Yamaha UMAX, Service Manual

Page 1: ...SERVICE MANUAL UTILITY VEHICLE J0F F8197 E1 YUM1A YUM2A YUM2E LIT 19616 A0 37...

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Page 3: ...d is continually striving to improve all of its models Modifica tions and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in futu...

Page 4: ...tle To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded d...

Page 5: ...Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearanc...

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Page 7: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE YUM1A YUM2A 5 FUEL SYSTEM YUM1A YUM2A 6 DRIVE TRAIN 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9...

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Page 9: ...DURE 1 2 DISCHARGE THE MOTOR CONTROL UNIT CAPACITOR 1 2 RECOMMENDED JACK POINTS 1 2 IMPORTANT INFORMATION 1 3 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 3 REPLACEMENT PARTS 1 3 GASKETS OIL SEALS AND O...

Page 10: ...r the cargo bed ENGINE SERIAL NUMBER YUM1A YUM2A The engine serial number 1 is affixed to the cyl inder head cover TRACTION MOTOR SERIAL NUMBER YUM2E The traction motor serial number 1 is affixed to t...

Page 11: ...om moving out of neutral posi tion YUM1A YUM2A 4 Move the tow switch 1 to the TOW posi tion YUM2E DISCHARGE THE MOTOR CONTROL UNIT CAPACITOR 1 Turn the main switch to OFF position 2 Move the tow switc...

Page 12: ...the correct installation of all parts 5 Keep all parts away from any source of fire REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for a...

Page 13: ...air because this will damage the bearing surfac es CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use Whe...

Page 14: ...its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s hea...

Page 15: ...attery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE Be sure to connect the battery leads to the correct battery terminals Reversing the b...

Page 16: ...rning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V YUM1A YUM2A or 6V YUM2E NOTICE Never inser...

Page 17: ...lock before disconnecting the coupler NOTICE When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler...

Page 18: ...the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Digital circuit tester CD732 90890 03243 Model 88 Multime...

Page 19: ...da use part number starting with YM YU YS YK or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Mult...

Page 20: ...ve guide remover 6 0 mm YM 04064 A 5 13 Valve guide installer 6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 13 Valve guide reamer 6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 13 Rotor...

Page 21: ...l pressure adapter 90890 03186 Fuel pressure adapter YM 03186 6 3 Primary fixed sheave puller 90890 01876 Primary clutch puller YG 01876 7 4 Bolt JY2 SECND ST 1 7 5 7 6 Tool JY2 SECND ST 2 7 5 7 7 Nut...

Page 22: ...spark checker YM 34487 8 55 Test harness S pressure sensor 5S7 3P 90890 03207 Test harness S pressure sensor 5S7 3P YU 03207 8 58 PC GENIUS2 diagnostic tool 90890 J0CDC 00 9 8 DISCHARGE TESTER 36 48V...

Page 23: ...AL SPECIFICATIONS YUM1A YUM2A 2 9 ELECTRICAL SPECIFICATIONS YUM2E 2 11 TIGHTENING TORQUES 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 ENGINE TIGHTENING TORQUE YUM1A YUM2A 2 13 FUEL SYSTEM TIGHT...

Page 24: ...ht 302 mm 11 9 in Minimum ground clearance 115 mm 4 5 in Weight Curb weight without sun top 424 kg 935 lb YUM1A 455 kg 1003 lb YUM2A 630 kg 1390 lb YUM2E Curb weight with sun top 452 kg 997 lb YUM1A 4...

Page 25: ...GENERAL SPECIFICATIONS 2 2 1174 kg 2589 lb YUM2E Hill claiming ability 20 YUM1A 15 YUM2A YUM2E...

Page 26: ...16 US qt 0 97 Imp qt Cooling system Type Forced air cooled Spark plug Manufacturer model NGK BPR4ES Spark plug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Warpage limit 0 05 mm 0 002 in Camshaft Camsh...

Page 27: ...mm 1 43 in Limit 34 4 mm 1 35 in Cylinder Bore 85 000 85 020 mm 3 3465 3 3472 in Wear limit 85 050 mm 3 3484 in Piston Piston to cylinder clearance 0 043 0 057 mm 0 00017 0 0022 in Diameter 84 977 84...

Page 28: ...YUM2A 2 5 Air filter Type Oil spread over pleated paper urethane foam pre filter Fuel pump Pump type Electrical Fuel line pressure 246 254 kPa 2 46 2 54 kgf cm 35 7 36 8 psi Fuel injector Model quanti...

Page 29: ...ront 1 0 mm 0 04 in Rear 1 0 mm 0 04 in Steering system Type Rack and Pinion Steering angle left 1 85 turn Steering angle right 1 85 turn Brake Brake system Mechanical drum brake on each rear wheel wi...

Page 30: ...0 1010 mm 1 22 39 75 in V belt wear limit 28 0 mm 1 10 in Secondary sheave torque cam angle 2 B Transmission Governor type Oil bath flyweight Secondary reduction system Helical gear Secondary reductio...

Page 31: ...ndary reduction ratio 15 31 1 Differential type Bevel gear Transmission oil Type SAE 80W 90 or SAE 90 gear oil Quantity 355 cm 0 38 US qt 0 31 Imp qt Traction motor Model AMT7179 Rated output 5 kW Ope...

Page 32: ...2 oz Commutator diameter limit 39 0 mm 1 54 in Mica undercut depth 0 70 mm 0 03 in Belt tension 8 12 mm 0 31 0 47 in 100 N 10 kgf 22lb Voltage regulator Charging voltage above 14 V at 5000 r min Fuel...

Page 33: ...ELECTRICAL SPECIFICATIONS YUM1A YUM2A 2 10 USB fuse 5 A...

Page 34: ...rate 115 minutes at 75 A Fuses Main fuse 10 A MCU fuse 3 A USB fuse 1 A Battery charger DC output Voltage normal 48 V Voltage maximum 67 2 V Current maximum 18 A AC input Voltage maximum 85 265 V Freq...

Page 35: ...warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications...

Page 36: ...rator nut M8 1 25 N m 2 5 kgf m 18 lb ft Starter generator lead terminal nut M6 4 5 N m 0 5 kgf m 3 7 lb ft Rear bracket bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Brush holder screw M5 2 4 2 N m 0 42 kgf m...

Page 37: ...t Tighten the cylinder head bolts to 50 N m 5 0 kgf m 37 lb ft in the proper tightening sequence TIP Crankcase cover bolt Tighten the crankcase cover bolts to 30 N m 3 0 kgf m 22 lb ft in the proper t...

Page 38: ...e Q ty Tightening torque Remarks Fuel tank bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Fuel tank retainer bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Fuel pump nut M6 6 7 N m 0 7 kgf m 5 2 lb ft Air filter case bolt...

Page 39: ...5 lb ft Rear axle assembly bolt M10 8 73 N m 7 3 kgf m 54 lb ft Bearing cap bolt 3 8 4 55 N m 5 5 kgf m 41 lb ft Differential cover bolt 5 16 10 28 N m 2 8 kgf m 21 lb ft Ring gear nut 3 8 4 81 N m 8...

Page 40: ...8 kgf m 5 9 lb ft Tailgate inner cover bolt short M6 4 8 N m 0 8 kgf m 5 9 lb ft Tailgate inner cover bolt M6 8 8 N m 0 8 kgf m 5 9 lb ft Hinge shaft bolt M6 3 7 N m 0 7 kgf m 5 2 lb ft Rear side cov...

Page 41: ...N m 1 0 kgf m 7 4 lb ft Parking brake pedal nut M8 1 23 N m 2 3 kgf m 17 lb ft Parking brake pedal cover nut M6 2 7 N m 0 7 kgf m 5 2 lb ft Latch plate bolt M8 2 16 N m 1 6 kgf m 12 lb ft Steering col...

Page 42: ...kgf m 74 lb ft Rear suspension arm nut M13 1 90 N m 9 0 kgf m 66 lb ft Bushing bolt M10 2 53 N m 5 3 kgf m 39 lb ft Bottom panel bolt M6 6 7 N m 0 7 kgf m 5 2 lb ft USB plug bolt M6 2 7 N m 0 7 kgf m...

Page 43: ...TIGHTENING TORQUES 2 20...

Page 44: ...CABLE ROUTING 2 21 CABLE ROUTING YUM1A Frame top view A B C D 1 1 1 1 1 1 1 1 1 2 3 4 4 5 5 6 7 8 8 9 10 11 13 14 15 16 17 18 19 2 12...

Page 45: ...3 Main relay 14 Starter generator 15 Engine oil level switch lead 16 Rear brake cable right 17 Accelerator switch 18 Horn switch 19 Horn switch lead A Install the intake air temperature sensor complet...

