YAMAHA

SERVICE MANUAL
@YAMAHA
GOLF CAR
GI-AM3
EXHAUST VALVE

1. Cylinder
2. Piston
3. Ring nut ass'y
4. Shaft
View in direct~onof A 5. Butterfly exhaust valve
6. Exhaust plpe
7. Plug
8. Bear~ng
9. Gasket
10. Gasket cover
11. Lever
12. Locknut
13. Exhaust pipe spring
14. Speed limiter lever
15. Speed adjust screw
16. Rod ass'y 2
17. Connector comp. (crank)
18. Clamp
19. Rod ass'y 1
20. Return spring
21. Locknut
22. Locknut
23. Torsion spring
24. Throttle wire ass'y
Fig. 1 25. Choke wire ass'y
26. Cl~p
27. Stopper

Fig. 2
A. ADJUSTMENTS

View in direction of B

Fig. 3

1. Locknut 6. Connector arm 11. Lever

2. Joint rod 7. Clamp 12. Butterfly valve
3. Speed adjust screw 8. Connector rod 2 13. Exhaust flange
4. Governor lever 9. Return spring 14. Exhaust pipe
5. Connecter rod 1 10. Shaft

NOTE: 2. Setting the engine idle speed

Before adjusting, remove the return spring
installed between connector rod 2 and the
exhaust pipe.
1. Setting the governor lever
Adjust the length of the joint rod 1 so when
the accelerator pedal is fully depressed, and the
governor lwer is turned counterclockwise,
the carburetor thorttle valve just reaches the
fully open position. (To adjust the joint rod
length, loosen two locknuts, adjust the
length, then tighten the locknuts.)
With the V-belt removed, make sure the
engine idles a t 1,200 rlmin. (When the V-belt
is mounted, the idling speed i s 1,000 rlmin.)
If not, make an idle speed adjustment by
turning the throttle stop screw.
While making this idle speed adjustment, the
engine speed will not affect the opening of
the butterfly valve (exhaust valve).
3. Exhaust valve setting
Adjust the length of connector rod so when
the governor lever returns t o the closed posi-
tion, the butterfly valve in the exhaust port
closes completely. (To adjust the length of
connector rod 1, loosen two locknuts, and
after adjusting, tighten the locknuts.)
T o check that the exhaust valve is completely
closed, remove the exhaust pipe. The valve
-
distance A = distance A ' = 1 9 mm (0.75 in)
distance B = 20 25 mm (0.79 - 0 . 9 8 in)
4. Adjusting the throttle wire
Adjust the throttle wire so when the accelera-
tor pedal is fully depressed, the carburetor
throttle just reaches fu II-open position.
NOTE:
After adjusting the throttle wire, install the
return spring between connector rod 2, and
the exhaust pipe.
5. Governor adjustment
Fig. 5
1. Adjusting screw 2. Governor lever
position can be checked by looking into the
exhaust flange. As shown in Fig. 1, check the
valve position. The screw head should face the
exhaust pipe.
To facilitate checking the exhaust valve in the
full-closed position, prepare a tool as shown
in Fig. 4
1. Butterfly valve
2. Shaft
3. Exhaust flange
4. Engine
5. Plate
6. Bolt (or Screw)
7. Locknut
8. Stopper pin
Adjust the car speed by turning the adjusting
screw in either direction. The maximum
amount of adjustment is about 4.8 kmlh
( * 3 m.p.h.1
Tightening the adjust screw increases the
speed; loosening it decreases the speed.
Approx. 2,700 r/min at 19.2 kmlh
(12 m.p.h.) on hard, level surface.
After this operation, check the following
points:
Check whether both links and butterfly
valve move smoothly.
Check whether the links move beyond
dead center, and become locked.
Check for abnormal noise from the but-
terfly valve and related parts.
6. Rod assembly 2 adjustment
Adjust the rod ass'y 2 length by turning the
shaft so that when the throttle valve is a t a
closed (idle) position (by pushing the speed
limiter lever slightly), the exhaust valve is a t a
closed position as illustrated on the next page.
Tighten the locknut, keeping the plastic ends
at a 90" angle to each other.

GOOD
Carb. throttle valve position at idling

ENGINE
NOTE:
Check t o see that when the throttle valve i s
fully open, the exhaust valve is also fully
open.

B. DISASSEMBLY AND ASSEMBLY

In general, except when links are damaged or
the joint is extremely worn, neither removal
nor disassembly is necessary. When dismoun-
ting the engine from the chassis or reassembl-
ing links after replacing parts, the adjustments
specified in D, above must be performed.

1. The link adjustment should be made

only by adjusting the length of the joint
rod and connector rod 1. I t is unneces-
sary to adjust the length of connector
rod 2 because it is already adjusted by
the factory.

Standard eye-to eye distance of con-

nector rod (2): 179 mm (7 in)

2. As illustrated, the bracket should be in-

stalled with the open end facing down-
ward, and all joints should be installed
squarely facing the ball so that move-
ment is free throughout i t s operating
range.

Bracket Joint

3. Do not apply grease t o the contact sur-

face of the joint.
 SPECI FICATIONS

A. General

Model
GI -AM3
Item
Model:
Code No. J24
Frame I.D. No. & Starting NO. J24-000 101
Engine I.D. No. & Starting No. J24-000 101

Dimensions:
Overall length 2,403 mm (94.6 in)
Overall width 1,140 mm (44.9 in)
Overall height (steering height) 1,180 mm (46.5 in)
Height of floor 295 mm (11.6 in)
Height of seat from floor 428 mm (16.9 in)
Wheel base 1,550 mm (61.0 in)
Tread: Front 900 mm (35.4 in)
Rear 900.mm (35.4 in)
Min. ground clearance 1 110 mm ( 4.3 in)
Weight:
Dry weight
Performance:
Maximum loading limit 340 kg (750 Ib)
Maximum speed 19 kmlh (12 mph)
Starter generator red zone 4,000 rlmin (25 kmlh)
Cranking speed Appx. 800 rlmin
Minimum turning radius 3,000 mm (118 in)
Braking distance 4,500 mm (177 in) at 19 kmlh (12 mph)
Seating capacity 2 persons
Hill climbing ability 30" (57%grade) on pavement
Fuel consumption 20 kmlP at 19 km/h on pavement
Oil consumption 4,500 km/P at 19 kmlh on pavement

6. Engine
-

Description:
- .
Model
G1-AM3

Engine type Reversible, 2-stroke, Gasoline, 7-port piston reed valve

Number of cylinder Forward-inclined, Single
Displacement 214 cm3 (13.06 cu.in)
Bore x Stroke 68 x 59 mm (2.68 x 2.32 in)
Compression ratio 5.7 : 1
Cooling system Forced air cooled
Starting system Normal & Reversible starter generator
Ignition system C.D.I.
Lubrication system "Autolube" oil injection

Cylinder head:
Combustion chamber volume (with spark plug) 31.3 cm3 (1.91 cu.in)
Compression chamber type Dome + Squish
Head gasket thickness 0.6 mm (0.024 in)
 Model
GI-AM3
Item
Cylinder:
Material Cast iron sleeved aluminum
Bore size 68 mm (2.677 in)
Taper limit 0.05 mm (0.0020 in)
Out of round limit 0.01 mm (0.0004 in)
Piston:
Piston skirt clearance (measuring point) Std. -
0.030 0.035 mm (0.0012 0.0014 in)-
(10 mm (0.39 in) from piston skirt end)
Max. 0.1 mm (0.0039 in)
Piston oversize 1st. 68.25 mm (2.687 in)
2nd. 68.50 mm (2.697 in)
Piston pin outside diameter x Length 4 1 8 x 55 mm (40.709 x 2.165in)
Piston ring:
Piston ring design (Top)/l.D. mark Kevstonel" RN"
Piston ring design (2nd)ll.D. mark

Ring end gap (installed)(Top)

(2nd)
Keystone1"R"
-
0.2 0.4 rnrn (0.008
-
0.2 0.4 mm (0.008
-- 0.016 in)
0.016 in)
Small end bearing:
Needle bearing
Big end bearing:
I Type I Needle bearing
Crankshaft: I
+O
Crankshaft assembly width ( A ) 56 TE.05mm (2.20 -0.002 in)
Crankshaft deflection ( 0 )
Connecting rod big end side clearnace (C)
Connecting rod small end deflection (P)Max.
0.02 mm (0.008 in)
0.25- 0.75 rnm (0.010
2.0 mm (0.079 in)
- 0.030 in)

CLUTCH SIDE

40 rnrn (1.57 in)

