10 ® t o the reverse
buzzer.
CAUTION
minals are easily damaged which can cause faii
Y-689 ure symptoms.
A If OK, replace controller.

B. If open circuit, repair and recheck opera
ti on.
THE CAR'S TOP SPEED SLOWS

CHECK BRAKES AND CHASSIS
1. Confirm that brakes are not dragging, chassis
toe-in is with in specification, and nothing is
rubb ing against the wheels.
VISUAL INSPECTION
2. Check the batteries, speed controller and t rac
tion motor f or loose, shorted or separated
connections.
CHECK BATTERIES
3. Check t he batt er ies fo r sulfatio n and d is
charge capacity.
Chec k t h e battery elect rolyte level an d
charged cond ition . Refer to Ch apter 2,
"BATTERY INSPECTION" .
TEST THROTTLE POSITION SENSOR

4. Check the t hrottle position sensor. Refer to
page 8-8, "THROTTLE POS IT ION SENSOR
CHECK" .
CHECK TRACTION MOTOR

5. Check the traction motor for worn o r separat
ed brushes, or dirty com m ut ator. Ref er to
Chapter?, "TRACTION MOTOR".
CAR ONLY RUNS IN ONE DIRECTION

CHECK FORWARD/REVERSE DIRECTION
SWITCH
1. Check di rection wiring and t est di rect ion
switc h . Refer to page 8- 10, " DIR ECTIO N
SWITCH CHECK".
8·4
TROUBLESHOOTING FOR G19E IJn.?bl ? I
CAR WON'T RUN EITHER DIREC
TION, SOLENOID DOES NOT CLICK
RESET CONTROLLER
1. Confirm that controller has been reset. Refer
to page 8-1, "ELECTRICAL TROUBLESHOOT
ING".
2. Place Forward/Reverse direction switch in
reverse position. If reverse warning sounds,
go to step 9. If no warning sounds, go to step
3.
VISUAL INSPECTION
3. Visually inspect for loose connections or bro
ken wires.
A. If OK go to step 4.
B. If not OK, repair.
CHECK BATTERIES
4. Check battery condition. Refer to Chapter 2,
"BATTERY INSPECTION".
B. If not OK, service or replace batteries.
FUSE CHECK
5. Check fuse. (Should have power on both red
wires.)
A. Check for power to fuse holder CD.
B. If no voltage is present on either wire
repair open circuit between fuse and
charge receptacle.
C. If voltage is present on only one side of
the fuse, replace the fuse.
Y-676 D. If voltage is present on both wires fuse is
OK, go to step 6.
Y-677
8-5
TROUBLESHOOTING FOR G19E IJmbl ? I
TOW SWITCH TEST
6. Test Tow switch. (It should have power on
both red and red/yellow wires when in
"RUN" position G).) Jump these two circuits
together to bypass the switch.
A. If car operates, replace tow switch.
B. If it doesn't, go to step 7.
C. If there is no power to the switch, repair
the open circuit between the tow switch
Y-678 and the fuse.
WIRE CHECK SOLENOID TO TOW SWITCH

7. Check for voltage at red/yellow wire at sole
noid (small wire) @.
A. If no voltage is present, repair the open
circuit between the tow switch and sole
noid.
B. If voltage present, go to step 8.
Y-679
CONTROLLER GROUND WIRE CHECK

8. Test the ground wire@ at the controller with
a voltmeter to see if it is grounded.
(Voltmeter from positive battery terminal to
negative wire terminal at controller.)
A. If not repair the ground connection.
B. If OK, go to step 9.
Y-680
SOLENOID GROUND BYPASS

9. Connect a temporary ground (jumper) from
the red/black wire of the solenoid (small
wire) @) to battery pack ground side. Note:
Key doesn't need to be ON and pedal need
not be depressed.
A. If the solenoid still doesn't click, go to
step 11.
B. If the solenoid now clicks go to step 10.
Y-681
8-6
WIRE CHECK - SOLENOID TO CONTROLLER
10. Check continuity of red/black wire from sole
noid to controller. (Ground it from controller
terminal #11 CD to controller main ground.)
You must disconnect the controller connector
for this test.
CAUTION
Use care when probi ng the female connectors
v-a24 inside the wire harness controller plug. The ter
ure symptoms.
A. If the so lenoid clicks reconnect compo

nents and test the car. If relay does not
click, replace controller.
B. If the relay does not click, repair the open
in the red/bl ack wire between the sole
noid and controller.
SOLENOID RELAY BENCH TEST