Page 46: ...CABLE ROUTING 2 23 YUM1A Front and rear A B C 1 1 1 1 2 3 4 3 4 1 2 3 4 5 6...

Page 47: ...ess 2 USB port 3 Starter generator 4 Negative battery lead 5 USB plug 6 Sub wire harness A Route the headlight leads through the clamps B Fasten the wire harness at the white tape with a plastic band...

Page 48: ...CABLE ROUTING 2 25 YUM1A Left side A B D C 1 2 3 4 4 4 4 5 6 7 8 9...

Page 49: ...5 Reverse buzzer 6 Horn 7 Voltage regulator 8 Fuel pump relay 9 USB couplers A 0 45 B Fasten the wire harness at the white tape with a plastic band C Pass the wire harness through the hole of the foo...

Page 50: ...CABLE ROUTING 2 27 YUM1A Brake and throttle cables A B 1 3 2 3 1 2 2 4 5...

Page 51: ...28 1 Throttle cable 1 2 Rear brake cable right 3 Rear brake cable left 4 Shift control cable reverse 5 Shift control cable forward A Route the throttle cable 1 above the frame and rear suspension arm...

Page 52: ...CABLE ROUTING 2 29 YUM1A Shift cables 1 2 3 1 2 4 1 2...

Page 53: ...CABLE ROUTING 2 30 1 Shift control cable forward 2 Shift control cable reverse 3 Plastic band 4 Reverse switch...

Page 54: ...CABLE ROUTING 2 31 YUM2A Frame top view A B C 1 1 1 2 3 4 5 6 7 8 1 1 1 1 1 2 3 6 9 10 11 12 13 14 15 16 D E...

Page 55: ...elerator switch 15 Horn switch 16 Horn switch lead A Make sure that there is no slack in the wire harness B Fasten the wire harness at the white tape to the starter generator with the plastic band Fac...

Page 56: ...CABLE ROUTING 2 33 YUM2A Front and rear A B C D 1 1 1 1 1 2 2 3 3 4 4 3 4 5 6 7...

Page 57: ...ive battery lead 5 USB plug 6 Sub wire harness 7 Ground lead A Route the headlight leads through the clamps B Fasten the wire harness at the white tape with a plastic band C Route the sub wire harness...

Page 58: ...CABLE ROUTING 2 35 YUM2A Left side A B C D 1 2 3 4 4 4 4 6 7 8 9 10 5...

Page 59: ...buzzer 6 Reverse buzzer lead 7 Horn 8 Voltage regulator 9 Fuel pump relay 10 USB couplers A 0 45 B Fasten the wire harness at the white tape with a plastic band C Pass the wire harness through the hol...

Page 60: ...CABLE ROUTING 2 37 YUM2A Brake throttle and shift cables A A B C D 1 1 2 3 3 4 5 4 5 6 6 7 8 9...

Page 61: ...ble left 7 Rear brake cable left 8 Rear brake cable right 9 Reverse switch A Pass the front brake cable through the guide Align the guide with the white tape on the front brake cable B Pass the front...

Page 62: ...CABLE ROUTING 2 39 YUM2E Frame top view A A B 1 2 3 4 5 6 7 C D E E 6 6 6 8 9 10 11 12...

Page 63: ...6 Wire harness 7 Accelerator switch coupler 8 TPS throttle position sensor 9 Accelerator switch 10 Horn switch lead 11 Horn switch 12 Main switch A Fasten the taillight lead with the plastic band B F...

Page 64: ...CABLE ROUTING 2 41 YUM2E Front and rear 1 1 2 3 4 3 A...

Page 65: ...CABLE ROUTING 2 42 1 USB port 2 Battery gauge warning light 3 Shift switch 4 USB plug A Route the headlight leads through the clamps...

Page 66: ...CABLE ROUTING 2 43 YUM2E Left side B 2 1 3 4 5 6 7 8 9 10 11 A 9...

Page 67: ...ative battery lead 6 MCU motor control unit 7 Positive battery lead 8 Main relay 9 Wire harness 10 Voltage regulator 11 USB couplers A Pass the wire harness through the hole of the footrest B Fasten t...

Page 68: ...CABLE ROUTING 2 45 YUM2E Brake cable A A B C 1 2 4 3...

Page 69: ...3 Rear brake cable right 4 Rear brake cable left A Pass the front brake cable through the guide Align the guide with the white tape on the front brake cable B Pass the front brake cables through the g...

Page 70: ...CABLE ROUTING 2 47...

Page 71: ...3 6 CHECKING THE BODY AND CHASSIS 3 7 CHECKING THE FASTENERS 3 7 CHECKING THE REVERSE BUZZER 3 7 MONTHLY CHECKS 3 8 CHECKING THE DRIVE BELT YUM1A YUM2A 3 8 REPLACING THE DRIVE BELT YUM1A YUM2A 3 8 CH...

Page 72: ...16 CHECKING THE BATTERY TERMINALS 3 16 CHECKING THE WIRE HARNESS YUM1A YUM2A 3 17 TESTING THE DISCHARGE LOAD YUM2E 3 17 CHECKING THE REAR AXLE BEARINGS 3 17 CHECKING THE STEERING KNUCKLES 3 17 ADJUST...

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Page 74: ...CS CS Check fuel lines for leakage CS CS CS CS CS CS Check fuel level CS CS CS CS CS CS Check for looseness and cor rosion of battery terminals and hold downs CS CS CS CS CS CS Check brake pedal free...

Page 75: ...play Adjust wheel alignment CA CA CA Check wheel nut tightness front wheel bearing play CS CS CS Check transaxle oil level and inspect for leakage CS CS CS Adjust parking brake release CA CA CA EVERY...

Page 76: ...and rivets CS CS CS CS CS CS Check reverse alarm operation CS CS CS CS CS CS EVERY MONTH Check electrolyte level CS CS CS CS CS Check for loose or broken con nections CS CS CS CS CS Clean Lube pedal c...

Page 77: ...il level NOTICE Do not allow foreign materials to enter the crankcase 5 Check the engine oil level again NOTICE Be sure the engine oil is at the correct level otherwise engine damage may result CHECKI...

Page 78: ...an rag 3 Check Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 4 Check Battery hold down plate Loose Tighten 5 Charge Battery Refer to CHECKING AND CHARGING THE BATTER...

Page 79: ...airs to the wheel Ride conservatively after installing a tire to allow it to seat itself properly on the rim 2 Check Radial wheel runout Lateral wheel runout Refer to CHECKING THE WHEELS on page 4 19...

Page 80: ...n out tire When the tire tread reaches the wear limit re place the tire immediately CHECKING THE BODY AND CHASSIS 1 Check Body Chassis Cracks damage Replace CHECKING THE FASTENERS 1 Check Fasteners Lo...

Page 81: ...ke 2 Remove the under seat panel YUM1A Refer to GENERAL CHASSIS 1 on page 4 1 3 Lift up the cargo bed 4 Replace Drive belt a Pull up on the drive belt and push it out ward over the edge of the seconda...

Page 82: ...al Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immedi ately Eyes Flush with water for 15 minutes and get prompt medical attention Ba...

Page 83: ...olvent NOTICE Do not twist the air filter element when squeezing it c Properly dispose of the used solvent d Carefully wash the air filter element in soap water e Thoroughly rinse the air filter eleme...

Page 84: ...e harness Cracks frayed corrosive Replace CHECKING THE BRAKE CABLES 1 Check Brake cables Cracks damage Replace Brake operation Improper operation Adjust the brake CHECKING THE SHOCK ABSORBERS The foll...

Page 85: ...INE OIL LEVEL YUM1A YUM2A on page 3 4 8 Install Dipstick 9 Start the engine warm it up for several min utes and then turn it off 10 Check Engine for engine oil leaks 11 Check Engine oil level Refer to...

Page 86: ...1 6 Turn the governor lever 1 counterclockwise until it stops 7 Measure Clearance a The clearance is between the throttle lever 1 and throttle valve angle adjusting tool 2 Out of specification Adjust...

Page 87: ...Clean or replace 5 Install Exhaust pipe tail screen 1 Washer 2 Exhaust pipe tail cap 3 TIP When installing the exhaust pipe tail cap 3 in stall the cap all the way onto the exhaust pipe and then move...

Page 88: ...Clean 4 Check Starter generator belt tension a Apply 100 N 10 kg 22 lb of force to the cen ter of the starter generator belt Out of specification Adjust 5 Adjust Starter generator belt tension a Loos...

Page 89: ...ry Before performing repairs mark the pres ent limiter setting with a paint mark for fu ture reference Return the adjustment to the original setting after repairs are completed then test the vehicle s...