Crank pin outside diameter x Length

Crankpin type
1 00'945-0.0005 x 2 . 1 6 5 2 : ~in)
Solid shaft
~ ~ ~

Crank bearing type (Left) x Q'ty #6306 c3 (Nylon retainer) x 1 pc

Crank bearing type (Right) x Q'ty #6306 c3 (Nylon retainer) x 1 pc
Crank oil seal type (Left) x Q'ty FPJSO 72 8 x 1 PC
Crank oil seal type (Right) x Q'ty FPJ-30 48 8 x 1 PC
 Model
- G I -AM3

Air cleaner:
Element type Wet paper with element cover
Element assembly PIN J10-14450-10
Element cover PIN J10-14417-00

Intake reed valve:

Type "V" type
A t rest open limit 0.3 mm (0.012 in)
Valve l i f t 10.4 f 0.2 mm (0.409 f 0.0078 in)

Choke cable:
Free play 1 mm (0.04 in)

Carburetor:
ModelIMaker BV21-161MIKUNI
PINO. J24-14101-00
I.D. mark J2400
Venturi diameter (Ven. T.) 4 16
Main jet (M.J.) #97.5
Air jet (A.J.) 41.2
Main nozzle. (M.N.) 2B
Pilot jet (P.J.) #42.5
Pilot air jet (P.A.J.) 4 1.o
Throttle valve (Th.V.) # 100
Valve seat (V.S.) 41.0
By-pass (1 ) (B.P.-1) 4 0.8
By-pass (2) (B.P.-2) $0.7
Pilot outlet (P.O.) 41.1
Pilot screw (P.S.) 1 and 318 turn out
Float height (F.H.) 18 mm (0.7 in)
Engine idling speed" 1,200 rlmin

Fuel pump:
Part No. J10-24410-02
ManufacturerIType MIKUNIIDF-36 (Diaphragm)

Fuel tank:
Fuel grade Any grade gasoline
Fuel tank capacity 25.5 L (5.6 Imp gal, 6.7 US gal)
Fuel tank position Front of left rear wheel
MaterialIColor PolyethyleneIBlack
Gauge position 1 Side of filler cap
Lubrication system: Separated lubrication
Autolube pump - Type YAMAHA Automatic oil injection system
(controlled by exhaust pressure)
- Color code Pink
- Minimum stroke - -
0.50 0.55 mm (0.020 0.022 in)
- Maximum stroke - -
1.80 1.85 mm (0.071 0.073 in)
- Reduction ratio 111.9 x 1/84
Max. output (690 mmAg exhaust pipe 111) Approx. 21 .Icm3/h at 3,250 rlmin
Max. output (0 mmAg exhaust pipe Min.) Approx. 5.9 cm3/h at 3,250 r/min
Mixing ratio 150 : 1 at Max. Dower
-4
Model
G I -AM3
Item
Oil tank:
Oil Yamalube Golf Car oil or if not available, any two
stroke oil that is B.I.A. certified for service T.C.W.
Oil tank capacity 1.7 L (1.5 Imp qt, 1.8 US qt)
Oil tank position Top of left rear fender
MaterialIColor Polyethylene/White
Jet senser:
TYpe One hole (G0.85) orifice plate type with cleaner: Wire
Pipe dia.1Material 4 6.35 mm (0.25 in)lStainless

C. Transmission

Model
GI-AM3
Itern
Transmission:
TYpe V-belt automatic centrifugal engagement
Primary reduction ratio 3.1 : 1 - 0 . 8 : 1
Clutch engagement rlrnin 1,500 rlrnin
Shift rlrnin 3,600 rlmin
Primary spring:
Parts No. 90501-32557
Outside dia. x Wire dia. 42.9 x 3.2 rnrn (1.69 x 0.126 in)
Set IoadISpring rate 7.8 kg10.372 kglrnm
No of turnslfree length 6.5182 rnm (2.95 in)
Color code Cr plated (Silver)
Secondary spring:
Part No. 90501-45600
Outside dia. x Wire dia. 54.5 x 4.5 rnrn (2.15 x 0.177 in)
No. of turnslfree length 6.371101 rnrn (3.98 in)
Color code Cr plated (Gold)
Torque cam angle Forward 50 deglReverse 45 deg
Sheave center to center distance 231 mrn (9.09 in)
Sheave offset 26 mrn (1.02 in)
V-belt part No. J17-46241-00
V-belt width and outer line length 31 x 925 rnrn (1.22 x 36.4 in)
V-belt wear limit 27 rnm (1.06 in)
-

DifferentialIReduction gear:
Secondary reduction system 1 Helical gear
Secondary reduction ratio 2.952 x 4.588
Differential type SPUR gear 4 pinion
Lubricantlcapacity SAE 90 Gear oil1800 crn3 (27 02.)
Governor:
TYpe Oil bath flyweight
Adjustment Screw with locknut
Factory speed setting 19 krnlh (12 rnph)
-
D. Chassis
- Model G1-AM3
Item
Frame:
Type Ladder type pipe structure
Material Tubular steel (STKM)
Color Yamaha Black

Front cowl:
Type (RIM)
Material Urethane
Color lvory white

Rear cowl:
Type Match metal die shell type fiber galss (SMC)
Material Fiber reinforced plastic (FRP)
Color Ivory white

Seat:
Seat cover Material Vinyl chloride leather + Nylon lining
Color Ivory white
Seat cushion Material Urethane foam
Bumper:
Front Steel + EVA end
Rear Steel + EVA end

Steering system:
Type Worm and pin
Steering angle (L, H I 1.4 turn
(R, H) 1.4 turn
Turning radius 3.0 m
Lubricant Type SAE 90 Gear oil
Capacity 150 cc (5.1 oz)

Front axle:
Type Single wish bone
Toe-in 10 ? 5 mm (0.394 f 0.197 in)
Camber 0 deg
Caster 7 deg
Kingpin inclination 3 deg
Rear axle:
Rear wheel axle type Semi-floating split
Toe-in 0 mm (0 in)
Camber 0 deg
Front suspension:
Type Single swingarm (independent suspension)
Coil springs with hydraulic shock absorbers
(Single action type)
Spring rate 3.6 kgfmm
Coil spring free length 185 mm (7.28 in)
Damper type Oil damper (Single actionftension only)
Rear suspension:
Type Axle type trailing arm (Unit swing)
Coil springs with hydraulic shock absorbers
(double action type)
Spring rate 2.1 kgfmm
Coil spring free length 240 mm (9.45 in)
Damper type Oil damper (Double actionfBoth Comp & Tens)
 Model
GI -AM3
Item
Brakes:
Brake system Mechanical brake linkage to individual drum brakes
on each rear wheel with self-adjusting brake shoe.
Dual internal expanding shoe
Method of operation LeadingITrailing shoes (self-adjusting)
Lining thickness StdIMin. 4 mm (0.157 in)/1.5 mm (0.06 in)
Brake drum inside dia. 160 mm (6.30 in)
Linkage adjustment (Brake wire free play) - -
0.1 0.5 mm (0.004 0.020 in)
Parking brake Type Foot type; Parking brake with automatic release
Release timing - -
0 0.5 mm (0 0.02 in)
(Free play of throttle wire end) Lightly depress the accelerator pedal with your hand
(The parking brake i s not released.)
Wheel :
Tire type Front Tubeless (Rib)
(pattern) Rear Tubeless (Block)
Tire size Front 18 x 8.50 - 8.0014 ply rating
Rear 18 x 8.50 - 8.0014 ply rating
Tire pressure FrontIRear 0.8 kg/cm2 (12 psi)
Rim size FrontIRear 7.00 - I - 8.00

E. Electrical

Flywheel magneto (C.D.I. type)

ModelIManufacturer F3T35671lM ITSUBISHI
Pulser coil resistance (Color code) 1 4 ~ + 1 0 % a t 2 0 ~ ~ ( 6(WhiteIRed-Black)
8~~)
4.5V AC @ Cranking speed*
Charging coil resistance (Color code) 350a + 10%a t 20' ( 6 8 ' ~ ) (Brown - Black)
Output (Min.) 40V AC @ Cranking speed*
Ignition timimg Static B.T.D.C. 1.3 mm (0.051 in) by dial indicator

9 mm (0.35 in)/300 rlmin.