11. Bench test the solenoid relay.
A. Remove:
• Seat
B. Turn the main switch to "ON" .
C. Check:
• Solenoid relay CD {clicking sound)
Press accelerator pedal to close the
If clicking .... Check for continuity
between the· two contact posts with
Pocket Tester while the solenoid is acti
Y·11 6 vated. If there is no continuity, replace
the relay.
If not clicking .... Measure coil resistance
in solenoid.
D. Check:
• Solenoid relay {no clicking sound)
Disconnect battery negative lead before remov

ing solenoid leads.
Disconnect solenoid leads.
Measure coil resistance use the Pocket
Tester.
Out of specification -. Replace.
6-7
-
_____ ___
TROUBLESHOOTING _l_sTRHTBGLI_
FOR G19E ?I _
Pocket Tester:
YU-31 12-C, 90890-03112

336Q at 20· C (68. F)
Installation
E. Inst all:
• Solenoid relay
F. Con nect:
• Leads
Nut (Terminal) :
6 Nm (0.6 m • kg, 4.3 Ft • lb)
CAR WON'T RUN EITHER DIREC

TION, SOLENOID DOES CLICK
VISUAL INSPECTION
1. Visually inspect for loose connect ions o r bro
ken w ires.
A. If loose repair.
B. If OK go to step 2.
CHECK BATTERIES
2. Test batteries to determine if they are
installed correctly and with a hyd romet er and
voltmeter. Refer to Chapter 2, "BATTERY
INSPECTION".
B. If not OK correct as necessary.
THROTTLE POSITION SENSOR CHECK

3. Disconnect the three wire connector to t he
th rottl e posit ion senso r (blue, black an d
o range harness wires.) Check the resistance
across t he sensor side of the connector G). A
good sensor will read the following:
Blue t o Black - 5000 ohms (5K) peda l, any
position
Orange to Black - Use an analog ohmme
Y-825 ter. The reading should vary from 0 - 150
ohms w ith accelerator pedal at rest, to up
to 5000 (5K) ohms with peda l fully
depressed.
8-8
__________T_R_ou_s_L_e_sH_o_o_T_IN_G_F_o_R_G_1_9e_l~l?l
NOTE: -----------------------
Resistance should even ly sweep while slowly
pressing the accelerator pedal. This is why an
analog ohmmeter is preferable. If there is a dead
spot, it could result in intermittent operation of
the car.
A. If the senso r checks good, reconnect it

and go to step 4.
B. If the throttle position sensor is bad ,
replace it.
MAIN SWITCH CHECK

4. Check for voltage on the red/yellow and
red/white wires at the main switch @ . Key
must be on and tow switch on.
A. If voltage is present on both, go to step 5.
B. If there is no voltage on red/yellow wire,
repair open circuit between tow and main
switch.
C. If there is voltage on the red/yellow but
Y·826 not the red/White, with key on, replace the
main switch.
ACCELERATOR STOP SWITCH CHECK

5. Check for voltage on the red/white at acceler
ator (stop) switch<D with key on.
A. If no voltage is present, repair the open
circuit between the main switch and the
B. If voltage is present on the red/white wire
with accelerator pressed and key on, but
is not present on the brown wire of the
v.ess accelerator switch, replace the accelerator
stop switch.
C. If voltage is present on both wires of the
switch and terminal 3 at the controller 'QO
to step 6.
NOTE:-----------------------
If there is voltage on the brown wire at the stop
switch but not on terminal 3 of the controller,
repair the open circuit in the brown wire between
the controller and accelerator stop switch.
8-9
DIRECTION SWITCH CHECK
6. With tow switch "onn (run), check for voltage
on the red/yellow wire at the direction switch
@.
A. If no voltage is present on the red/yellow
wire repair open circuit between direction
swi1tch and tow switch.
B. If voltage is present, place direction
switch in forward. Check for voltage on
Y·827 the white wire of the switch® and at ter
minal 4, of the controller connector.
• If voltage is present at terminal 4,
replace the controller.
• If voltage is not present on the white
wire of the switch, replace the switch.
• If voltage is present on the white wire
of the switch but not terminal 4, repair
the open circuit between the controller
and the direction control switch.
• If car still won't run, go to step 7.
SOLENOID RELAY BENCH TEST

7. Test solenoid. Refer to page 8-7, "SOLENOID
RELAY BENCH TEST". If car still won't run,
go to step 8.
CHECK TRACTION MOTOR

8. Test traction motor:
• Insulation res istance
• Field coi l resistance
• Armature resistance
Refer to Chapter 7, "INSPECTION AND
TESTING" .
• If traction motor tests good replace con
troller.
8-10
__________T_R_o_u_e_LE_s_H_o_o_n_N_a_~_R_a_19_EI~I?I
TRACTION MOTOR