Page 90: ...ly by hand b Move the rear axle up and down CHECKING THE STEERING KNUCKLES 1 Park the vehicle on a level surface and apply the parking brake 2 Raise the front end of the vehicle so that there is no we...

Page 91: ...rod end locknuts 1 of both tie rods c The same number of turns should be giv en to both the right and left tie rods 2 until the specified toe in is obtained This is to keep the length of the tie rods...

Page 92: ...en ter the transmission case 4 Install Oil level plug ADJUSTING THE PARKING BRAKE RELEASE TIMING 1 Adjust Parking brake release timing NOTICE Before performing parking brake release ad justment adjust...

Page 93: ...g Cylinder head cover Refer to CYLINDER HEAD AND ROCKER ARMS on page 5 6 4 Measure Valve clearance Out of specification Adjust a Carefully insert a dial gauge through the spark plug hole until it touc...

Page 94: ...ing brake 2 Place a container under the transmission case 3 Remove Differential cover 1 Gasket Completely drain the transmission case of its oil 4 Install Gasket Differential cover 5 Remove Oil level...

Page 95: ...ded transmission oil NOTICE Take care not to allow foreign material to en ter the transmission case 7 Check Oil level Refer to CHECKING THE TRANSMISSION OIL LEVEL on page 3 19 CHECKING THE BRAKE SHOES...

Page 96: ...4 YEAR CHECKS 3 23...

Page 97: ...FRONT AND REAR WHEELS 4 16 REMOVE THE WHEELS 4 19 CHECKING THE WHEELS 4 19 CHECKING THE WHEEL HUBS 4 19 FRONT AND REAR BRAKES 4 20 CHECKING THE BRAKES 4 22 INSTALLING THE BRAKES 4 22 PEDAL ASSEMBLY 4...

Page 98: ...34 CHECKING THE STEERING KNUCKLES 4 34 INSTALLING THE FRONT LOWER ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES 4 34 REAR SUSPENSION COMPONENTS 4 36 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES 4 38 CHECKI...

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Page 100: ...ving the seats Order Job Parts to remove Q ty Remarks Cargo bed Lift up 1 Seat cushion 2 2 Under seat panel 1 3 Driver seat frame 1 4 Passenger seat frame 1 5 Seat back 2 3 4 2 4 4 5 1 16 N m 1 6 kgf...

Page 101: ...dure applies to both of the seats 1 Install Seat cushion 1 WARNING A loose seat could cause the operator to lose control or cause the operator or passenger to fall a Insert the projections a on the re...

Page 102: ...GENERAL CHASSIS 2 Removing the cargo bed Order Job Parts to remove Q ty Remarks 1 Cargo bed 1 2 Cargo bed damper 2 YUM2A YUM2E 2 2 1 30 N m 3 0 kgf m 22 lb ft T R 16 N m 1 6 kgf m 12 lb ft T R 16 N m...

Page 103: ...go panel 2 10 Front corner post 2 11 Rear corner post left 1 12 Rear corner post right 1 13 Damper 2 14 Latch 1 15 Cargo bed base 1 16 Cargo bed frame 1 15 7 1 4 9 5 10 6 6 9 12 13 3 2 16 14 4 9 4 4 9...

Page 104: ...der 2 2 Tailgate inner cover 1 3 Wire clip 2 4 Rod 2 5 Lock assembly left 1 6 Lock assembly right 1 7 Latch handle 1 8 Hinge shaft 1 9 Tailgate case 1 9 7 3 8 4 5 3 6 1 4 4 1 8 2 7 N m 0 7 kgf m 5 2 l...

Page 105: ...emarks Cargo bed Refer to GENERAL CHASSIS 2 on page 4 3 1 Tail cover 1 2 Rear side cover left 1 3 Rear side cover right 1 4 Rear frame cover left 1 5 Rear frame cover right 1 6 Rear upper cover 1 5 6...

Page 106: ...r cover left 1 for YUM1A 4 Rear inner cover left 1 for YUM2A YUM2E 5 Rear inner cover right 1 for YUM1A 6 Rear inner cover right 1 for YUM2A 7 Rear inner cover right 1 for YUM2E 8 Mudguard left 1 for...

Page 107: ...r With mudguard 2 Remove Mudguard 1 TIP Unhook the projections a on the mudguard from the rear inner cover INSTALLING THE MUDGUARD The following procedure applies to both of the mudguards 1 Install Mu...

Page 108: ...SSIS 5 on page 4 10 1 Side panel left 1 for YUM1A 2 Side panel left 1 for YUM2A YUM2E 3 Side panel right 1 for YUM1A 4 Side panel right 1 for YUM2A YUM2E 5 Clip 1 for YUM1A YUM2A 6 Shift lever 1 for Y...

Page 109: ...at 1 2 Service lid 1 3 Front frame cover left 1 4 Front frame cover right 1 5 Light switch lead 3 Disconnect 6 Meter coupler 1 Disconnect 7 Meter panel 1 8 USB connector 2 9 Ornament 1 10 Instrument p...

Page 110: ...bling the instrument panel assembly Order Job Parts to remove Q ty Remarks 1 Hinge cover 4 2 Hinge 2 3 Hood 1 4 Hood stopper 2 5 Nut plate 2 6 Circlip 2 7 Pin 1 8 Handle 1 2 5 N m 0 25 kgf m 1 8 lb ft...

Page 111: ...ERAL CHASSIS 5 4 12 REMOVING THE HOOD 1 Remove Hinge cover TIP When removing the hinge cover 1 use a flat head screwdriver to push the cover outward and release the projection a 2 Remove Screws Hood a...

Page 112: ...assembly Refer to GENERAL CHASSIS 5 on page 4 10 1 Scorecard holder 1 2 Steering wheel 1 3 Steering grommet 1 4 Storage compartment mat left 1 5 Storage compartment mat right 1 6 Main switch coupler...

Page 113: ...ERING WHEEL 1 Install Steering grommet 1 Steering wheel 2 Scorecard holder 3 TIP With the front wheels pointing straight ahead install the steering wheel as shown in the illustration T R Steering whee...

Page 114: ...ard Refer to GENERAL CHASSIS 6 on page 4 13 1 Skid plate 1 2 Headlight coupler 2 Disconnect 3 Front grille 1 4 Headlight left 1 5 Headlight right 1 6 Front cowl 1 6 5 4 3 1 2 2 1 8 N m 0 18 kgf m 1 3...

Page 115: ...e front wheels YUM1A Order Job Parts to remove Q ty Remarks The following procedure applies to both of the front wheels 1 Front wheel 1 2 Dust cover 1 3 Axle nut 1 4 Front wheel hub 1 New 102 N m 10 2...

Page 116: ...M2E Order Job Parts to remove Q ty Remarks The following procedure applies to both of the front wheels 1 Front wheel 1 2 Brake drum 1 3 Dust cover 1 4 Axle nut 1 5 Front wheel hub 1 New 102 N m 10 2 k...

Page 117: ...Order Job Parts to remove Q ty Remarks The following procedure applies to both of the rear wheels 1 Rear wheel 1 2 Brake drum 1 3 Dust cover 1 4 Axle nut 1 5 Rear wheel hub 1 New 210 N m 21 kgf m 155...

Page 118: ...THE TIRES on page 3 6 and CHECKING THE WHEELS on page 3 6 WARNING After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an acciden...

Page 119: ...procedure applies to both of the front brakes Front wheel hub Refer to FRONT AND REAR WHEELS on page 4 16 1 Front brake cable left 1 Disconnect 2 Brake shoe clamp 2 3 Brake shoe 2 4 Brake shoe spring...

Page 120: ...ocedure applies to both of the rear wheels Rear wheel hub Refer to FRONT AND REAR WHEELS on page 4 16 1 Rear brake cable left 1 Disconnect 2 Brake shoe clamp 2 3 Brake shoe 2 4 Brake shoe spring 2 5 B...

Page 121: ...inner surface Oil deposits Clean Remove the oil with a rag soaked in lacquer thinner or solvent Scratches Repair Lightly and evenly polish the scratches with an emery cloth 5 Check Brake lever assembl...

Page 122: ...switch coupler 1 Disconnect 2 Throttle cable 1 1 Disconnect 3 Brake cable locknut 1 4 Brake cable adjusting nut 1 5 Clip 2 6 Pin 2 7 Rear brake cable left 1 Disconnect 8 Rear brake cable right 1 Disco...

Page 123: ...4 Brake cable locknut 2 5 Brake cable adjusting nut 2 6 Circlip 4 7 Front brake cable left 1 Disconnect 8 Front brake cable right 1 Disconnect 9 Rear brake cable right 1 Disconnect 10 Rear brake cabl...