11 mm (0.43 in)/3.000 rlmin
Primary winding resistance 1.0a + 15% a t 2 0 ' ~(68" F) (Orange - Black)
Secondary winding resistance 5.9ka ? 15 % at 2 0 " ~(68' F)
(High tension code - Black)
- Diode (Yes or No) No
= Cranking speed approximately 800 rlmin

- 11 -
 GI-AM3

Spark plug:
Type & Quantity NGK BP-6HS x 1 pc
Spark plug gap -
0.6 0.7 rnrn (0.024 - 0.028 in)
Thread size M14x P1.25
Spark plug cap:
T Ype Noise supGessor
Noise suppressor resistance 5kQ 2 15% at 2 0 " ~(68" F)
C.D.I. unit:
ModelIManufacturer F8T 02171/MITSUBISHI
Minimum C.D.I. output 4.OV @ Cranking speed*
Charging StartingISystern:
TYpe Starter generator
ModelIManufacturer GSBI 07-02lHITACH I
Starting output 0.6 kw
Charging output 14V-15A15,OOO rlmin
Armature coil resistance *
0.01 3Q 20% at 2 0 " ~(68" F) (A1 - A2)
Field coil resistance
Shunt coil (Battery charging) 5Q + 10% at 2 0 " ~(68°F) (Red - Green)
Series coil (Starting) 0.006Q ? 20% at 20" C (68" F) (F1 - F2)
Brush port number J10-81111-10
Bursh length StdIMin. 23 rnrn (0.9 in)/16 rnrn (0.63 in)
Spring pressure/Qrty
Commutator outside dia.
700 - -
900 g (24.7 31.7 oz)/4 pcs.
41 + 0.1 rnrn (1.61 + 0.004 in)
Mica undercutINo. of slot 0.7 rnrn (0.028 in)/41 pcs
Voltage regulator:
Type Tillil type
Model/Manufacturer T107-23lHITACH I
Regulated voltage (No load) 14.8 + 0.5V
Voltage regulator
Core gap
Yoke gap
0.6 - 1.0 rnrn (0.0024 -- 0.04 in)
0.9 rnrn (0.035 in)
Point gap - -
0.35 0.45 rnrn (0.014 0.01 8 in)
Voltage coil resistance *
10.3!2 20% at 20°C (68°F)
Soleniod relay:
Model (P/No.)/Manufacturer YZ18 (J17-81950-00)/ASAHI DENS0
Amperage rating 60A
Cut in voltage Less than 8V
Winding resistance 11.8Q + 5% at 2 0 " ~(68" F)
Battery: I
I
For U.S.A. and Canada I For Australia and Japan
I
ModelIManufacturer Group 24 I N-50lFURUKAWA
Capacity (Rating minimum) 12V-48 AH I 12V-50 AH
I
Specific gravity 1.26 1 1.26
Gross weight - 1 15kg
Electrolyte quantity - I 4,500 cc
I
Dimension (W x H x T) 6-314x10-114x9in 1 252~225xl65mm
Terminal description

OQQQOO

= Cranking speed approximately 800 rlmin

- 12 -
 G 1-AM3
l tern
Battery charger:
A.C. Input (House hold use) At your requirement 50160 Hz, 410 VA
D.C. Out put - -
6 12V 20A, 18 24V 10A
Battery charge rating 5% of AH rating
Back buzzer:
TYpe Continuous beep
ModelIManufacturer S-121NIKKO
Frequency 600 2 100 Hz.
Current Less than 0.08A
Fuse:
Plus fuse: ArnperagelQ'ty 10Al1pc plus one spare
Minum fuse: Amperage/Q1ty 10A/l pc plus one spare
10-3. TIGHTENING TORQUE

Part t o be tightened Part name Thread size Remarks

[Engine]
Spark plug
Airshroud x Cylinder head crankcase Bolt Use LoctiteB
Airshroud cylinder 1 x 2 Pan head Use LoctiteB
Cylinder head: First Nut
Final
Cylinder x Exhaust pipe ring nut Bolt
Carburetor x Joint Clamp & Tightening
Pan head steady
Oil pump ass'y x Gear unit ass'y Pan head
Fan x CDI magneto Bolt Use loctitea
Flywheel magneto Nut
Crankcase x Engine bracket Bolt
Crankcase left x Right Pan head

[Crankcase righrening sequence]

[Drive]
Primary sheave cap x Engine Bolt
Secondary sheave x Input shaft Castle nut
Transmission case x Rear arm Bolt
Transmission case x Rear arm housing Bolt
Transmission case 1
Nut
x Transmission case 2
Differential case x Ring gear Bolt
Governor fork x Governor shaft Pan head
[Chassis]
Tension rod x Front lower arm Bolt
Tension rod x Frame Bolt
Front lower arm x Frame Bolt
Rear arm comp. x Frame Bolt
Tie rod x Ball joint Nut
King pin x Steering knuckle Nylon nut
Pitman arm x Idler arm Nylon nut
Steering gear housing x Steering cover Bolt
Steering adjusting bolt x Nut Nut
Wheel x Hub or drum Nut
Back plate ass'y x Rear axle housing Bolt
Back lower support x Hinge Nut

[Electrical]
Battery hold down x Battery Nylon nut
Traction motor terminal x Wire Nut
Relay terminal x Wire Nut
GENERAL TORQUE SPECIFICATIONS General torque
This chart specifies torque for standard fas- specifications
teners with standard I.S.O. pitch threads. (Nut) ("It) Nm 1 m-kg I ft-lb
Torque specifications for special components
or assemblies are included in the applicable
sections of this book. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross fashion, in progressive stages, until full
torque is reached. Unless otherwise specified,
torque specifications call for clean, dry
threads. Components should be a t room
temperature.

CONVERSION TABLES

METRIC TO INCH SYSTEM INCH TO METRIC SYSTEM

Known Multiplier Result Known Multiplier Result
9.807 Nrn Nm 0.10197
mekg
7.233 ft-Ib ft-lb 0.13826
N 0.10197
kg
Ib 0.4535

Imp oz 28.35

-1
129.57
Imp gal 4.545
L (liter) L (liter)
US gal 3.785
1 0.8802 Imp qt Imp qt 1.136
L (liter)
1 1.057 v US q t
N/mm
3.785
0.10197
L (liter)

kg/mm
Ib/in 0.0178
k Pa 0.0102
kg/cm2
psi 0.0703
1 33.3 pa pa 0.0075
mmHg
0.03937 inHg inHg 25.4
I Centigrade ('c) 915 roc) t32 ( Fahrenheit (OF) ( Fahrenheit (OF) 519 (OF) - 32 1 Centigrade (OC)
DEFINITIONS OF TERMS

m-kg = Meter Kilogram(s) (usually torque)

9 = Gram(s)
kg = Kilogram(s) (1000 grams)
L = Liter(s)
cm3 = Cuoic centimeter(s)
(volume or capacity)
kglmm = Kilogram(s) per millimeter
(usually spring compression rate)
kg/cm2 = Kilogram(s) per square centimeter
(pressure)
 INDEX
GENERAL INFORMATION

PERIODIC INSPECTIONS
AND ADJUSTMENTS

ENGINE OVERHAUL

CARBURETION

POWER TRAIN

CHASSIS

ELECTRICAL

ELECTRIC CAR

TROUBLESHOOTING

APPENDIX
 .
CHAPTER 1 GENERAL INFORMATION
1.1 . EXTERNAL VIEW ........................................ 1-1

1.2 . LOCATION OF THE

"CAUTION AND SPECIFICATION LABELS" .................. 1-2

1.3 . DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 . CAR IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.5 . FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
CLUTCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
YAMAHA AUTOLUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

1.6 . SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

1.7 . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

 GENERAL INFORMATION
1-1. EXTERNAL V I E W
1-2. LOCATION OF THE "CAUTION AND
SPECIFICATION LABELS"

( ) indicate label location.

....ForG1-Aonly
*:
For G I - E only
"No asterisks" applies boih G I - A and GI-E.

(Steering handle)
i F r o n t c a l top1
6 b
FOR YOUR SAFETY OPERATING INSTRUCTIONS
[ I n s t r u m e n t panel) SELECT PROPER SWITCH POSITION BEFORE STARTINGTHE CAR.

@r
ALHAVSSET BRAKE BEFORE LEAWILG CAR
ORIVE SLOWLY O h rl$LLS.SLOPES b INCL.LES
AVOIDSrlARP W I C K TURNS
O h L V ZPASSENGERSALLOWED
DO NOT CHANGE 1 CAR STARTSAUTOMATICALLY WHEN ACCELERATOR PEOAL 15
DEPRESSED. AND STOPS WHEN THE PEOAL IS FULLY RELEASED.