MOTOR DOES NOT TURN 1. Brushes are off commutator. 1. Adjust properly or replace.
2. Motor terminals are loose or 2. Tighten or clean.
corroded.
3. Leads are broken. 3. Check for breaks at bend or
joint. Replace or repair leads.
4. Field coil is open. 4. Repair or replace at a service
shop.
5. Armature coil is open 5. Repair or replace at a service
shop.
MOTOR TURNS SLOWLY 1. Terminals are loose or 1. Retighten or clean.
corroded.
2. Leads are nearly broken or 2. Check for any defect of leads
connections are faulty. at bend or joint. Replace leads
or repair connections.
3. Mechanical problem inside 3. Check.
motor.
MOTOR IS NOISY 1. Bolts are loose. 1. Retighten.
2. Motor has foreign matter 2. Clean motor interior.
inside.
3. Bearings are faulty. 3. Replace.
4. Bearings contain foreign 4. Replace.
matter.
5. Bearings need grease. 5. Replace.
BEARING HEAT EXCESSIVE 1. Bearings are faulty or lack 1. Replace.
grease.
2. Improperly installed. 2. Adjust, replace if necessary.
POOR MOTOR 1. Load exceeds specification. 1. Adjust load to spec.
PERFORMANCE 2. Armature is out of round. 2. Repair or replace at service
shop.
3. Brushes are worn beyond 3. Replace.
limits.
4. Commutator is excessively 4. Smooth with sandpaper
rough. (#500 - 600).
5. High mica segment. 5. Recondition at service shop.
6. Commutator is dirty with oil 6. Clean with a cleaner, and
or dust. dry cloth.
7. Armature coil is shorted or 7. Repair or replace at service
broken. shop.
VIBRATION 1. Motor installed loosely. 1. Retighten.
2. Motor turns irregularly. 2. Repair or replace at service
shop.
8-11
______________M_A_tN_T_E_NA_N_c_e_s_P_e_c_tF_t_c_AT_t_o_Ns__Fo_ _ R_G_19_E_ISPEC~~~~
ELECTRICAL
Item G19E
Voltage: 48V DC, 8V Battery x 6 pes series
(locally supplied)
Traction Motor:
Model/Manufacturer 5BC58JBS6272A I GE
Rated Voltage 48VDC
Power/Horsepower 2.0 kw/2.7 hp for 30 minutes
Current 44A
Voltage 48V
Set Torque 5.4 Nm (0.54 kg-m, 3.9 ft-lb)
Revolutions 3,650 r/min
Allowable Maximum Revolutions 5,500 r/min
Direction of Rotation Clockwise and counter clockwise
Brush Length-Std/Min. 34.3 mm (1.35 in)/14.5 mm (0.57 in)
Brush Spring Pressure-Max./Min. 720- 1,080 g (24.3- 36.5 oz)/450 g (15.2 oz)
Mica Undercut-Std/ Min. 0.79 mm (0.031 in)/0.25 mm (0.010 in)
Armature Coil Resistance 0.0228 - 0.02320 at 20°C (68°F)
Field Coil Resistance 0.891 - 1.0890 at 20°C (68°F)
Insulation Resistance (All measurements) 1MO
Motor Controller: FET (Field Effect Transistor) chopper

Model/Manufacturer JRI-100/GE
Solenoid Relay:
Modei/M an ufactu rer 586-120111 -3/ESSEX CONTROLS
Amperage Rating 100A, PEAK at 300A for 3 minutes
Solenoid Coil Resistance (Z) Z: 3360± 10%
Resistance (X) X: OFF oo
ONOO
X
,..----,
T:::
C c.-._ Fixed contact
Mo.able conlacl
Solenoid coil
U Y-714
9-1
_____________M_A_I_NT_E_N_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_N_S_F_O_R_G_1_9_E ISPECIJO:rl
Item G19E
Shift Switch:
Voltage/Maximum Current Capacity 125 VAC I 15A Rated
Type-SPDT-2 position maintained contact
Battery: Locally supplied