Page 124: ...le position sensor bracket 1 for YUM2E 4 Throttle position sensor shim 1 for YUM2E 5 Accelerator pedal 1 6 Spring 1 7 Pin 1 8 Accelerator pedal shaft 1 9 Accelerator pedal arm 1 10 Bushing 2 New New N...

Page 125: ...rake sector 1 5 Brake pedal 1 6 Parking brake pedal cover 1 7 Parking brake pedal 1 8 Latch plate 1 9 Brake pedal pad 1 10 Brake rod damper 1 11 Pedal base 1 New New New New New New 6 N m 0 6 kgf m 4...

Page 126: ...E THROTTLE CA BLES YUM1A YUM2A on page 3 12 3 Adjust Brake pedal free play Refer to CHECKING THE BRAKE PEDAL FREE PLAY on page 3 5 ADJUSTING THE THROTTLE POSITION SENSOR YUM2E NOTICE Handle the thrott...

Page 127: ...on sensor angle tighten the throttle position sensor screws 2 Test harness TPS 3P 90890 03204 Test harness TPS 3P YU 03204 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer...

Page 128: ...1 3 Steering shaft 1 4 Tie rod end 2 5 Dust boot 2 6 Tie rod 2 7 Rack gear 1 8 Steering assembly 1 New New New New LS 22 N m 2 2 kgf m 16 lb ft T R 22 N m 2 2 kgf m 16 lb ft T R 39 N m 3 9 kgf m 29 l...

Page 129: ...pplies to both of the tie rod ends 1 Check Tie rod end free play and movement Rough movement Replace the tie rod end 2 Check Tie rod end Bends damage Replace Rubber boot damage Replace the tie rod end...

Page 130: ...c on the steering as sembly housing 7 Install Steering wheel Refer to INSTALLING THE STEERING WHEEL on page 4 14 8 Adjust Toe in Refer to ADJUSTING THE WHEEL ALIGN MENT on page 3 17 LUBRICATING THE S...

Page 131: ...6 Brake plate for YUM2A YUM2E Refer to FRONT AND REAR BRAKES on page 4 20 1 Steering knuckle arm 1 2 Spacer 1 3 Steering knuckle 1 4 Dust cover 2 5 Bushing 2 6 Front shock absorber assembly 1 7 Front...

Page 132: ...ng the front under bracket Order Job Parts to remove Q ty Remarks Skid plate Refer to GENERAL CHASSIS 7 on page 4 15 1 Front under bracket 1 1 2 Front under bracket 2 1 1 2 47 N m 4 7 kgf m 35 lb ft T...

Page 133: ...k absorber assembly CHECKING THE STEERING KNUCKLES The following procedure applies to all of the steering knuckles 1 Check Steering knuckle 1 Cracks damage Replace Bushings Wear damage Replace INSTALL...

Page 134: ...FRONT SUSPENSION COMPONENTS 4 35 4 3 1 2 5 a...

Page 135: ...FRONT AND REAR WHEELS on page 4 16 Rear brake cable Refer to FRONT AND REAR BRAKES on page 4 20 1 Rear shock absorber assembly 2 2 Stabilizer joint 2 3 Stabilizer holder 2 4 Bushing 2 5 Stabilizer 1 6...

Page 136: ...panel 1 100 N m 10 kgf m 74 lb ft T R 7 N m 0 7 kgf m 5 2 lb ft T R 30 N m 3 0 kgf m 22 lb ft T R 64 N m 6 4 kgf m 47 lb ft T R 64 N m 6 4 kgf m 47 lb ft T R 73 N m 7 3 kgf m 54 lb ft T R 73 N m 7 3 k...

Page 137: ...er spring Move the spring up and down Fatigue Replace the rear shock absorber assembly CHECKING THE REAR SUSPENSION ARM 1 Check Rear suspension arm 1 Bends cracks damage Replace Bushings 2 Wear damage...

Page 138: ...REAR SUSPENSION COMPONENTS 4 39...

Page 139: ...NG THE VALVES 5 15 STARTER GENERATOR 5 17 CHECKING THE STARTER GENERATOR 5 19 ASSEMBLING THE STARTER GENERATOR 5 20 FLYWHEEL 5 21 REMOVING THE FLYWHEEL 5 22 INSTALLING THE FLYWHEEL 5 22 CAMSHAFT 5 24...

Page 140: ...tabilizes WARNING To prevent sparking ground the spark plug lead before cranking the engine b If the compression pressure is above the maximum specification check the cylinder head valve surfaces and...

Page 141: ...driver and passenger Refer to GENERAL CHASSIS 1 on page 4 1 1 Baffle plate 1 for YUM2A 2 Muffler duct 1 3 Muffler 1 4 Gasket 1 5 Exhaust pipe 1 6 Gasket 1 6 3 1 4 5 2 New New 7 N m 0 7 kgf m 5 2 lb f...

Page 142: ...BODY on page 6 5 Starter generator Refer to STARTER GENERATOR on page 5 17 Primary sheave Refer to PRIMARY AND SECONDARY SHEAVE YUM1A YUM2A on page 7 1 1 Band 1 2 Ignition coil connector 2 Disconnect...

Page 143: ...REMOVAL 2 5 4 Removing the engine Order Job Parts to remove Q ty Remarks 1 Engine mounting nut 4 2 Engine mounting bolt 4 3 Engine 1 1 1 1 1 2 2 3 54 N m 5 4 kgf m 40 lb ft T R 54 N m 5 4 kgf m 40 lb...

Page 144: ...HE ENGINE 1 Install Engine 1 Engine mounting bolts Engine mounting nuts 2 Tighten Engine mounting nuts TIP Before tightening the nuts push the engine to ward left side a of frame T R Engine mounting n...

Page 145: ...Refer to THROTTLE BODY on page 6 5 Baffle plate for YUM2A Refer to ENGINE REMOVAL 1 on page 5 2 1 Cylinder head breather hose 1 2 Spark plug cap 1 Disconnect 3 Ignition coil connector 2 Disconnect 4...

Page 146: ...e 5 21 1 Air shroud 2 2 Valve adjusting screw locknut 2 3 Valve adjusting screw 2 4 Push rod 2 5 Rocker arm shaft set bolt 2 6 Rocker arm shaft 2 7 Rocker arm 2 8 Cylinder head 1 9 Cylinder head gaske...

Page 147: ...that the piston can be positioned at TDC during cylinder head installation 3 Remove Push rods Rocker arm shafts Rocker arms TIP Make a note of the position of each push rod rocker arm shaft and rocke...

Page 148: ...ratches Replace or check the lubrication system 3 Measure Rocker arm inside diameter a Out of specification Replace 4 Measure Rocker arm shaft outside diameter a Out of specification Replace CHECKING...

Page 149: ...stall Rocker arm shafts 1 Rocker arm shaft set bolt TIP When installing a rocker arm shaft set bolt be sure to fit the bolt into the groove a in the rocker arm shaft T R Rocker arm shaft set bolt 2 3...

Page 150: ...Order Job Parts to remove Q ty Remarks Cylinder head Refer to CYLINDER HEAD AND ROCKER ARMS on page 5 6 1 Valve cotter 2 2 Valve spring retainer 2 3 Valve spring 2 4 Intake valve 1 5 Exhaust valve 1 6...

Page 151: ...e the valve cotter by compressing the valve spring with the valve spring compressor 1 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 intake side only TIP Identify the positi...

Page 152: ...valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem end Mushroom shape or diameter larger than the body of the valve stem Replace the valve 5 Measure Valve stem...

Page 153: ...ed one another the blueing will have been re moved 4 Lap Valve face Valve seat TIP After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapp...

Page 154: ...ve seat width c again If the valve seat width is out of specification reface and lap the valve seat CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure Val...

Page 155: ...valve cotter with its rounded side a facing toward the valve Install the valve cotter by compressing the valve spring with the valve spring compressor 2 5 To secure the valve cotter onto the valve ste...

Page 156: ...Cargo bed Lift up 1 Band 1 2 Starter generator coupler 1 Disconnect 3 Starter generator lead red 1 Disconnect 4 Starter generator lead black 1 Disconnect 5 Starter generator 1 6 Starter generator driv...

Page 157: ...older 1 3 Brush 4 4 Stator assembly 1 5 Pulley 1 6 Front bracket 1 7 Armature assembly 1 7 N m 0 7 kgf m 5 2 lb ft T R 2 0 N m 0 20 kgf m 1 5 lb ft T R 4 2 N m 0 42 kgf m 3 1 lb ft T R 4 2 N m 0 42 kg...

Page 158: ...Connect the digital circuit tester and check the continuity b If there is no continuity replace the starter generator 5 Measure Series field coil resistance Out of specification Replace the stator as...

Page 159: ...mature with the front bracket 1 TIP Align the pin hole of the front bracket with the stator pin 3 to assemble 2 Install Rear bracket 1 TIP Align the pin hole of the rear bracket with the sta tor pin 2...