KEEP FEET A h D ARMS IhSlDE CAR SWITCH POSITION SET PARKING BRAKE BY FIRMLY DEPRESSING THE TOP SECTION
N O C r l I L O R E h TOOPERATE CAR WHILE CAR IS MOVING OF BRAKE PEDAL WHEN LEAVING CAR. BRAKE AUTOMATICALLY
KEEP PROPER DISTANCE FROM GREENS. TEES b RELEASES WHEN ACCELERATOR PEDAL IS DEPRESSED.
OBSERVE CLUB RULES FOR CAR OPERATION BRINGCAR TO COMPLETE STOP BEFORE REVERSING DIRECTION.
DRIVE STRAIGHT UP AND DOWN INCLINES.
YOU ARE RESPONSIBLE FOR A N Y DAMAGE
I DRIVE SLOWLY WHEN MAKING SHARP TURNS.
WARNING
THIS VEHICLE WAS NOT MANUFACTURED FOR USE
ON PUBLIC STREETS AND W E S NOT COMPLY WlTH
FEDERAL MOTOR VEHICLE SAFETY STANOARDS

@ 1 POISONIDANGER
CAUSES SWERE BURNS 1 APPLICABLE TO PASSENGER CARS.
b

** I S o l e n o ~ cover) ( I n f r o n t of oil tank)

1
d

@ 00 NOT SPRAY @ + NOTICE! THIS CAR IS EOUIPPEDWITH AUTOLUBE

OIL INJECTION SYSTEM DO NOT USE A GASOLINEOIL MIX

I
HIGH PRESSURE WATER F I L L WlTH YAMALUBE 2 OIL
ON THE SOLENOID TOPS
OR UNDER THIS COVER I A 81A. TC-W TYPE O I L C A N BE USED I F YAMALUBE 2 IS NOT AVAILABLEI

CHECK O I L LEVELSIGHT GAUGE DURING SERVICING TO MAINTAIN

PROPER OPERATING LEVEL

[Back o f fuel I l d )
( C o w l s u p p o r t i n g leg I
NOTICE

USE STRAIGHT GASOLINE ONLY CLOSING OF B O D Y . I N S E R T P I N O R

SCREWORIVER IN H O L E
DO NOT USE A G A ~ O L I N E ~ I L M I X

THIS CAR 1s EQUIPPED WITH AUTOLUBE OIL INJECTION SYSTEM

CHECK O I L T A N K LEVEL PERIODICALLY

1-3. DESCRIPTION

rn
Fuelefficient torque Score card holder Back-up buzzer Seat Air cleaner
induction engine \ Fuses \ / /
Golf bag support
Transmission

Beverage holder

ual drum brakes

Choke knob Parking brake pedal mud flap Startergenerator belt injection system

Main switch

Charging receptacle

Beverage holder

Front wheei Front m i d flap Brake G d a l ~ A r e r i e s &istor

 Expanded View of A

I
Expanded View of B

1. Steering wheel Parking brake pedal

2. F r o n t wheel Brake pedal
3. Rear wheel Accelerator pedal
Tire size (Tubeless) Choke k n o b
( F I 1 8 x 8.50-8-4PR Main switch
( R l 1 8 x 8.50-8-4PR Lid
4. Battery Buck u p buzzer
5. Fuel tank Solenoid relay
6. Starter-generator be1t Speed controller
7. Clutch belt Resistor
8. O i l tank Charging receptacle
9. Transmission Motor
10. A i r cleaner
1-4. CAR IDENTIF ICAPION
Frame serial number
The frame serial number is located on the left-
hand side of the rectangular pipe by the rear
bumper. The first three digits identify the
model. This is followed by a dash. The re-
maining digits identify the production num-
ber of the unit.
1. Frame serial number
Engine serial number
The engine serial number is located on the
right-hand side of crank case cover. The prefix
indicates engine type and displacement. The
prefix is followed by a dash and the serial
number. Normally both frame and engine
serial numbers are identical.
Starting engine serial No.
G 1-A3 J17-000101
1-5
1-5. FEATURES
Autolube
Yamaha's exclusive New Autolube Oil Injec-
tion System supplies oil to the engine precise-
ly as it is needed. The gasoline-to-oil ratio is
metered automatically, insuring proper mix-
tures a t all speeds and under all terrain condi-
tions. This means minimum carbon buildup
long engine life, improved combustion effi-
ciency, economical oil consumption, and
decreased exhaust smoke and odor. There's
no more gas and oil mixing hassle, which
means you're ready to move right from the
gas pump to the fairway, eliminating separate
pre-mix storage. The autolube pump is care-
fully adjusted at the factory and does not re-
auire anv adiustment or maintenance.
CDI electronic ignition
A first for gasoline golf cars. Yamaha-designed
solid state Electronic Ignition. Eliminates
points. Spark plug burns cleaner and longer.
The CDI contributes significantly to main-
tenance free operation, and requires no ad-
justment or maintenance.
Quietness
Yamaha is the quietest gasoline golf car on
the market. In almost every respect we have
reduced the noise level of the gasoline golf
car: Our exclusively designed engine operates
a t low RPMs. We have "quiet-tuned" the
muffler and exhaust system. The entire car
has been engineered with silence as a primary
consideration.
Load sensing drive
The automatic centrifugal clutch and the V-
belt torque converter basic design has been
proven by years of reliable high performance
use on other Yamaha recreational vehicles.
Coupled with the high-torque, low speed
engine, this drive system assures supersmooth
starts, easy on both turf and passengers.
Four wheels provide smooth, stable ride
Four low pressure tires and wide contact areas
protect turf and provide a smooth and stable
ride over widely varying terrain.
Ease of service
The body shell is hinged to fully open to the
rear, allowing easy access to the internal
working components.
Durability
The front cowl is made of flexible urethane so
that it can withstand a severe impact.
To increase the wear-resistance of the floor
mat, it contains more fibers. All screws and
floor metallic surfaces are specially treated for
rust-resistance.
Fuel consumption
The engine cylinder, muffler and carburetor
a l l are improved for better fuel economy.
Quietness
Yamaha has used every possible means t o
reduce the operating noise to the lowest pos-
sible level.
Acceleration
The 6-speed control switch allows smooth and
powerful acceleration while reducing contact
surface buring and wear.
Riding comfort
Coil springs and shock absorbers provide
suspension for both front and rear wheels for
greatly improved comfort. This also improves
steering and ensures stability .
ENGINE:
ENGINE DESCRIPTION
The engine used in the Yamaha Golf Car i s
packed with features exemplifying Yamaha's
high level of engineering sophistication ac-
quired through many years of experience in
the manufacture of recreational vehicles. In
order to meet the functional requirements of
the engine, such as quiet operation, climbing
ability, operational economy and durability,
the engine design combines Yamaha's original
torque induction system. Autolube pump
(automatic oil injection), and CDI (capacitor
discharge injection) system.
Features of the Yamaha Golf Car
Outstanding performance under any oper-
ating conditions
Smooth steering and engine operation
Sure engine starting
Clean exhaust, excellent lubrication and
better oil economy due t o Autolube
Quiet engine operation
Engine durability proven with Yamaha
motorcycles and snowmobiles
PRINCIPLES OF ENGINE OPERATION
Two-stroke engine operation involves six pro-
cesses within the engine to produce power
from the gasolinelair mixture. They are:
1. Intake

Reliability
The reliability of Yamaha products is widely
known among users. The direct drive mecha-
nism simplifies the golf car's construction and
increases i t s reliability.

Ease of service
The body shell is hinged to fully open to the
rear, allowing easy access t o the internal
Remark
working components.

Durability
-+
L--
Piston movement
Mixture gas
Exhaust gas

The front cowl is made of flexible urethane so

that it can withstand a severe impact.
To increase the wear-resistance of the floor
mat, it contains more fibers. All screws and
floor metallic surfaces are special1y treated for
rust-resistance.
2. Compression and Intake 6. Transfer and Exhaust

3. Power Each particle of the mixture passes through

each one of these processes in the order listed
above.
All six of these processes occur during one
revolution of the crankshaft. Each of them
"overlaps" a t least one of the other processes.
By examining the following diagram of one
crankshaft revolution you can determine what
is happening within the engine a t any given
time.

4. Crankcase Compression

5. Exhaust
 *
Processes shown inside o f t h e circle
take place inside t h e crankcase.
Processes shown outside o f t h e circle
take place i n t h e cylinder.

-rDC

A well designed muffler system prevents

mixture loss during this time (between
transfer closing and exhaust closing) and
"supercharges" the engine for greater
efficiency.