Type BV Electric vehicle deep cycle GC-2
Quantity/Connection 6 pes/Series
Minimum Recommended Output 105 minutes at 56A at 80°F
Specific Gravity As specified by manufacturer at 80°F
Maximum difference (at 1.200 corrected min.) 0.050
[Battery Arrangement and Terminal
Connections]
FWD
0
~
:
0 0 0 0
0 0
0 .. 0
: 0
0
:
0 0
Y-831
Tow Switch:
Mfg NKK
Rated Load 30VDC/20A
Volts 125 VAC/ 15A
Type SPST, 2 position maintained contact
9-2
MAINTENANCE SPECIFICATIONS FOR G19E I IP'll
SPEC
Item G19E
Back Buzzer:
Type Piezo Ceramic Buzzer
Model/Manufacturer JRI-OONAMAHA
Current Less than 25 mA
Sound Pressure 83 dB/1 min./36V
Minimum Operating Voltage 10VDC
Plus Fuse:
Amperage 3A
Fusible Link Type 14AWG I HYPALON INSULATION
9-3
_______________________ cA_B_L_~__IR_E_R_o_uT_IN_G_ISPECI JP:rl
FOR G19E
CD Positive lead (J) Accelerato r stop switch
® Negative lead @ Solenoid relay
@ M ain switch @ Tow switch
® Batteries @ Direction switch
® Traction motor @ Speed sensor
® Buzzer @ Throttle position senso r
9-4
Q) To battery (negative) ® Control unit
® Charging receptacle ® Solenoid relay
@ To traction motor @) Control unit to speed sensor
@) Tow I storage switch ® Control unit to throttle position sensor
® To solenoid relay (positive) @ Control unit to main switch,
® Receptacle to solenoid relay, accelerator stop switch,
battery side (posi tive) forward I reverse switch, buzzer
CV Receptacle to fuse (3A) to tow I @ Battery to solenoid relay (positive)
storage switch (positive) @Fuse holder and 3A fuse
@) Negative lead wire with charging circuit fusible link
9-5
,
w@
0
::c
~
R
R!Y
OFF ON
L
0
0
~
® ® --;; : o;
RIW
0"
:)
K
RIY
w
y
REV FWD
0
0
0
®
CD Main switch
® Tow/storage switch
-
C)
CD
m
k,~ G8ll
0
3 ~ 1
@ Buzzer
R!Y R w y @ Directional switch
188011 @ DC motor
RIW
R
CD
'-,.OFF ON
0 r-- RNV
0 r--~
Ri 8
RIW RW
RY~ R!Y
RIW
(~
1 Br
I(PJ(BJI
p B
!(wJ(~( vjl
WM y
(J) Controller
@ Throttle sensor
@Relay
9
@Receptacle
10
@Fuse
11 (3A)
R!Y
R!Y @Batteries (6 x 8V)
1
RIW
PJY RIB
R _[~~p
G
B~ ~
-- T
A
COLOR CODE
B .. ................... Biack
L ............... .. ...... Biue
G ............. ...... Green
l0l§JI 11
1 2 3 6 10 4 5
15
A1 A2
Y ................... Yellow
~
~ RIWYRI~ 9~ ;Ht-
-v.-.EB""EB""EB""EB""'EB~""EB~ 16
al_N. ® R ........... .. ... ... ....Red
R ~ ~ P ....................... Pink
w I r- ------ -1
Br. .... ............. .Brown
®j
e
~
\±)
ilr Cit~~~- B o o B-
I
I
I *+»II (P) {A1)
1
...,.
1"'11 3/4 REC
(A2}
~
I
I w....................
B/R. ......... Black/Red
White
~
I MOSFET
le 8 Y/B ... ... Yellow/Black
L:TI:_ ® *
CONTROL BOARD
I BOARD ASSY R/Y .... .. ..Red/Yellow
,-±
~
@ I
I
ASSY I
I R/W ........ Red/White
~
[<±r
® I
~----------~
(N)
J _ _ _ _ _J
I
~
B (j)
Y-671
G20A
MULTI-PASSENGER SERVICE MANUAL
SUPPLEMENT
FOREWORD
for the G20A Multi-Passenger vehicle. For com
plete information on service procedures, it is
necessary to use this Supplement Service
Manual together with following manuals:
G14A/G14E
SERVICE MANUAL
G16A/G16E
G20A
1st edition, August 1999
Printed in U.S.A.
P/N/ LIT-19616-00-00
INTRODUCTION
This manual has been written by Yamaha Motor Manufacturing Corpo ration of America for use by
Authorized Yamaha dea lers and their qualified mechanics. It is not possible to put an entire mechan
and repairs on Yamaha golf cars have a basic understanding of the mecha nica l concepts and proce
Yamaha Motor Manufacturing Co rporation of America is continually striving to further improve all
models manufactured by the company. Modifications are therefore inevitable and w ill, where applic

YAMAHA MOTOR
AMERICA

The Safety A lert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS

INVOLVED!
golf car occupants, a bystander, or a person inspecting or repair ing the golf
car.
to the golf car.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequentia l, step-by-step format. The informa
• Bearings
Pitting/Damage - Replace.
EXPLODED DIAGRAM
1 ~1 6 1
GEN ~ 1 Symbols CD to ® are designed as thumb tabs
INFO 0 0 to indicate the contents within a chapter.
"""" """" CD General information
® ® ® Periodic inspection and adjustment
lcHAsl~l IPO,-WRI~I
@ Chassis
® Power train
® Engine overhaul
ICONI3 CON M
® Carburetion
® Troubleshooting
ENG \. lcARBI f I ""'" ""'K
® Specifications
(J) ®
IELEcliiiil IJnfbl ? I ""'" CON"
IsPEcIfJ'i I CONOO
Symbols @) to @ are used to identify specifi