Page 160: ...e harness 1 5 Crankshaft position sensor 1 6 Flywheel nut 1 7 Flywheel 1 8 Woodruff key 1 9 Air shroud 1 10 Air shroud damper 1 11 Engine temperature sensor 1 10 N m 1 0 kgf m 7 4 lb ft T R 10 N m 1 0...

Page 161: ...ft Make sure the flywheel puller is centered over the flywheel INSTALLING THE FLYWHEEL 1 Install Flywheel 1 Washer Flywheel nut TIP Hold the flywheel with the rotor holding tool 2 while tightening the...

Page 162: ...LYWHEEL 5 23 2 Install Flywheel cover 1 TIP Install the flywheel cover bolts in the 4 locations a but do not install a bolt in the 1 location b T R Flywheel cover bolt 8 N m 0 8 kgf m 5 9 lb ft a a 1...

Page 163: ...e 5 6 1 Dipstick 1 2 Engine oil filler cap 1 3 Engine oil drain bolt 1 4 Crankcase cover 1 5 Crankcase cover gasket 1 6 Dowel pin 2 7 Oil level switch lead guide 1 8 Oil level switch 1 9 Oil level swi...

Page 164: ...Out of specification Replace the camshaft 4 Measure Crankcase hole inside diameter a Out of specification Replace the crank case 5 Measure Crankcase cover hole inside diameter a Out of specification...

Page 165: ...m TIP Check that the decompression pin 1 projects from the camshaft Check that the decompression cam 2 and de compression pin 1 moves smoothly CHECKING THE VALVE LIFTERS 1 Check Valve lifters Damage w...

Page 166: ...TIP Route the oil level switch lead as shown in the il lustration 3 Install Crankcase cover TIP Tighten the bolts in the proper sequence as shown T R Crankcase cover bolt 30 N m 3 0 kgf m 22 lb ft 1 8...

Page 167: ...Refer to FLYWHEEL on page 5 21 Camshaft Refer to CAMSHAFT on page 5 24 1 Balancer 1 2 Connecting rod cap 1 3 Connecting rod and piston assembly 1 4 Crankshaft 1 5 Piston pin clip 2 6 Piston pin 1 7 Co...

Page 168: ...groove and the piston s pin bore ar ea If both areas are deburred and the piston pin is still difficult to remove remove it with the pis ton pin puller set 3 4 Remove Top ring 2nd ring Oil ring TIP Wh...

Page 169: ...and piston rings as a set TIP Before measuring the piston ring side clearance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP U...

Page 170: ...a set CHECKING THE CRANKSHAFT AND CONNECTING ROD 1 Measure Crankshaft runout Out of specification Replace the crank shaft 2 Check Crankshaft journal surfaces Crankshaft pin surfaces Scratches wear Re...

Page 171: ...tate until the clearance measure ment has been completed e Tighten the connecting rod cap bolts to the specified torque in two stages f Remove the connecting rod and connect ing rod cap g Measure the...

Page 172: ...when as sembling the piston to the connecting rod Install the piston pin clips so that the clip ends are 45 degrees c or more from the cutout d in the piston 4 Offset Piston ring end gaps 5 Lubricate...

Page 173: ...Install the connecting rod cap making sure that the arrow mark a on the connecting rod 2 is aligned with the arrow mark b on the connect ing rod cap Tighten the connecting rod cap bolts to the specif...

Page 174: ...CRANKSHAFT AND PISTON 5 35...

Page 175: ...P 6 2 INSTALLING THE FUEL TANK 6 2 CHECKING THE FUEL PRESSURE 6 3 AIR FILTER CASE 6 4 THROTTLE BODY 6 5 REMOVING THE THROTTLE BODY 6 6 CHECKING THE FUEL INJECTOR 6 6 CHECKING THE THROTTLE BODY 6 6 CHE...

Page 176: ...er to GENERAL CHASSIS 4 on page 4 9 Front panel Refer to GENERAL CHASSIS 4 on page 4 9 Baffle plate for YUM2A Refer to ENGINE REMOVAL 1 on page 5 2 1 Canister hose 1 Disconnect 2 Fuel hose 1 Disconnec...

Page 177: ...Fuel pump bracket Fuel pump Fuel pump gasket NOTICE Do not drop the fuel pump or give it a strong shock Do not touch the base section of the fuel sender CHECKING THE FUEL PUMP BODY 1 Check Fuel pump...

Page 178: ...e a Remove the under seat panel Refer to GENERAL CHASSIS 1 on page 4 1 b Remove the drive belt Refer to REPLACING THE DRIVE BELT YUM1A YUM2A on page 3 8 c Disconnect the fuel hose 1 from the fuel tank...

Page 179: ...age 4 1 Cargo bed Lift up YUM2A 1 Air filter case cover 1 2 Air filter 1 3 Air filter element 1 4 Canister hose 1 Disconnect 5 Cylinder head breather hose 1 Disconnect 6 Intake air temperature sensor...

Page 180: ...rottle body 1 3 Throttle body gasket 1 4 Injection coupler 1 Disconnect 5 Intake air pressure sensor coupler 1 Disconnect 6 Fuel hose 1 Disconnect 7 Intake manifold 1 8 Intake manifold gasket 1 9 Fuel...

Page 181: ...ck Fuel injector Obstruction Replace and check the fuel pump fuel supply system Deposit Replace Damage Replace 2 Check Fuel injector resistance Refer to CHECKING THE FUEL INJEC TOR on page 8 58 CHECKI...

Page 182: ...uel hose is in the correct position otherwise the fuel hose will not be properly installed TIP Connect the fuel hose securely onto the fuel in jector until a distinct click in heard To connect the fue...

Page 183: ...ING THE SECONDARY SHEAVE 7 5 ASSEMBLING THE PRIMARY SHEAVE 7 6 ASSEMBLING THE SECONDARY SHEAVE 7 6 TRANSMISSION YUM1A YUM2A 7 8 DISASSEMBLING THE TRANSMISSION 7 12 CHECKING THE TRANSMISSION 7 12 ASSEM...

Page 184: ...iver seat frame for YUM1A Refer to GENERAL CHASSIS 1 on page 4 1 Battery plate for YUM1A Rear shock absorber for YUM1A Refer to REAR SUSPENSION COMPO NENTS on page 4 36 Side panel left Refer to GENERA...

Page 185: ...Spider 1 3 Primary sliding sheave 1 4 Primary fixed sheave 1 5 Collar 3 6 Roller 3 7 Washer 6 8 Slider 6 9 Collar 3 10 Weight 3 11 Washer 6 12 Oil seal 2 13 Grease nipple 1 LS LT LS 6 3 5 N m 0 35 kg...

Page 186: ...ob Parts to remove Q ty Remarks 1 Circlip 1 2 Spring collar 1 3 Spring seat 1 4 Secondary sheave spring 1 5 Secondary sliding sheave 1 6 Secondary fixed sheave 1 7 Washer 1 8 Grease nipple 1 9 Oil sea...

Page 187: ...height where the primary sheave bolt 1 can be accessed 4 Remove Rubber cap Primary sheave bolt TIP Use the rotor holding tool 1 to hold the primary sheave 5 Remove Primary sheave assembly TIP Use the...

Page 188: ...efore disassembling the sec ondary sheave to make assembly work later easier 4 Remove Nut Tool 1 Bolt NOTICE When detaching the nut from the bolt hold the tool securely so that the tool 1 and sec onda...

Page 189: ...mark a on the primary fixed sheave shaft is positioned opposite the grease nipple b as shown 3 Install Primary sheave cap 1 TIP Align the cutout a in the primary sheave cap with the grease nipple 2 on...

Page 190: ...ip contacts it and make sure the nut contacts the threaded part of the bolt 4 while pushing the tool 4 Tighten Nut TIP After tightening the nut to a certain extent press down the secondary sheave hold...

Page 191: ...SSIS 1 on page 4 1 Cargo bed Refer to GENERAL CHASSIS 2 on page 4 3 1 Shift cable forward 1 2 Shift cable reverse 1 3 Equalizer bracket 1 4 Clip 1 5 Shift lever 1 6 Reverse switch coupler 1 Disconnect...

Page 192: ...SUSPENSION COMPO NENTS on page 4 36 Rear stabilizer Refer to REAR SUSPENSION COMPO NENTS on page 4 36 1 Throttle cable 1 1 Disconnect 2 Throttle cable 2 1 Disconnect 3 Dust cover 2 4 Brake drum 2 5 R...

Page 193: ...Bearing cap 2 5 Differential assembly 1 6 Ring gear 1 7 Set screw 1 8 Spring 1 9 Ball 1 10 Transmission case cover 1 11 Idle gear 1 12 Reverse gear 1 13 Shift fork 1 14 Dog clutch 1 15 Forward gear 1...