BDC

There are several types o f two-cycle engines,

including t h e piston valve, rotary valve, and
reed valve types, but each o f t h e m has b o t h
advantages and disadvantages. Yamaha has
succeeded i n improving piston valve engine
performance by adopting a reed valve i n t h e
engine cylinder. Thus, Yamaha's two-cycle
engines are greatly improved w i t h o u t losing
t h e positive features o f piston valve engines.
A reed valve is provided i n t h e inlet p o r t o f a
standard t y p e piston valve engine, and a new
transfer p o r t (called a "7th port") is added t o
t h e upper part o f t h e inlet p o r t .
As a result, t h e engine features high perform-
ance a n d efficiency throughout t h e entire
speed range.
FEATURES OF TORQUE INDUCTION
1. 'The intake timing is controlled by the
reed valve, thus the time during which
the inlet port is open can be increased,
inducing a greater amount of air-fuel
mixture.
2. Better engine response and efficiency
results from eliminating the blow-
back of mixture with the reed valve.
Furthermore, the low speed engine per-
formance, which is an important factor
in operating golf cars, has greatly im-
proved.
GOVERNOR:
3. The scavenging efficiency has been in-
creased by the adoption of the 7th port,
contributing much to better engine per-
formance.
4. The engine has been designed with em-
phasis on the smooth low and medium
speed performance and with the aim of
improved operational economy and
stability.

Throttle cable

Bracket throttle

Speed limiter lever

Governer shaft

Covernor fork
Pan head screw

Governer weight
A. Construction

I J
1. Secondary sheave 3. Lifter 5. Speed limiter lever 7. Throttle valve 9. Torsion spring
2. Weight 4. Governor fork 6. Throttle rod 8. Carburetor 10. Throttle wire
1 1. Rear wheel

B. Operation The car speed is transmitted to the weight

The Yamaha golf car is equipped with a speed assembly through the secondary shaft from
limiter. This speed limiter automatically con- the rear wheel.
trols the maximum car speed to about 12 The weight assembly turns according to the
MPH (19 kmlh) so smooth and quiet opera- car speed, and centrifugal force is produced
tion can be ensured. by the weights installed in the weight assem-
The main parts of the speed limiter are bly.
housed in the transmission case. By this centrifugal force, the weights are
thrown outward and cause the lifter to move
- - - - - - - - - - - -- - - - -- - - - -- - - - - - - - - - - 7 the fork so that the throttle valve opening i s
I Function (Parts) I
I
L _ _ _ _ - _ _ _________________ _--____ I
control led.
The force applied to the accelerator pedal is
1 Car speed detection (Secondary shaft) 1 transmitted to the throttle valve through the
spring.
I Turn
Weight retainer
( assembly
When the car speed exceeds 12 MPH (about
19 kmlh), the centrifugal force of the weights

1 Collar is moved b y
centrifugal foce
(Weight)
(2) increases, and the force on the fork (4)
and lever (5) also increases.
The force produced overcomes the force of
Movement of weight
the spring (9), and causes the throttle valve
(Lifter) (7) to close partially as required. Thus the car
is transmitted t o fork
0 speed can be controlled to lower than 12

I Throttle valve is
controlled
(Rod)
MPH.

Engine output is Carburetor throttle

controlled ( valve
1

1-10
CLUTCHES:
A. Construction
FWD

1. Primary fixed sheave

2. Primary sliding sheave
3. Weight
OUTPUT 4. Sheave cap
5. Compression spring
6. V-belt
7. Secondary fixed sheave
8. Secondary sliding sheave
9. Rampshoe
10. R a m p shoe
11. Compression spring

B. Operation
The primary clutch assembly is mounted on
the engine crankshaft, and the secondary
clutch assembly is secured to the input shaft
of the transmission.
1. Idling
As the engine starts, the primary sheave
assembly mounted on the crankshaft
rotates.
POWER
At the same time, the weights are turned INPUT
and thrown outward by centrifugal
force, but the force is not yet sufficient
to overcome the spring force. Thus the
sliding sheave is still kept in the open
position.
 Clutch-in
When the engine speed rises t o about
1,100 - 1,200 r/min the centrifugal
force of the weights overcomes the force
of compression spring and causes the
weights t o push the sliding sheave to-
ward the fixed sheave. As a result, the V-
belt is firmly held by both sliding and
fixed sheaves, and the golf car begins t o
move.
Primary Clutch Assembly
nput
LOW SPEED Low Spee
3. High speed
When the engine speed further increases,
the centrifugal force of the weights also
increases, and the sliding sheave is push-
ed, further toward the fixed sheave.
This forces the V-belt outward, and the
reduction ratio decreases, thus causing
the secondary sheave t o turn faster, and
the golf car speed t o increase.
* On the Yamaha Golf Car, the reduc-
tion ratio automatically changes be-
tween 3.1 :1 and 0.8: 1.
Dl FFERENTIAL:

Transmission case 2

Straight screw plug

Differential pinion

Transmisison case 1

Counter shaft
A. Construction
Transmission (Reduction gear, differential
gear) diagram

1. Transmission case
2. Counter gear
3. Ring gear
4. SidegearB
5. Pinion gear (b)
6. Rear axle
7. Pinion gear (b')
8. Differential case
9. Pinion gear (a')
10. Pinion gear (a)
11. Side gear A
12. Counter gear shaft
13. Counter gear
14. l n p u t shaft
15. Inputgear
16. Reduction gear
17. Differential gear

O n t h e Yamaha golf car transmission, t h e re- B. Operation

d u c t i o n gear and differential gear are housed 1. Forward
i n t h e transmission case. l n p u t shaft
T h e differential gear consists o f spur gears,
instead o f standard bevel gears, and t h u s it is R e d u c t i o n gear section 4
b u i l t compactly. T h e differential gear also
features exceptional durability, l o w noise and
1I Gear i n p u t
Counter gear 1
Counter aear 2 I I
easy access f o r service. D i f f e r e n t i a l gear section 1

1 Side gear
(A, B l 1 p i n i o n gears
a. a'. b. b')

1 Rear axle 1

When t h e car is driven forward, t h e engine

power is carried o n t h e secondary shaft.
-. T h e shaft speed is reduced one step by
1. Governor assembly 5. Counter gear 2
( f o r speed limiter) 6. R i n g gear t h e reduction gear, t h e n t h e engine power is
2. I n p u t shaft 7. Pinion gear (a, a') transmitted t o t h e differential gear.
3. Counter gear 8. Pinion gear (b, b')
4. Counter gear shaft 9. Differential case I n t h e differential gear, t h e ring gear (dif-
ferential case, p i n i o n gear, a, a', b, b') turns
together w i t h t h e side gears, A and B, and
axle shaft.
 faster than the other)
The differential pinion gear is in mesh
with the side gears and turns, and per-
mits the outer rear wheel to turn more
rapidly than the inner rear wheel.
C

BRAKES:

BRAKE SYSTEM INCLUDING PARKING

BRAKE
The Yamaha Golf Car brake system consists
B Side gear B b. Pinion gears (b, b') of the main brake and parking brake.
C Ring gear
These brakes are of a mechanical drum type
2. Rounding a Curve (Operation of dif- which features high reliability and easy adjust-
ferential when one rear wheel turns ment.

rake cable (LIH)

Parking brake sector

e arm comp.
REAR DRUM BRAKE

Brake shoe comp.

SELF-ADJUSTING BRAKE

Guide groove for

brake shoe
A. Construction

Pivot adjuster assembly

Tension spring (upper, large)

Shoe clamp spring Tension spring (lower, small)

Shoe clamp spring

Shoe holddown pin

Shoe hold-down pin

Brake shoe (drive)

Back plate sub-assembly

Brake shoe (driven)
Brake lever

The back plate assembly made up of the

brake shoe (2 pcs.), tension springs (2pcs.),
adjuster assembly, brake lever etc.

Brake arm complete

Brake cable ( R I H )

Brake cable ( L I H )
Brake pawl

The parking pedal is fitted to the top of the

brake arm so that brake operation when park-
ing the car is easy. The rear wheel brake i s
operated by the brake cable whose housing is
secured to the frame with a circlip. The inner
cable i s connected to the brake equalizer with
a pin.
The brake arm is connected to the equalizer
by a rod for sure operation.
B. Operation
When the brake pedal is depressed, the equal- cables, both right and left, are pulled evenly
izer is pulled by the rod, so that the brake by the equalizer.

