Yamaha G22 A/E - Symbol Identification

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Symbol Identification6
Index7
General Information9
Safety Precautions11
Prepare for Emergencies11
Handle Fuel Safely11
Handle Batteries Safely11
Secure the Vehicle12
Recommended Jack Points12
Discharge the Speed Controller Capacitor12
Wear Protective Clothing13
General Service Information14
Serial Numbers14
Washing and Cleaning15
Correct Tools15
Tightening Torque15
All Replacement Parts16
Gaskets, Oil Seals and O-Rings16
Lock Washers/Plates and Cotter Pins16
Bearing and Oil Seals16
Circlips17
Disassembly and Assembly Suggestions17
Special Tools for Tune up18
Special Tools for Engine Service18
Special Tools for Power Train19
Special Tools for Chassis Service20
Special Tools for Electrical Components21
Periodic Inspection and Adjustment23
Periodic Maintenance25
Inspection and Adjustment Engine for G22A28
Valve Clearance Adjustment28
Engine Oil Level Measurement30
Engine Oil Replacement30
Crankcase Breather Hose Inspection31
Air Filter Cleaning32
Compression Pressure Measurement33
Carburetor Adjustment35
Accelerator Stop Switch36
Inspection/Accelerator Pedal Position Adjusting Bolt Height Adjustment36
Throttle Cable Adjustment36
Speed Limiter Adjustment38
Choke Cable Adjustment40
Fuel Pump Inspection40
Fuel Filter Inspection42
Fuel Hose Inspection42
Power Train43
Transmission Oil Level Measurement43
Transmission Oil Replacement44
Drive Belt Inspection for G22A45
Primary Sheave Lubrication for G22A46
Sheave Inspection46
Lubrication Secondary Sheave47
Shifting Cable Adjustment47
Chassis Brake Cable Inspection48
Chassis Parking Brake Adjustment49
Chassis Brake Shoe Lining Inspection49
Brake and Accelerator Pedals51
Steering Inspection52
Steering State Axial Play52
Steering Linkage Inspection53
Tie Rod End53
Wheel Alignment54
Toe-In54
Tire and Wheel Inspection56
Front Wheel Bearing Inspection56
Rear Axle Bearing Inspection57
Shock Absorber Inspection57
Electrical for G22A58
Spark Plug Inspection58
Starter Belt Inspection59
Starter Belt Adjustment59
Battery Inspection60
Battery Charging61
Electrical for G22E62
48V Charger Features63
48V Charger Operating Instructions63
Led Readings - Normal Charge Cycle63
Led Readings - Abnormal Charge Cycle64
Charge Receptacle Inspection68
Controller Connector Inspection68
Discharge Minutes Adjusted for Temperature71
Battery Discharge Chart72
Battery Discharge Testing72
Chassis73
Front and Rear Bumper Removal75
Front and Rear Bumper Installation75
Bumpers76
Seat Removal77
Seat Installation77
Seat78
Front Cowling Removal79
Front Storage Panel Removal79
Front Cowling Installation80
Front Cowling81
Rear Body Removal82
Rear Floor Cover Removal82
Rear Body Installation83
Rear Cowling for G22A84
Rear Cowling for G22E85
Front Wheel86
Front Wheel Removal87
Front Wheel Inspection88
Front Wheel Installation89
Rear Axle Wheel for G22A90
Rear Axle Wheel for G22A Removal91
Rear Axle Wheel for G22A Inspection91
Rear Axle Wheel for G22A Installation92
Rear Axle Wheel for G22E94
Rear Axle Wheel for G22E Removal95
Rear Axle Wheel for G22E Inspection95
Rear Axle Wheel for G22E Installation96
Brake98
Brake Pedal99
Brake Pedal Disassembly100
Brake Pedal Inspection101
Brake Pedal Assembly102
Accelerator Pedal for G22A105
Accelerator Pedal for G22E106
Steering System107
Steering System Removal108
Steering System Disassembly110
Steering System Inspection111
Steering System Assembly113
Steering System Adjust114
Steering System Installation115
Front Suspension117
Front Suspension Removal118
Front Suspension Inspection119
Front Suspension Installation121
Rear Arm Suspension for G22A122
Rear Arm Suspension for G22E123
Rear Arm Suspension Removal124
Rear Arm Suspension Inspection125
Rear Arm Suspension Installation125
Cable Maintenance126
Frame for G22A128
Frame for G22E129
Power Train for G22A133
Primary Sheave133