@) @
~ ~
@) Filling fluid
® Lubricant
ICO'tt!O IC~ t n
@ Special tool
@ Tightening torque
@ @
~
~
@ Engine speed
@ Q, V, A
ICOfl t l2 ICON t 13
@ @)
~ ICON t it
[01 tc0N t 15

@) @
[11] ICC»UII
a
J.
ICONI\7
lubricant.
@ Apply engine oil
@ @) Apply gear oil
@) @)
l -l l
-
@ Apply molybdenum disulfide oil
Q e Q @ Apply lightweight lithium soap base grease
....._ ----
ICON t iiUtwull20
@ @ @
--- ICON"2111Yut23
ii
INDEX
GENERAL (Refer to G16AIE

Service Manual ~
INFORMATION
Supplement) GEN
(Refer to G16AIE
PERIODIC INSPECTION Service Manual
Supplement)
AND ADJUSTMENT
CHAS
(Refer to G16AIE
Service Manual
POWER TRAIN Supplement)
ENGINE OVERHAUL
(Refer to G16AIE
Service Manual
Supplement)
\.
ENG
CARBURETION
(Refer to G16AIE
Service Manual
Supplement)
I
CARB
(Refer to G16AIE
Service Manual iii
ELECTRICAL Supplement)
ELEC

SPECIFICATIONS
iii
TABLE OF CONTENTS
CHAPTER 2 - PERIODIC INSPECTION
AND ADJUSTMENT
MAINTENANCE CHART ......... . ....... 2- 1
CHAPTER 9- SPECIFICATIONS
SPECIFICATIONS ... . . . . . .............. 9-1
GENERAL SPECIFICATIONS ......... . ... 9-1
CABLE/WIRE ROUTING for G20A . . . . . . . . 9-10
EMISSION CONTROL SYSTEM . . . . . . . . . . 9-12
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . 9-13
iv
PERIODIC INSPECTION AND ADJUSTMENT I~ Ihi
A WARNING
FOR G20A
C- CHECK CA- CHECK AND ADJUST R - REPLACE S - SERVICE CL- CLEAN AND LUBRICATE L - LUBRICATE
Remarks Opera 100 miles 600 mls 1200 mls 2500 mls 5000mls
PRE Check engine oil c c c
OPER Check air cooling duct c c c c c c
ATION Check fuel lines for leakage c c c c c c
CHECKS Check fuel level c c c c c c
damage
nuts, and screws
operation

EVERY 6 Wash pre-filter, check air s s s s
condition** I Check compression

2-1
-~~~~~~~~~-1 ANDJ~I~I
1
PERIODIC INSPECTION AND ADJUSTMENT . . ~.
C - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
Pre· 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs
YEAR Adjust throttle cables,** CA CA CA


damage and tension

wear or scratches

sheave bearing.

and insulation




and leakage


2 YEARS commutator for dirt

4 YEARS fuel hoses


2-2
______________________ G_E_N_E_R_A_L_s_Pe_c_I_FI_cA_r_lo_N_s_ISPECI JO~I
SPECIFICATIONS
GENERAl SPECIFICATIONS
~ m G20A
Model Code: JR8