The brake lever (2) which is pulled by the force F, and the brake shoe (b) by the force
brake cable (4) turns upon the pin (3). F', that is, both brake shoes are forced against
The brake shoe (a) is pushed outward by the the brake drum, braking the rear wheels.
BRAKE ADJUSTER SERVICE
There is a self-adjusting assembly in the
lower side of the brake plate. On one side i s a
bolt and ratchet unit.
C. Operation of parking brake
Depress the brake pedal (1) so the brake is
applied, and then depress the parking pedal
(2).In this case, only the parking pedal can be
depressed, and the parking brake sector is
pushed backward. As a result, the parking
brake sector comes in mesh with the locking
pawl and locks the wheels. To release the
parking brake, depressthe accelerator pedal.
(The locking pawl is connected directly to the
accelerator pedal shaft. When the accelerator
pedal is depressed, the locking pawl turns and
comes off the parking brake sector and the
parking brake is released.)

1. Brake arm 3. Locking pawl

2. Parking pedal 4. Parking brake sector
YAMAHA AUTOLUBE B. Autolube pump mechanism
LUBRICATION METHOD
A. Description of autolube pump (Autolubri- 1. Pre-mixed fuel lubrication (Standard
cation system) t y pel
PURPOSE OF THE AUTOLUBE
The Yamaha Golf Car employs an oil injec-
tion system called "Yamaha Autolube Pump"
1
Premixed fuel

which is a revolutionary new lubrication

device for golf cars.
The adoption of the Yamaha Autolube Pump
in golf cars eliminates the following problems:
Pre-mixingof oil with gasoline
Smoky exhaust and offensive smell of ex-
-+ Lubrication ~
haust gases 2. Yamaha Autolube
Inadequate or excessive oil supply
The Autolube Pump will thus greatly con-
tribute to golf link environmental protection
and enjoyable golfing.
MERITS OF THE AUTOLUBE
1 Fuel tank
Gasoline Yamalube 2

1. Oil supply to meet the demand of the

( Carburetor 1 I o i l pump I
engine
The Autolube Pump supplies an opti-
Atomization
I I Suctionldischarge
(Automatic)

mum quantity of oil depending on the

engine speed and load (Output). Engine
2. Reduced exhaust smoke and offensive
exhaust gases. By supplying an optimum
quantity of oil, the gasoline-oil ratio can
-
be maintained between 150:l 300:1,
and exhaust smoke and offensive smell is
reduced. In addition, maintenance fre-
quency for the spark plug, cylinder and
piston is reduced because of decreased
carbon deposits.
3. As the quantity of oil contained in gas-
oline particles is decreased, the fuel com-
bustion efficiency is improved. (The re-
sult is better fuel economy.)
4. Oil consumption is reduced
An optimum quantity of oil is supplied
depending on the engine demand. Oil
consumption is reduced to about half
that of the pre-mix lubrication. Oil use is
approximately 2,000 kmlliter (1,900
kmlqt). (There will be a slight difference
from golf course to golf course.)
5. Refueling is easy.
No pre-mixing of oil with gasoline is
necessary, so refueling is very simple.
 AUTOLUBE PUMP MECHANISM I. Oil tank 9. Sensor jet
2. Oil filter 10. Diaphragm chamber
3. Oil line (in the pump)
4. Oil pump Ass'y 11. Reduction gear unit
5. Distributor & Plunger 12. Worm gear & w o r m wheel
6. Delivery line ( w i t h reversing clutch)
7. Carburetor Ass'y 13. Muffler
8. Oil inlet nozzle on carburetor

- ---
Oil flow
Exhaust pressure

OIL PUMP CONSTRUCTION DIAGRAM

1. Construction diagram

1. Distributor 9. Worm wheel gear

2. Check valve 10. Plunger
3. Cam lobe 11. Suction port
4. Exhaust pressure inlet 12. Discharge port
5. Diaphragm 13. A i r bleeding screw
6. N u t adjusting 14. Worm gear (shaft)
7. Bolt adjusting 15. Worm wheel
8. Stroke control cam
 AUTOLUBE PUMP MECHANISM I. Oil tank 9. Sensor jet
2. Oil filter 10. Diaphragm chamber
3. Oil line (in the pump)
4. Oil pump Ass'y 11. Reduction gear unit
5. Distributor & Plunger 12. Worm gear & w o r m wheel
6. Delivery line (with reversing clutch)
7. Carburetor Ass'y 13. Muffler
8. Oil inlet nozzle on carburetor

Oil flow
e- -- Exhaust pressure

OIL PUMP CONSTRUCTION DIAGRAM

1. Construction diagram

1. Distributor 9. Worm wheel gear

2. Check valve 10. Plunger
3. Cam lobe 11. Suction port
4. Exhaust pressure inlet 12. Discharge port
5. Diaphragm 13. A i r bleeding screw
6. N u t adjusting 14. Worm gear (shaft)
7. Bolt adjusting 15. Worm wheel
8. Stroke control cam
 2. Power transmission
a. Pump drive
Crankshaft
Primary
reduction gear
1 Worm gear I I Distributor
IOpening and closing
J. (or suction and dis-
Worm wheel Plunger
Pin to be rotated
along cam
3. Operation
a. Engine power is transmitted through the
drive gear unit to the worm gear shaft,
thus turning the worm gear (b).
b. The pin (d) of the plunger (c) moves into
the cut in the worm gear (b), and thus
the worm gear rotates the plunger. Since
the pin is moved up and down by the
cam (el, the plunger is moved back and
forth in the axial direction. This recipro-
cating plunger causes oil to flow in and
out. The figure (left) shows the plunger
on the discharge stroke, and the figure
(right) indicates the plunger on the suc-
tion stroke.
c. The distributor (f), which is integrated
with the worm gear, rotates together
with the plunger as it strokes. As a
result, when the hole in the oil chamber
a t the end of the plunger aligns alternate-
b. Automatic stroke adjustment for dif-
ferent load conditions
I Exhaust pipe
-1 (Exhaust gases)
D Jet sensor
-1 (Pressure)
1 1
I
Diaphragm position
I
I
1 Control cam position 1
Plunger stroke
l
ly with the suction and discharge holes,
oil is drawn in and delivered.
d. The amount of the plunger stroke is
regulated by the control cam (h). That
is, the jet sensor attached to the exhaust
pipe detects the exhaust gas pressure and
causes the diaphragm to move. This
causes the control cam to move back and
forth, thus controlling the plunger
stroke.
e. In short, the frequency of plunger stroke
(the frequency of oil discharge) is in pro-
portion to the engine rpm, and the
plunger stroke (the discharge of oil) is
controlled according to the engine load
(the exhaust gas pressure). This means
that the engine always receives an
optimum amount of oil.
1-22
1-6. SERVICE NOTES
A. No flame sources
Avoid any flame sources in the service shop.
B. Washing and cleaning
Thoroughly clean the exterior of the car
body and engine so that no dust and dirt
enters the engine. While cleaning, take care to
protect the electrical parts, such as relay
switches, motor, resistors, controllers, etc,
from high pressure water splashes.
C. Using special tools
To avoid damaging parts, use the special tools,
as required. Use the right tools and instru-
ments. (Avoid using open-end wrenches in
place of box wrenches or socket wrenches.)
D. Using genuine Yamaha parts
Always use genuine Yamaha parts, oil and
grease, or recommended makes. Never use
imitation products.
E. Expendable parts
Always use new gaskets, O-rings, cotter pins,
circlips, and lock washers.
F. Tightening torque
Some critical parts must be tightened to
proper torque valve to assure reliability. These
values are called out in specific sections and in
the appendix (refer to page 10-3).
G. Use of jack and stands Support the car with stands a t both ends
Be sure to place jacks and stands on level of the rectangular pipe frame.
ground. When working under the car, be sure
to set stands.
1. Front side
Place a jack under the frame base to
which the tension rod i s connected, and
jack up the car.

H. Opening and closing of the rear body

1. Opening the body
When checking the machine with the
rear body opened, be sure to lock the
body for safety by inserting the safety
lock pin attached to the body stay into
Support the car with stands a t both ends the hole in the other stay.
of the front bumper stay.

Be sure to insert the safety lock pin into the

hole.

2. Rear side
Place a jack under the rear of the rectan-
gular pipe frame and jack up the car.

1. Rectangular pipe frame 2. Jack

 I. Disconnect the negative battery cable

To prevent possible injury, disconnect battery

before working on vehicle. Remove the nega-
tive battery cable as shown below.

NOTE:
Depress the parking brake pedal when open-
ing the body.
- - - - -

I Remove this battery cable before working I

2. Closing the body I on car. I
Pull out the safety lock pin and insert it
into the original hole (home position),
then close the body slowly.

Don't lose your hold of the cowl, or it will

fall down of its own weight and may be
damaged.