Primary Sheave Removal134
Primary Sheave Disassembly135
Primary Sheave Inspection135
Primary Sheave Assembly136
Primary Sheave Installation137
Secondary Sheave138
Secondary Sheave Disassembly139
Secondary Sheave Inspection140
Secondary Sheave Assembly140
Drive V-Belt Inspection and Replacement142
Transmission143
Transmission Removal144
Transmission Differential Disassembly146
Transmission Differential Inspection147
Transmission Disassembly147
Transmission Inspection149
Transmission Assembly150
Differential Assembly152
Differential Installation153
Power Train for G22E155
Power Train for G22E Transmission Removal156
Power Train for G22E Transmission Disassembly156
Power Train for G22E Transmission Inspection159
Power Train for G22E Transmission Assembly159
Power Train for G22E Transmission Installation160
Engine Overhaul161
Engine Removal163
Preparation for Removal163
Drive Belt164
Primary Clutch164
Air Cleaner Case164
Carburetor164
Wiring and Hose165
Starter Generator165
Muffler166
Engine Oil Drain167
Air Shroud167
Flywheel168
Cylinder Head169
Crankcase Cover169
Camshaft170
Balancer Shaft and Crankshaft170
Piston and Connecting Rod171
Oil Sender and Wire Guide Plate171
Bearings171
Cylinder Head Inspection and Repair172
Valve174
Valve Seat175
Valve Spring178
Valve Installation179
Rocker Arm180
Gears182
Cylinder and Piston182
Piston Ring and Pin183
Piston Ring Oversize184
Piston Pin185
Crankshaft Runout186
Crank Pin Outside Diameter186
Connecting Rod Oil Clearance186
Piston, Connecting Rod and Crankcase Cover188
Bearings Installation189
Piston and Connecting Rod Installation189
Crankshaft, Balancer Shaft and Camshaft191
Cylinder Head and Rocker Arm196
Ignition Unit198
Remounting Engine199
Carburetion203
Carburetor Section View206
Main Metering System206
Float System207
Electrical215
G22A Wiring Diagram217
Electrical Component Locations218
Electrical Components (Engine)219
Ignition System220
Ignition System Components221
Troubleshooting222
The Starter Does Not Turn222
No Spark or Wear Spark226
G22A Ignition System Troubleshooting228
Engine will Not Run, no Spark228
The Battery Is Not Charged230
Starter-Generator233
Solenoid Relay239
Voltage Regulator240
Generator Voltage Inspection240
Signal System (Oil Warning/Reverse Buzzer)242
Signal System Components243
The Oil Level Indicator Light Does Not Come on244
The Reverse Buzzer Does Not Operate247
G22E Wiring Diagram250
Electrical Components252
Traction Motor253
Traction Motor Removal254
Traction Motor Disassembly255
Tractor Motor Inspection and Testing257
Tractor Motor Assembly260
Tractor Motor Installation261
Motor Control Unit262
Electrical Troubleshooting267
Acceleration Becomes Rough, Uneven or Jerky267
Visual Inspection267
Test Throttle Position Sensor267
Car Does Not Slow on Downhill Grade And/Or Car will Roll Away Without Slowing268
Speed Sensor Wire Harness Check268
Car Has no Reverse Warning Beeper269
Speed Sensor Test269
Speed Sensor Magnet Check269
Buzzer Wiring Check269
The Car's Top Speed Is Slower270
Ground Wire Check270
Check Brakes and Chassis270
Car Won't Run Either Direction, Solenoid Does Not Click271
Reset Controller271
Fuse Check271
Tow Switch Test272
Wire Check Solenoid to Tow Switch272
Controller Ground Wire Check272
Solenoid Ground Bypass272
Wire Check - Solenoid to Controller273
Solenoid Relay Bench Test273
Car Won't Run Either Direction, Solenoid Does Click274
Throttle Position Sensor Check274
Main Switch Check275
Accelerator Stop Switch Check275
Direction Switch Check276
Check Traction Motor276
Z-1 Diagnostic Tester278
Z-1 Harness Identification278
Operation Instructions280
Specifications285
General Specifications287
Engine Specifications288
Transmission Specifications291
Electrical Specifications293
Power Train Specifications295
Cable/Wire Routing for G22A296

Yamaha G22 A/E - Symbol Identification

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