Frame Serial Number JR8-000101 -
Dimensi ons:
Overall Length 128.0 in (3250 m m)
Overall Width 47.2 in (1200 mm)
Overall Height (Stee ring height) 46.8 i n (1190 m m )
Heig ht of Floor 11.8 in (300 mm)
Whee lbase 97.8 in (2483 mm)
Tread:
Front 34 .3 in (870 m m )
Rear 38.6 in (980 mm)
Min. Ground Clea rance 3.8 i n (97 mm)
Weight:
Dry Weight (witho ut battery) 855 lb (388 kg)
Perfor mance:
Maximum Speed 12 m ph
(19 km/h)
M inimum Turning Radius 167.0 in (4.24 m)
Seating Capacity 4 persons
9-1
_____________M_A_IN_T_E_N_A_N_c_E_s_P_EC_I_F_Ic_A_TI_O_N_s_F_o_R_G_2_oA
__ ISPECI~~~
MAINTENANCE SPECIFICATIONS FOR G20A
ENGINE
Item G20A
Description
Compression Ratio 8.1 : 1
1,150 kPa (11.5 kg/cm2, 164 psi)
Minimum:
1,000 kPa (10.0 kg/cm2, 142 psi)
Ignition System TCI Magneto
Cylinder Head:
Combustion Chamber Volume (With spark
plug)
Head Gasket Thickness
~
1 *
32.6-32.8
*0.20- 0.23 mm (0.0078- 0.009 in)
Y-736
Cylinder:
Piston:
Piston-to-Cylinder Clearance 0.03- 0.05 mm (0.0012- 0.0020 in)
<Limit> < 0.1 mm (0.004 in) >
2 0.50 mm (0.02 in)
Piston Pin Outside Diameter 19.995- 20.000 mm (0.7872 - 0.7874 in)
Piston Pin-to-Piston Clearance 0.004 - 0.020 mm (0.0002 - 0.0008 in)
<Limit> < 0.07 mm (0.003 in) >
Piston Ring:
Top Ring
Type Barrel
Dimensions (B x T)
End Gap (Installed)
I It B
1.5 x 3.5 mm (0.059 x 0.137 in)
0.2- 0.4 mm (0.008- 0.016 in)
<Limit> 1--T-1
Y-737
< 1.0 mm (0.04 in)>
<Limit> < 0.1 mm (0.004 in) >
Engine Oil:
SE, SF, or SG
Oil Change Quantity 1.0 U.S. qt (0.9 L, 0.191mp gal)
9-2
MAINTENANCE SPECIFICATIONS FOR G20A I IfJ ~ I
SPEC
Item G20A
2nd Ring:
Type Taper
End Gap (Installed) 0.2-0.4 mm (0.008- O.D16 in)
<Limit> < 1.0 mm (0.04 in)>
Side Clearance Y·738
0.03 - 0.07 mm (0.0012 - 0.0028 in)
Oil Ring:
End Gap (Installed) 0.2 - 0.7 mm (0.008- 0.028 in)
Y·739
Small End Bearing:

Type None
Big End Bearing:

Type None
Crankshaft:
Connecting Rod Big End Side Clearance "C" 0.2- 0.65 mm (0.008- 0.025 in)
Y·740
Crank Pin Outside Diameter 35.97-35.98 mm (1 .416- 1.417 in)
Crank Oil Seal Type (Both) x Q'ty SO 35 50 8 x 2 pc
Camshaft:
Drive Method Gear d rive
Cam Cap Inside Diameter 16.00- 16.05 mm (0.630- 0.632 in)
Camshaft Outside Diamet er 15.90- 15.97 mm (0.626- 0.628 in)
Shaft-to-Cap Clearance 0.03 - 0.05 mm (0.0011 - 0.0020 in)/
<Limit> < 0.15 mm (0.0059 in)>
9-3
MAINTENANCE SPECIFICATIONS FOR G20A ISPECIrp'j I
Item G20A
Cam Dimensions:
Intake "A" 32.495- 32.595 mm (1.279- 1.283 in)
I
11811 c 26.029- 26.129 mm (1.024- 1.028 in)
ncu 6.495- 6.595 mm (0.255- 0.259 in)
A
Exhaust "A" 32.495-32.595 mm (1.279- 1.283 in)
~
11811 26.029- 26.129 mm (1.024- 1.028 in)
nell 6.495 - 6.595 mm (0.255 - 0.259 in)
Y-741

Arm-to-Shaft Clearance 0.01 - 0.07 mm (0.0004 - 0.0028 in)

EX. 0.1 mm (0.004 in)
Valve Dimensions:
bB" be·
Face Width Seat Width ~"0'
Thickness
Y-742

EX. 27 mm (1.062 in)
"8" Face Width IN. 2.6 mm (0.102 in)
EX. 1.6 mm (0.088 in)
EX. 1.0 mm (0.0393 in)
EX. 1.0 mm (0.0393 in)
Valve Spring Free Length 36.2 mm