Page 194: ...Q ty Remarks 16 Counter shaft 1 17 Input shaft 1 18 Governor shaft 1 19 Shift lever 1 19 4 2 7 10 16 17 18 LS New New New New FW FWD LS 42 N m 4 2 kgf m 31 lb ft T R 55 N m 5 5 kgf m 41 lb ft T R 28...

Page 195: ...eck Forward and reverse gear dogs Dog clutch Cracks damage rounded edges Replace 3 Check Shift fork Bends damage scoring wear Replace 4 Check Bearings Damage Replace ASSEMBLING THE TRANSMISSION 1 Inst...

Page 196: ...TRANSMISSION YUM1A YUM2A 7 13 Refer to CHECKING THE SHIFT LEVER YUM1A YUM2A on page 3 8...

Page 197: ...NENTS on page 4 36 1 Traction motor lead 3 Disconnect 2 Speed sensor coupler 1 Disconnect 3 Traction motor temperature sensor coupler 1 Disconnect 4 Traction motor 1 5 Dust cover 2 6 Brake drum 2 7 Re...

Page 198: ...ANSMIS SION OIL on page 3 21 1 Differential cover 1 2 Gasket 1 3 Axle shaft 2 4 Bearing cap 2 5 Differential assembly 1 6 Ring gear 1 7 Counter shaft 1 8 Input shaft 1 3 2 10 8 4 4 2 6 5 7 1 FW FWD Ne...

Page 199: ...ION YUM2E 7 16 CHECKING THE TRANSMISSION 1 Check Ring gear Counter gear Input gear Blue discoloration pitting wear Replace 2 Check Counter shaft Input shaft Bend pitting Replace 3 Check Bearings Damag...

Page 200: ...er to TRANSMISSION YUM2E on page 7 14 1 Terminal plate 1 2 Terminal plate seal 1 3 Speed sensor 1 4 Front bracket 1 5 Dust cover 1 6 Circlip 1 7 End bracket 1 8 Armature 1 9 Stator 1 3 4 4 8 9 7 1 2 5...

Page 201: ...End bracket 1 TIP Align the match mark a on the stator with the slot b on the end bracket 2 Install Front bracket 1 TIP Align the match mark a on the stator with the slot b on the front bracket T R T...

Page 202: ...TRACTION MOTOR YUM2E 7 19...

Page 203: ...15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 LIGHTING SYSTEM YUM2E 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 SIGNALING SYSTEM YUM1A YUM2A 8 23 CIRCUIT DIAGRAM 8 23 TROUBLESHOOTING 8 25 SIGNALING...

Page 204: ...56 CHECKING THE FUEL SENDER 8 56 CHECKING THE REVERSE BUZZER 8 57 CHECKING THE ENGINE TEMPERATURE SENSOR 8 57 CHECKING THE INTAKE AIR PRESSURE SENSOR 8 57 CHECKING THE INTAKE AIR TEMPERATURE SENSOR 8...

Page 205: ......

Page 206: ...OFF ON H L SW R B Br B R Br Br Br R W Br Br R R B B B B B B R R R R R B R R R W R B B R B B B B B B B B B B B B B B B R R R W R W R R R O R W W R B W W R B B B B B R W O B W B R R R Br Br R W Br R W...

Page 207: ...YUM1A YUM2A 8 2 5 Main switch fuse 6 Main fuse 18 Main switch 19 Accelerator switch 25 ECU engine control unit 29 Crankshaft position sensor 31 Frame ground 35 Battery 36 Spark plug 37 Ignition coil 3...

Page 208: ...page 8 51 Clean the battery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG YUM1A YUM2A on page 3 10 Re gap or replace the spark plug 4 Check the igni...

Page 209: ...ING THE SWITCHES on page 8 48 Replace the accelerator switch 9 Check the main switch Refer to CHECKING THE SWITCHES on page 8 48 Replace the main switch 10 Check the entire ignition system wir ing Ref...

Page 210: ...M YUM1A YUM2A CIRCUIT DIAGRAM PIN 1 4 Br R 3 2 WIRE COLOR OFF ON H L SW R B Br B R Br Br Br R W Br Br R R B B B B B B R R R R R B R R R W B R W R B B R B B B B B B B B B B B B B B B R W R W R R W R G...

Page 211: ...ELECTRIC STARTING SYSTEM YUM1A YUM2A 8 6 5 Main switch fuse 6 Main fuse 18 Main switch 19 Accelerator switch 31 Frame ground 33 Starter generator 34 Main relay 35 Battery 38 Engine ground...

Page 212: ...y terminals Recharge or replace the battery 3 Check the starter generator opera tion Refer to CHECKING THE START ER GENERATOR OPERATION on page 8 55 Starter generator is OK Perform the electric starti...

Page 213: ...STARTING SYSTEM YUM1A YUM2A 8 8 NG OK 8 Check the entire starting system wir ing Refer to CIRCUIT DIAGRAM on page 8 5 Properly connect or replace the wire har ness The electric starting system circui...

Page 214: ...T DIAGRAM PIN 1 4 Br R 3 2 WIRE COLOR OFF ON H L SW B B G R W R W G B B R W R W R W R W R W R W R G R G R B B B B B B B B B B B B B B B B B B B B R Br R Br Br Br R W Br Br R R R R R R R R R R R R W R...

Page 215: ...CHARGING SYSTEM YUM1A YUM2A 8 10 5 Main switch fuse 6 Main fuse 18 Main switch 19 Accelerator switch 32 Voltage regulator 33 Starter generator 35 Battery...

Page 216: ...attery terminals Recharge or replace the battery 3 Check the starter generator Refer to CHECKING THE START ER GENERATOR on page 5 19 Repair or replace the starter generator 4 Check the voltage regulat...

Page 217: ...CHARGING SYSTEM YUM1A YUM2A 8 12...

Page 218: ...CHARGING SYSTEM YUM2E 8 13 CHARGING SYSTEM YUM2E CIRCUIT DIAGRAM R R B R B B B B 27 28 27 Battery 28 Charging receptacle...

Page 219: ...s 1 Under seat panel NG OK NG OK 1 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 63 Clean the battery terminals Recharge or replace the battery 2 Check the entire charging sys...

Page 220: ...UM1A YUM2A CIRCUIT DIAGRAM PIN 1 4 Br R 3 2 WIRE COLOR OFF ON H L SW R Y B Br B B B Y B G G Y B R Y G Y B R Br Br B B B B B B B R Y R Y G W G W W G W R R R R R B B R R R B B R B B Y Y Y B B B B B R R...

Page 221: ...LIGHTING SYSTEM YUM1A YUM2A 8 16 3 Lighting fuse 6 Main fuse 15 Headlight right 16 Headlight left 17 Light switch 18 Main switch 35 Battery 38 Engine ground...

Page 222: ...50 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 51 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING...

Page 223: ...LIGHTING SYSTEM YUM1A YUM2A 8 18...

Page 224: ...G SYSTEM YUM2E CIRCUIT DIAGRAM R OFF ON R Y Y B G Y Y Y B G G G R Y G Y B B B B B B Y G G W G W B B B B B B B B R Y B B R Y R Y R Y R Y R Y B B R Y R Y R Y R Y R R R R R B B B R Y R R B B B R R Y G B...

Page 225: ...LIGHTING SYSTEM YUM2E 8 20 4 Headlight right 5 Headlight left 6 Light switch 9 Voltage regulator 12 Tow switch 24 Main fuse 27 Battery...

Page 226: ...2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 63 Clean the battery terminals Recharge or replace the battery 3 Check the tow switch Refer to CHECKING THE SWITCHES on page 8...

Page 227: ...LIGHTING SYSTEM YUM2E 8 22...

Page 228: ...B P P P R B P B P R R R R R R B R R R B B R B B B R R R Br Br Br Br R W Br Br R R B B R W B B B B B B B B B B B B B R R R R W R W R W R P Br P B Br B R R W Br R W B B B B B R W Br R R B R B R R P B R...

Page 229: ...fuse 6 Main fuse 8 Reverse switch 9 Reverse buzzer 10 Horn switch 11 Horn 18 Main switch 19 Accelerator switch 21 Engine oil level switch 22 Meter assembly 23 Fuel pump assembly 25 ECU engine control...

Page 230: ...Refer to CHECKING THE FUSES on page 8 50 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 51 Clean the battery terminals Recharge or replace the battery 3 C...

Page 231: ...r switch 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 23 Properly connect or replace the wire har ness Replace the meter assembly or ECU 1 Check the reverse switch Ref...