FORWARD

4 3

Remove this battery cable before working

on car.
J. Removing and installing the drive belt

1. How to remove the V-belt

2. How to install the V-belt

K. Notes on disassembly and reassembly 3. Keep the removed parts separately in
1. Let the engine cool off before working groups so that they will not be misplaced
on it. or confused.

2. Be careful that the battery fluid does

not spill on your clothes or the car body.

The battery emits combustible gases while

being charged. So take special care to prevent
any explosion.
Keep open flames away. Prevent sparks.
Never smoke near the battery, or gases may 4. After disassembling the parts, wash them
explode. in solvent oil and blow them dry with
Never charge the battery in a closed place, compressed air.
or there is a danger of explosion.
Take care so that no battery fluid (diluted
sulfuric acid) splashes on your skin, eye or
clothes.
First-aid:
o Should the battery fluid splash on your
skin or clothes, immediately wash it away
with water.
o Should the battery fluid splash in your eye,
immediately wash with water and see your
doctor.
 -
5. When installing parts, oil the contact sur- Key to Symbol
faces of moving parts.
1 Oiling is required for the part

a indicated.

Greasing i s required for the

partindicated.

Bond should be applied to the

a part indicated.

1-7. SPECIAL TOOLS

6. After installing the parts of each group,
make sure of their movements and of
tightening parts t o specification.
A. Special tools for golf car
The proper special tools are necessary for
complete and accurate tune-up and assembly.
Using the correct special tool will help pre-
vent damage from improper tools or impro-
vised techniques.

( ): Indicate for U.S.A.

Crankcase separator
PIN 90890-01135
(YU-01135)

Be careful during service work so that

you will not get injured.

Rotor holding tool

PIN 90890-01235
(YU-01235)
3-Way universal puller Ring nut wrench (Main switch for J10lJ16)
PIN 90890-01990 PIN 90890-01268
(YU-90105) ( Y U-01268)

Secondary sheave holder

PIN 90890-01705 PIN (YG-40103)
( N. A. )

Sheave holder
PIN 90890-01701 PIN (YS-01880)
( N. A. )
Valve pin and piston pin puller Steering wrench
PIN 90890-01 183 PIN 90890-01710

Bush remover
PIN 90890-017 15
( N. A. )

1. Primary sheave puller

PIN 90890-01876
(YG-01876)
2. Socket wrench (Brake adjusting tool)
PIN 90890-01886
( N.A.
3. Brake adjusting tool
PIN (YG-40104)
 Crankshaft installation set
-
&
PIN (YG-40101)
- - - - - - - - - - - - - - - - - - - - - - - - - - - -- - -,
I
I I
I
I
I I

w
I
I
I
I III
I
I
I
I
I I
I I

1
II I
I

I
<@@
Crank pot installing set
PIN (YU-90050)
I

I
I
&
I
I I
I
I
1. Crankshaft setting pot I
I 4. Pot spacer
I
I PIN 90890-01274 I PIN 90890-01818
I (YU-90058) I (YU-90070)
I
1 2. Setting bolt I
I
5. Crank adaptor
I PIIV 90890-01275 I PIN 90890-01280
I I
I (YU-90060) I (YM-90067)
1 3. Spacer (small)
I
I 6. Adaptor
I PIN (YU-90059) I PIN 90890-01287
I
I
I
I t (YG-40101-1)
L ---- - - - - - - - - - - - - - - - - - - - --------- J

Crankshaft jig assembly

PIN (YU-02200)

1. Crankshaft jig

dJ@ PIN (YU-02200-1)

2. Press plate (2 reg.)
PIN (YU-02200-4)
3. Press box
PIN (YU-02200-2)
4. Wedge
PIN (Y U-02200-5)
5. Press pin
PIN (YU-02200-3)

"..- 6.
PIN (YU- 1

Width gauge (55,75 mm) Crankcase separator adaptor

PIN (Y U-02213) PIN 90890-01804
( Y U-01804)

1-31
6. Special tool kit for golf car (PIN 90890-01983)

REF. NO. PART NO. PART NAME Q'TY REMARKS US. TOOL NO.
1 90890-01135 Crankcase separating tool 1 set YU-01135
2 90890-01235 Rotor holding tool 1 YU41235
3 90890-01990 Magneto puller 1 set YU-90105
3-1 9089041 848 Body, magneto puller 1 NA
3-2 90890-01803 Bolt, magneto puller 1 NA
3-3 90890-01817 Handle, magneto puller 1 r$12~150 NA
3-4 90890-01805 Screw, cylinder head 3 6x50 NA
3-5 90890-01871 Screw, cylinder head 3 8x80 NA
4 90890-01804 Attachment 1 YU-01804
C. Adjustment and measuring tools

Ignition coil tester Pocket tester

PIN 90890-03074 PIN 90890431 12

-
Engine tachometer Timing light
PIN 90890431 1 3 PIN 9089043109

Booster cable (Type: BC-50) Compression gauge

PIN 9089043081
 CHAPTER 3. ENGINE
3 1. ENGINE REMOVAL ...................................... 3-1

3 2. DISASSEMBLY AND INSPECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

A . Shroud Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
B. Flywheel Magneto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
C. Primary Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .: . . . . . 3-4
D. OilPump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
E. TopEnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
F. Bottom End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3 3. ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

A . Bottom End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
B. TopEnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
C. Oil Pump Gear Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
D. Primary Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
E. Flywheel Magneto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

3.4 . ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

3.5 . EXHAUST PIPE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

 ENGINE
3-1. ENGINE REMOVAL
You do not have to remove the engine in
order t o service the following major com-
ponents:
Cylinder
Piston
Flywheel Magneto
To remove the engine, with mount bracket,
remove or disconnect the following compo-
nents in the order given below.
1. Disconnect the battery negative terminal
lead.
2. Remove the drive V-belt.
3. Removing the muffler.
Remove the jet sensor pressure hose on
the exhaust pipe end.
Remove the hook springs (at 2 places)
with pliers. Remove the 2 bolts securing
the muffler bands to the engine bracket,
and remove the muffler.
4. Removing the choke wire etc.
a. Loosen the choke wire clamp screw.
NOTE:
When installing, adjust choke wire play t o 1
mm.
b. Remove the cotter pin from the clevis
pin connecting the choke wire to the
choke lever, and remove the clevis pin.
5. Remove the carburetor.
a. Remove the Autolube delivery line.
b. Remove the fuel line.
c. Loosen the clamp bolt that secure the air
cleaner hose t o the carburetor.
d. Loosen the clamp bolt securing the
carburetor in the rubber joint.
e. Remove the link connecting the throttle
t o the speed limiter lever on the lever
side.
6. Remove the pulse line connecting the
fuel pump t o the engine. (Disconnect
the line on the crank case side.)
7. Remove the oil line on the Autolube
pump end.
NOTE: _
Plug the end of the removed oil line t o keep
oil from leaking out. (A golf tee works well)
8. Remove the engine bracket tensioner 10. Remove the four holding bolts as shown.
wire end. Remove the engine with starter motor.

9. Disconnect the electrical lead wire from

the starter motor, ignition coil and CDI 11. Remove the air shroud from the engine.
magneto.
3-2. DISASSEMBLY AND INSPECTION

A. Shroud Fan
B. Flywheel Magneto (C.D.I.)

1. Using the sheave holder or clutch hold- C. Primary Sheave

ing tool, loosen the securing nut, and Hold the fixed sheave with the sheave holder
remove the flywheel from the magneto. and remove the clutch bolt. Remove the
r primary sheave from the crankshaft with the
Sheave holder: 90890-01701 primary sheave puller.

Sheave holder:
T LS-90018-80-00(U.S.A.)
90890-0170 1
Primary sheave puller:
90890-01898 .

2. Using the 3-way puller, remove the

magneto.