<Limit> <35.0mm>
Spring Force IN. 7.0 kg
EX. 9.0 kg

Cable 1 0.2- 0.5 mm (0.008- 0.020 in)
Cable 2 0.5 mm (0.020 in)
Choke Cable Freeplay 1.0 mm (0.040 in) >
9-4
MAINTENANCE SPECIFICATIONS FOR G20A ISPECIfJ'I I
Item G20A
Carburetor:
Model/Maker BV26-18-47/MIKUNI
I.D. Mark JN6-01
Venturi Diameter (Ven. T.) 018
Main Air Jet (M.A.J.) 01.6
Pilot Jet (P.J.) #61.3
Pilot Air Jet (P.A.J.) 00.9
Valve Seat (V.S.) 01.2
By-pass (1) (B.P. 1) 00.7
By-pass (2) (B.P. 2) 00.7
By-pass (3) (B.P.3) 01.0
Pilot Outlet (P.O.) 01.0
Pilot Screw (P.S.) 1-1/2 turn out
Float Height (F.H.) 16.5- 17.5 mm (0.65- 0.69 in)
Fuel Pump:
Manufacturer/Type MIKUNI/DF-52-205 (Diaphragm)
Fuel Tank:
Fuel Tank Material/Color Polyethylene/Natura I
TRANSMISSION
Item G20A
Transmission:
Secondary Spring:
Outside Diameter x Wire Diameter 59 x 4.5 mm (2.32 x 0.18 in)
No. of Turns/Free Length 7.25/100.5±1.5 mm (3.95±0.059 in)
Torque Cam Angle 37.5°
Sheave Off-Set 24.3mm
9-5
_______M_A_I_m_E_N_A_N_c_e_s_P_e_ci_F_Ic_~_T_IO_N_s_F_o_R_G_2_M_IS~CI,,I
Item G20A
Forward 11.34: 1
Reverse 15.25: 1
Governor:
9-6
MAINTENANCE SPECIFICATIONS FOR G20A I II'f I
SPEC
ELECTRICAL
Item G20A
Ignition System:
Type T.C.I.
Model/Manufacturer JR8/YAMAHA

~
cj
0
....,: 20°
@. /
....- -..___
Ol
c:
I
~ 10° I
c:
0
I
+=
·c:
£1
' I'-.
oo 4
1 2 3
Engine speed (x 103 rpm)
Y·7BO
Ignition:
Primary Winding Resistance 0.9 - 1.5Q ± 20% at 20°C (68°F)
(Coil base to terminal)
Secondary Winding Resistance 10.5- 12.9 kQ ± 20% at 2ooc (68°F)
(High tension cord to terminal)
9-7
TIGHTENING TORQUE
TIGHTENING TORQUE IsPEcIf'Jf I
ENGINE (FOR G20A)
Tightening torque
Nm m·kg ft·lb
Spark Plug M14 X P1.25 20 2.0 14
Air Shroud Bolt M6 x P1.0 8 0.8 5.8
Cylinder Head Bolt M10 x P1.25 50 5.0 36
Cylinder Head Cover Bolt M6 X P1.0 11 1.1 8
Valve Adjuster Locknut Nut M5 x PO.S 7 0.7 5.1
Connecting Rod Cap Nut MS x P1.25 20 2.0 14 With oil
splasher
Cylinder x Exhaust Pipe Nut M8 x P1.25 16 1.6 12
Exhaust Pipe x Bracket Bolt MS X P1.25 16 1.6 12
Exhaust Bracket x Rear Arm Bolt M8 x P1.25 16 1.6 12
Carburetor x Joint Nut M6 X P1.0 6.5 0.65 5
Flywheel Nut M18 x P1.5 120 12.0 87
Engine Bracket x Rear Arm Nut M8 x P1.25 26 2.6 19
Crankcase Drain Plug Bolt M12 x P1.5 20 2.0 14
[Cylinder Head Tightening Sequence] [Cra nkcase Cover Tightening Sequence]
Y·726
9·8
TIGHTENING TORQUE I Ipf I
SPEC
POWER TRAIN
Tightening torque
Nm m·kg ft·lb
For G20A
Primary Sheave x Engine Bolt 1/2-20UNF-2A 75 7.5 54
Secondary Sheave x Input Shaft Castle nut M12 X P1.25 65 6.5 47
Transmission Case x Rear Arm Bolt M8 x P1.25 23 2.3 17
Rear Arm Connecting Rod Nut M12 X P1.50 90 9.0 65
Bolt 5/16-18UNF-2B
Differential Case x Ring Gear Bolt M8 x P1.25 55 5.5 40 --a
9-9
~~~~~~~~~~~-cA_B_L_~~IR_E_R_o_uT_IN_G_Is~l ,,l
CABLE/WIRE ROUTING
FORG20A
G) Choke cable ® Brake cables
® Main switch wire ([) Negative lead
@ Pilot lamp wire ® Positive lead
@) Stop switch wire ® Lead wires to starter generator
® Accelerator cable @ T.C.I. unit wire lead
0 0
0 0
0
... ...
"
!=!
'--{P
""" ..
l
... .....I
r/
0
........
0
.........
0 0
Y-7468
9-10
____________c_Ae_L_E_Ro_u_n_NG_Is~cl p,l
CD Back-up buzzer switch lead (!) Stop re lay

® Solenoid relay ® Fuel hose to f uel tan k
@) Shift cab les ® Fuel hose to carburetor
@ Vo ltage regulator @) Pu lse hose to crankcase
@ Starter generator leads @ T.C.I. wire lead
® Fuse ® Oi l warni ng switch lead
Y-74 7
9-11
EMISSION CONTROL SYSTEM I Irp~ I
SPEC
EMISSION CONTROL SYSTEM COMPONENTS
<D Ai r cleaner
® Crankcase breather hose
@ Engine
@ Carburetor
® TCI Magneto
® Exhaust
~
I
Y-644
9-12
"":E
0 -
"2:!
G')2
CD NG')
cc
)>_
)>
G')
®r=;;;t- B~R ~
REV I8-- R~P COLOR CODE s:
$ .................... Black
@~: @{[It:
$L .................... Biue
<B ................... Green
y................... Yellow
~ ...................... Red
~ ...................... Pink
IBr .................. Brown
R --+-+-~------~
W...................White
B/R .........Black/Red
Br
Y/B ..... Yellow/Black
RIY ....... Red/Yellow
RIW ........ Red/White
@
R.R.
~~~B~~Y~B
L.A.
.-c~~B-t1-B-i>CJ-RB-D<J-G
L.A .
f-C~~B~-t:>C:J-W-D<rBr
® R G
®
B -:-
Y-191N1
B
CD Engine stop relay ® Oil level gauge ® Relay @ Accelerator stop switch @ Signal lights @
Head light switch
® Engine ground ® Blade fuse (10A) @) Battery @ Back switch @ Turn signal lever @
Flasher unit
@ Pickup Q) Voltage regulator ® Pilot lamp (12V, 3.4W) @ Buzzer @ Head lights @
Brake light switch
@) Rotor @ Starter generator @ Main switch @) Body ground @Taillights @
Brake light sensor