Page 232: ...CUIT DIAGRAM on page 8 23 Properly connect or replace the wire har ness Replace the horn 1 Check the engine oil level switch Refer to CHECKING THE SWITCHES on page 8 48 Replace the engine oil level sw...

Page 233: ...SIGNALING SYSTEM YUM1A YUM2A 8 28...

Page 234: ...P B P W Y Y W B B B W R R B R B B R Y R Y R Y R Y R Y B B R Y R Y R Y R Y R R R R R B B B B B B B B R Y B R R B B B B R R B B B B R W R Y B R W B R W R W R W R W R Y R Y B W R B R B B W Y B W R Y Y W...

Page 235: ...STEM YUM2E 8 30 7 Horn 8 Horn switch 9 Voltage regulator 10 Main switch 11 Battery gauge warning light 12 Tow switch 14 Reverse buzzer 15 Shift switch 20 MCU motor control unit 21 MCU fuse 24 Main fus...

Page 236: ...2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 63 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8...

Page 237: ...reverse buzzer Refer to CHECKING THE RE VERSE BUZZER on page 8 78 Replace the reverse buzzer 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 29 Properly connect or repla...

Page 238: ...R R R R R R Y L P Br B P R Y B Br B R R W Br R O G B R R W R W R W R W R W W R B W B W B W R Y O W G W G P R Y O W P G W B W G W B W W R Br W B B B W B W B W B B B R R W O B W O W G W G P G Br L B W...

Page 239: ...mp relay 22 Meter assembly 23 Fuel pump assembly 24 Diagnostic tool coupler 25 ECU engine control unit 26 Engine temperature sensor 27 Intake air pressure sensor 28 Fuel injector 29 Crankshaft positio...

Page 240: ...is play engine rpm and engine temperature 8 If there are error codes both the green power light 1 and the yellow warning light 2 will be on 9 Release the accelerator pedal to shut the en gine off Leav...

Page 241: ...2 seconds release the pedal 6 The screen should now display DIAG 2 7 Press and release the MODE button The screen will now display the diagnostic code 1 and the value of the code 2 8 Use the UP butto...

Page 242: ...FUEL INJECTION SYSTEM YUM1A YUM2A 8 37 TIP If the engine is not start in the diagnostic mode turn the main switch to OFF and disconnect the negative battery lead to release the diagnostic mode...

Page 243: ...FUEL INJECTION SYSTEM YUM1A YUM2A 8 38...

Page 244: ...OFF ON H L SW R B Br B R Br Br Br R R B B B B B B R R R R R B B B R R R B B R B B B B B B B B B B B B B B B R R R R R R R R Y L B R Y B B B B B B L B R R Br Br R W R W R W R W R W R W R Br R Y R R L O...

Page 245: ...MP SYSTEM YUM1A YUM2A 8 40 5 Main switch fuse 6 Main fuse 18 Main switch 19 Accelerator switch 20 Fuel pump relay 23 Fuel pump assembly 25 ECU engine control unit 31 Frame ground 35 Battery 38 Engine...

Page 246: ...ge 8 51 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 48 Replace the main switch 4 Check the accelerator switch Refer to...

Page 247: ...FUEL PUMP SYSTEM YUM1A YUM2A 8 42...

Page 248: ...Y R Y R R R R R B B B B B R W R W R W R W R W B B B R Y R Y B B R B R L L O B R R B B B B B R R R B R L R R B B B B B B B W G W B R B W G W R R L R B B B G W B B W L R O L B O B L O B L Y B W R Y Y W...

Page 249: ...witch 12 Tow switch 13 Accelerator switch 15 Shift switch 17 Motor temperature sensor 18 Motor speed sensor 19 Traction motor 20 MCU motor control unit 21 MCU fuse 24 Main fuse 25 TPS throttle positio...

Page 250: ...als Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the tow switch Refer to CHECKING THE SWITCHES on page 8 61 Repla...

Page 251: ...DRIVE SYSTEM YUM2E 8 46 NG OK 9 Check the entire drive system wiring Refer to CIRCUIT DIAGRAM on page 8 43 Properly connect or replace the drive sys tem wiring Replace the traction motor or MCU...

Page 252: ...Lighting fuse 7 Fuel pump relay 8 ECU engine control unit 9 Main relay 10 Voltage regulator 11 Intake air pressure sensor 12 Intake air temperature sensor 13 Starter generator 14 Engine temperature se...

Page 253: ...MPONENTS YUM1A YUM2A 8 48 CHECKING THE SWITCHES B R PIN 1 4 Br R 3 2 WIRE COLOR OFF ON H L SW R Y G B OFF ON R YG B Br R W 1 2 3 4 5 1 Light switch 2 Main switch 3 Reverse switch 4 Accelerator switch...

Page 254: ...switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are sh...

Page 255: ...Replace Blown fuse a Turn the main switch to OFF b Install a new fuse of the correct amperage rating c Set on the switches to verify if the electri cal circuit is operational d If the fuse immediatel...

Page 256: ...id battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged according to the appropriate charging method If the battery is over charged t...

Page 257: ...ay generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the...

Page 258: ...with a wire brush Loose connection Connect properly 9 Install Under seat panel Seat cushion Refer to GENERAL CHASSIS 1 on page 4 1 CHECKING THE RELAYS Check each switch for continuity with the digita...

Page 259: ...sistance Out of specification Replace a Disconnect the spark plug cap from the ig nition coil b Connect the digital circuit tester to the igni tion coil as shown c Measure the secondary coil resistanc...

Page 260: ...ft position sensor coupler as shown b Measure the crankshaft position sensor resistance CHECKING THE STARTER GENERATOR OPERATION 1 Check Starter generator operation Does not operate Perform the electr...

Page 261: ...pump assembly from the fuel tank 3 Check Fuel sender resistance Out of specification Replace the fuel pump assembly a Connect the digital circuit tester to the fuel sender terminals as shown b Move t...

Page 262: ...ce a thermometer 3 in the water d Heat the water or let it cool down to the specified temperatures e Measure the engine temperature sensor resistance 3 Install Engine temperature sensor CHECKING THE I...

Page 263: ...e sensor terminals do not get wet c Place a thermometer 3 in the water d Heat the water or let it cool down to the specified temperatures e Measure the intake air temperature sen sor resistance CHECKI...

Page 264: ...Replace a Check the oil level switch for no continuity b Drain the engine oil c Check the oil level switch for continuity Digital circuit tester CD732 90890 03243 Model 88 Multimeter with ta chometer...

Page 265: ...ning light 2 Light switch 3 Shift switch 4 Main switch 5 Battery 6 Tow switch 7 Voltage regulator 8 Main relay 9 MCU motor control unit 10 Motor temperature sensor 11 Motor speed sensor 12 Traction mo...

Page 266: ...OMPONENTS YUM2E 8 61 CHECKING THE SWITCHES OFF ON R R Y OFF ON W Y R Y REV FWD Br R W R Y G B OFF ON R YG B 4 2 3 5 6 1 1 Light switch 2 Main switch 3 Shift switch 4 Tow switch 5 Accelerator switch 6...

Page 267: ...mage the leads TIP When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example o...

Page 268: ...the lighting and ignition systems to malfunction and could possibly cause a fire 4 Lower the cargo bed CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain...

Page 269: ...t smoke when charging or handling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Always wear protective clothing gloves and goggles when handling batteries and elec trolyte and when...

Page 270: ...TS YUM2E 8 65 BATTERY CHARGER YAMAHA PROVIDED CHARGER Charger Safety Read the following label located on the top of the charger before operating or using the charger and promptly replace the label if...

Page 271: ...ll charge without excess gassing Step 5 Storage Keep the charger plugged into the AC outlet and the Yamaha vehicle while in storage Af ter 14 days from the last charge if the voltage becomes less than...

Page 272: ...AC cord set must be connected to an appropriate receptacle that is properly installed and grounded in accor dance with the National Electrical Code and all local codes and ordinances WARNING Improper...

Page 273: ...around battery is well ventilated while battery is being charged The operating instructions printed on the char ger as depicted below are for daily reference The charger is factory preset to use with...

Page 274: ...Displays approximate scale of current out put during Step 2 High internal charger temperature Current output reduced 80 Charge b Amber 80 charged Step 2 complete Begin Step 3 With no battery connecte...

Page 275: ...Check battery size and condition and reset charger interrupt DC connection for 15 seconds Battery Low Voltage Check battery size and condition and reset charger interrupt DC connection for 15 seconds...

Page 276: ...er AC On LED is illuminated Incorrect wiring or disconnection from DC cord receptacle and bat teries Battery voltage less than 20 V Ensure polarity for wiring is correct from DC cord receptacle and ba...

Page 277: ...rly connected and grounded see charger s owner s manual in sert the DC output into the golf car recepta cle WARNING Do not disconnect the DC output cord from the battery receptacle when the charger is...