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G14-A, G14-E

GOLF CAR SERVICE MANUAL

(Rev. 8/96) (Rev. 6/99)

TECHNICAL SERVICE DEPT

HOW TO USE THIS MANUAL

The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS

NOTE: This message provides additional key information.

I~EF~I~I lh~Jinl Symbols <D to ® are designed as thumb tabs

IENG l'-1 lcARslfl

IELECI iiii I ~~~~~? I

IsPEel P~l Symbols ®> to ® are used to identify specifi­

l l l @ Apply molybdenum disulfide oil

GENERAL SERVICE INFORMATION ............... 1-3

SPECIAL TOOLS ............................................... 1-7

PREPARE FOR EMERGENCIES

HANDLE FUEL SAFELY

Always clean up spilled fuel and dispose of

HANDLE BATTERIES SAFELY

Never check battery state of charge by connect­

Do not charge a battery if the battery is frozen.

Always charge batteries in a well venti lated

Battery electrolyte contains sulfuric acid and is

• Safety glasses with side shields or goggles

Avoid wearing loose clothing and jewelry which

KEEP WORK AREA CLEAN

Keep shop floor clean and dry to prevent acci­

GASKETS, OIL SEALS, AND 0-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

Do not use compressed air to spin the bearings

DISASSEMBLY AND ASSEMBLY

Follow these guidel ines when disassembling

• Clean and dry parts whenever they are dis­

• Oil contact surfaces of moving parts when

• After parts are assembled, make sure each

FOR ENGINE SERVICE

2. Valve Spring Compressor

1-7 (Rev. 6/99)

5. Piston Ring Compressor

FOR POWER TRAIN

2. Primary Sheave Puller

1-8 (Rev. 6/99)

FOR CHASSIS SERVICE

2. Mityvac® Pressure Tester

1-9 (Rev. 6/99)

3. Dynamic Spark Tester

1-10 (Rev. 6/99)

PERIODIC MAINTENANCE .................................2-1 CHASSIS ............................................................2-26

POWER TRAIN ...................................................2-21

**Related to emission control system.

2-1 (Rev. 6/99)

20 Rounds 125 rds 250 refs 500 rds 1000 rds

EVERY Apply battery terminal protectant s s s

20Rounds 125 rds 250rds 500 refs 1000 rds

2-2 (Rev. 6/99)

2.0 Rounds 125rds 250 rds 500 rds 1000 rds

Keep high pressure water away from all electrical parts.

2-3 (Rev. 6/99)

1. Remove the seat.

How to set the TDC on compression stroke:

• Paint matching marks onto the sheave and

2-6 (Rev. 6/99)

Intake Valve (Cold):

IsPEel P~l Symbols ®> to ® are used to identify specifi

Never check battery state of charge by connect

Keep shop floor clean and dry to prevent acci

• Clean and dry parts whenever they are dis

• Do not apply oil to the element cover; resis

Do not use any other setting or adverse perfor

1. Mark fuel pump hoses to allow for re-connec

6. Connect pressure hose from Mityvac® to vac

Do not allow foreign material to enter the trans