Page 278: ...The battery has a bad cell Batteries in these conditions should be taken to a specialist for further evaluation or retired from service Discharge Load Test WARNING Batteries generate explosive hydrog...

Page 279: ...logic board ensure the accu rate measurement and display of the information you need It can be programmed to shut off with time or voltage Discharge data can be viewed on the display or with a termina...

Page 280: ...urements you just recorded A differ ence of 0 5 V from the highest to lowest mea surement indicates a weak battery WARNING If the fan is running and you disconnect the unit a spark will be produced an...

Page 281: ...97 101 105 80 80 83 85 88 92 95 99 103 75 75 77 80 83 86 89 93 97 101 105 70 70 72 75 77 80 83 87 90 94 98 103 65 65 67 69 72 75 77 80 84 87 91 96 60 60 62 64 66 69 71 74 77 81 84 88 55 55 57 59 61 63...

Page 282: ...sure the cables do not lay across the battery vent caps Install the negative battery cable last 6 Using one battery lifting strap install each battery NOTICE Do not over tighten the battery hold down...

Page 283: ...ecification Replace the throttle position sensor a Connect the digital circuit tester to the throttle position sensor terminals as shown b Measure the throttle position sensor max imum resistance 3 In...

Page 284: ...ELECTRICAL COMPONENTS YUM2E 8 79...

Page 285: ...ON CHART YUM1A YUM2A 9 4 TROUBLESHOOTING YUM2E 9 6 GENERAL INFORMATION 9 6 POOR PERFORMANCE 9 6 POOR BRAKING PERFORMANCE 9 6 FAULTY SHOCK ABSORBER ASSEMBLY 9 6 UNSTABLE HANDLING 9 6 FAULTY LIGHTING SY...

Page 286: ...k breather hose joint Clogged fuel tank breather hose joint hose Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel pump relay Clogged or damaged fuel hose 3 Throttle body Dete...

Page 287: ...6 Secondary sliding sheave Worn secondary sliding sheave OVERHEATING Engine 1 Clogged cooling air passages 2 Cylinder head and piston Heavy carbon buildup 3 Engine oil Incorrect oil level Incorrect oi...

Page 288: ...ressures left and right Incorrect tire pressure Uneven tire wear 5 Wheel s Damaged wheel bearing Bent or loose wheel axle Excessive wheel runout 6 Frame Bent frame Damaged frame FAULTY LIGHTING SYSTEM...

Page 289: ...or open or short circuit ECU Wire harness Incorrectly installed sensor Yes D11 28 Engine temperature sensor Abnormal engine temperature values Engine temperature sensor open or short circuit ECU Wire...

Page 290: ...mode D70 Indicate the software version D91 Integration time of engine operation 100 100 hour 1 Indicate the time unit of 100 hour D92 Integration time of engine operation 1 1 1 hour Indicate the time...

Page 291: ...unction Fatigued or damaged shock absorber spring Bent or damaged damper rod Leaking oil UNSTABLE HANDLING 1 Steering wheel Bent or improperly installed steering wheel 2 Steering components Incorrect...

Page 292: ...uzzer 9 Red Motor speed sensor 10 White Motor speed sensor 11 Green Motor speed sensor 12 Red White Main switch 13 Brown Accelerator switch 14 Black Motor temperature sensor 15 White Motor temperature...

Page 293: ...unit MCU The PC genius diagnostic system is used in con junction with a computer running Windows not included The transfer of data from the car s MCU is accomplished by using a CAN BUS de vice for th...

Page 294: ...n will appear Help button The Help screen will appear with the following 13 topics When open the help screen click the Help button 1 Topics Check adapter before connection Communicating dialog Read bu...

Page 295: ...cation method is IrDA data is saved into PCG file When the method is CAN data is saved into CSV file Save As button User is prompted for saving destination Other functions are same as save button Open...

Page 296: ...ostic tool and check if any errors are continuously occurring OK Go to step 5 NG Go to step 3 3 Wire harness continuity Open or short circuit Properly connect or replace the wire harness Between the m...

Page 297: ...hicle stopped on page 9 23 Fault code No 22 Display name Over voltage Symptom Over voltage battery voltage failure Vehicle stopped Step Inspection items Diagnostic procedure Confirmation steps after d...

Page 298: ...ation check Set the TOW switch to RUN the main switch to ON depress the accelerator pedal and check if the vehicle runs OK Maintenance job completion NG Refer to Vehicle stopped on page 9 23 Fault cod...

Page 299: ...epress the accelerator pedal and check if the vehicle runs OK Maintenance job completion NG Refer to Vehicle stopped on page 9 23 Fault code No 29 30 31 33 Display name MCU internal error Symptom 29 D...

Page 300: ...ect the PC Genius diagnostic tool and check if any errors are continuously occurring OK Go to step 5 NG Go to step 4 4 Malfunction in MCU Replace the MCU Go to step 4 5 Operation check Set the TOW swi...

Page 301: ...ction items Diagnostic procedure Confirmation steps after diagnostic procedure 1 Resetting the MCU Cycle the TOW switch off and on RUN TOW RUN Connect the PC Genius diagnostic tool and check if any er...

Page 302: ...onfirmation steps after diagnostic procedure 1 Resetting the MCU Cycle the TOW switch off and on RUN TOW RUN Connect the PC Genius diagnostic tool and check if any errors are continuously occurring OK...

Page 303: ...main relay Refer to CHECKING THE RELAYS on page 8 77 Replace if defective Connect the PC Genius diagnostic tool and check if any errors are continuously occurring Go to step 3 3 Operation check Set th...

Page 304: ...K Go to step 6 NG Go to step 5 5 Wire harness continuity Open or short circuit Properly connect or replace the wire harness Between the battery terminal and the main fuse terminal Red Red Between the...

Page 305: ...k Set the TOW switch to RUN the main switch to ON depress the accelerator pedal and check if the vehicle runs OK Maintenance job completion NG Refer to Vehicle stopped on page 9 23 Fault code No 42 Di...

Page 306: ...runs OK Maintenance job completion NG Refer to Vehicle stopped on page 9 23 Fault code No 44 Display name Speed sensor error Symptom Motor speed sensor malfunction Vehicle stopped Step Inspection ite...

Page 307: ...r speed sensor failure Replace the motor speed sensor Connect the PC Genius diagnostic tool and check if any errors are continuously occurring OK Go to step 4 NG Go to step 3 3 Wire harness continuity...

Page 308: ...ace if defective No malfunctions were found Go to step 3 Repair the malfunctions Go to step 5 3 Wire harness continuity Open or short circuit Properly connect or replace the wire harness Between the M...

Page 309: ...egeneration MCU heat protection 26 Motor circuit short Interphase short circuit Motor output shut off vehicle stopped no regeneration Short circuit of the cable between the motor and MCU due to incorr...

Page 310: ...tion Vehicle stopped with regeneration Battery low voltage 41 Low voltage Low voltage failure Vehicle stopped with regeneration Battery low voltage 42 High voltage Over voltage failure Motor output sh...

Page 311: ...the OFF position while pro gramming otherwise a communication error will appear 1 Select the PC genius programmer icon on your laptop PC 2 The intro screen will appear automatically PC genius is auto...

Page 312: ...ode button 1 The user selects the intended mode number The number will flash green for the intended setting 1 2 When you clicked Set Mode button 2 PC genius start to communicate to the MCU 3 When comm...

Page 313: ...PC GENIUS GOLF CAR PROGRAMMING SYSTEM YUM2E 9 28...

Page 314: ...ine ground COLOR CODE YUM2E 1 Tail light left option 2 Tail light right option 3 Deluxe lighting kit option 4 Headlight right 5 Headlight left 6 Light switch 7 Horn 8 Horn switch 9 Voltage regulator 1...

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Page 317: ...B R R W W Y R O Br B R R O G B R G R W R W G B B R W R W R W R W R W R W R W R G R G W R B W B W B W R Y O W G W G P R Y O W P G B W G W B W W R Br W B Y B B B W B W B W B Y B B B R R W O B W O W G W...

Page 318: ...YUM1A YUM2A WIRING DIAGRAM PIN 1 4 Br R 3 2 WIRE COLOR OFF ON H L SW 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 10...

Page 319: ...Y R Y R Y R Y R R R R R B B B B B B B B W R W R W R W R W R W B B B B R R Y R Y R Y R Y B B B R B R L L O Gy B R R R B B Gy B R B B B R R R B R L R R B B B B B B B Gy Gy B W G W B R B W G W R R L R B...

Page 320: ...YUM2E WIRING DIAGRAM OFF ON Br OFF ON R W R Y REV FWD Y W R OFF ON R Y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28...