1. 3-Way Puller: 90890-01848

2. 3-Way Puller Attachment: 90890-01803
3. 3-Way Puller Attachment: 90890-01804 1. Sheave holder 2. Primary sheave puller
4. 3-Way Puller Screw: 90890-01906
5. Drive handle: 90890-01817

3. Remove the woodruff key from the

crankshaft. Remove the two securing
screws and remove the coil plate.
D. Oil Pump

1. Loosen the four gear-case bolts, and

remove the gear caseloil pump assembly
from the engine.
2. Remove the two gear case screws and
open the gear case.
3. Remove the snap ring and the two
washers, and remove the drive gear. Note
the relative positions of the washer. The
wave washer is against the drive gear.
4. Rotate the oil-pump drive shaft until the
securing pin is opposite the slot in the
gear case. Remove the pin and remove The oil pump should not be disas-
the pump from the gear case. sembled unless the pump stroke must be
5. Remove the drive shaft from the oil checked.
pump. Inspect the bearing surfaces of 6. If there is any problem with the oil
the shaft and the gear teeth. I f any part pump, a complete new pump should be
of the shaft is worn or pitted, the shaft instal led.
must be replaced.
E. Top End
Disassembly
1. Remove the spark plug, and remove the
cylinder head from the cylinder.

b. Check the pin and bearing for signs of

heat discoloration. I f excessive (indenta-
tion on pin, etc.), replace the pin and the
bearing.
2. Remove the reed valve.
c. Check the small-end bearing for exces-
3. Remove the cylinder from the crankcase.
sive wear or damage. Check the rollers
4. Cover the crankcase with a clean rag so
for signs of flat spots. I f such wear is
nothing with accidently drop into the
found, replace the pin and the bearing.
crankcase.
5. Remove a piston pin clip from the
piston. Lightly drive the piston pin out
from the opposite side while supporting
the rod and remove it from the piston.

d. Apply a light film of oil to the pin and

6. Remove the piston and the small-end
bearing from the connecting rod.
Inspection
1. Piston pin and bearing inspection.
a. Check the piston pin for signs of wear.
If any wear is evident, replace the pin
and the bearing.
bearing surfaces. Install them in the
connecting rod small end to inspect for
wear. Check for play. There should be
no noticeable vertical play. I f play exists,
check the connecting rod small end for
wear. Replace pin, connecting rod and/
or bearing, as required.
e. The piston pin should have no noticeable
free play in the piston. I f the piston pin
is loose, replace the pin and/or piston.
2. Piston
a. Remove the piston rings.
b. Remove any carbon deposits from piston
crown.
c. Carefully remove any carbon deposits
from the ring grooves with a broken ring.
d. Remove score marks and lacquer
deposits from the sides of the piston
using 600 - 800 grit wet sandpaper.
Lightly sand in a crisscross pattern. Do
not sand excessively.
e. Wash the piston in solvent, and dry it
with compressed air.
3-8
f. Measure the outside diameter of the
piston a t the piston skirt.
The measurement should be made a t a
point 10 mm (0.39 in) above the bottom
edge of the piston. Place the micrometer
at a right angle t o the piston pin.
The maximum piston diameter subtract-
ed from the minimum cylinder diameter
gives the piston clearance. If the clear-
ance is beyond tolerance, hone the
cylinder t o tolerance or bore it t o the
next oversize and install an oversized
piston.
Piston clearance:
Minimum ........ 0.035 mm (0.0014 in)
Maximum ........ 0.050 mm (0.0020 in)
Piston oversize:
68.25 mm (2.687 in)
68.50 mm (2.697 in)
I . 10 mm (0.39 i n )
3. Piston rings
a. Check the rings for scoring. I f any severe
scratches are noticed, replace the rings as
a set.
b. Push the ring into the cylinder, and
measure the ring end gap with a feeler
gauge. Push the ring into the cyinder
with the piston crown so the ring will be
a t a right angle t o the cylinder bore. I f
the end gap is not within specification,
replace the rings as a set.
I Ring end gap, installed:
Minimum .......... 0.20 mm (0.0079 in)
Maximum ......... 0.40 mm (0.0157 in)
4. Cylinder
a. Inspect the cylinder walls for scratches.
If vertical scratches are evident, the
cylinder should be rebored or replaced.
b. Measure the cylinder wall wear at the
places shown in the illustration; use a
cylinder bore gauge. If wear is excessive,
compression pressure will decrease; r e
bore or replace the cylinder.

Standard Wear limit

Cylinder bore
(2.677 -2.678 in) (2.679 in)

- 0.05 rnrn
Cylinder taper
(0.002 in)
Cylinder out-of-
round
- 0.01 rnm
(0.004 in)

c. Remove all carbon deposits from the

cylinder and from the ports. Carburetor
cleaner will help lift carbon from the
cylinder head. Thoroughly wash the
cylinder in solvent, and blow it dry with
compressed air. Immediately coat with
oi I.
F. Bottom End

Engine mounting bracket

Disassembly 3. Install the crankcase separating tool in

1. Remove the engine mounting bracket the crankcase (on the ignition side).
from the crankcase.
2. Remove the screws (M6 x 7).

1. Crankcase separating tool

NOTE:
Screw the separating tool bolts into the crank-
case until lightly bottomed. I f not, the crank-
case may be damaged.
By turning the separating tool handle,
disassemble the case.
4. Removing the crankshaft assembly.
a. Install the crankcase separating tool in
the ignition side crankcase.
NOTE:
The special tool bolts must be screwed in
until lightly bottomed.
1. Crankcase separating tool 2. Large tip adapter
b. Set the crankshaft at TDC, and hold the
crankshaft assembly firmly with your
hand.
NOTE:
I f the crankshaft and connecting rod assembly
is not held securely, it will turn together with
the special tool push screw and may damage
the connecting rod and/or crankcase.
d. l nspect the oil delivery passages in the
transfer ports for signs of blockage.
2. Bearings and oil seals
a. After cleaning and lubricating the bear-
ings, rotate the outer race with your
finger. I f rough spots are noticed, replace
the bearings.
b. Check the oil seal lips for damage or
wear. Replace the seals as required.
3. Bearing and oil seal installation
a. Install bearings with their manufacturer's
marks or numbers facing outward. They
should be visible when installed.
b. Install oil seals with their manufacturer's
marks also facing outward.
c. Always thoroughly lubricate bearings
and oil seals with the specified lubricant
before installing them on the crankshaft.
4. Crankshaft
a. Check the connecting rod axial play a t
the small end. This will indicate the con-
dition of the big-end bearing and crank-
pin. I f the rod axial play exceeds specifi-
cation, disassemble the crankshaft and
check the connecting rod, crankpin, and
big-end bearing. Replace any defective or
worn parts. Reassemble the crankshaft,
and recheck the rod axial play.

c. By turning the special tool handle clock-

wise, force the crankshaft assembly out
of the crankcase.

lnspection
1. Crankcase
a. Thoroughly wash the case halves in a
mild solvent. Blow them dry with com-
pressed air.
b. Thoroughly clean the crankcase mating
surfaces.
c. Visually inspect the case halves for
cracks or damage.
3-3. ASSEMBLY AND ADJUSTMENT

A. Bottom End

1. Fitting the crankshaft assembly.

a. Lightly grease the crankcase seal lips.
b. Carefully install the crankshaft (left
half) into the crankcase (left half).
c. Install the crankshaft setting tool.
d. Place the crank at TDC, and hold the
crankshaft assembly with your hand. 1 . Spacer
e. Using an off-set wrench, tighten the set-
ting bolt nut so that the crankshaft is fit- NOTE:
ted in position. Apply Yamalube 2 cycle oil to crankshaft
bearings and crankcase oil passages.

Hold the connecting rod positioned so as not 3. Tightening the crankcase bolts.
to interfere with the crankcase. Failure t o do Tighten the crankcase bolts in the order
this can result in damage to crankcase and/or shown.
connecting rod.
Tightening torque:
7 Nm (0.7 m-kg, 5 f-lb)

1 . Cranksahft setting bolt 3. Spacer

2. Crankshaft setting pot

2. Crankcase assembly 1 -7. Crankcase bolts tightening sequence

a. Thoroughly clean the sealing surfaces of
the crankcase with lacquer thinner.
b. Apply Yamaha Bond No. 4 t o the seal-
ing surfaces.
c. Lightly grease the crankcase seal lips.
d. Install the crankcase (right half) on the
crankshaft (right half), and install the
crankshaft setting tool.
e. Using an off-set wrench, tighten the nut
and assemble the crankcase.

Hold the connecting rod positioned so as not

to interfere with the crankcase. Failure t o do
this can result in damage to crankcase and/or
connecting rod.
B. Top End
1. Install the piston rings as shown in the
illustration. (Top-"RN", 2nd-" R")
Piston ring
2. Add oil to the crankcase through the oil
holes. Oil the connecting rod.
3. Cover the crankcase with a clean cloth so
nothing will fall into the crankcase.
4. Oil the small-end bearing and install it in
the connecting rod.
5. Oil the connecting rod, and install the
piston. The arrow on the piston crown
must point to the front of the engine.
6. Oil the piston pin, and install it in the
piston. Be sure the piston pin clip is
correctly seated in the groove.
7. Align the piston ring end gaps with the
locating pins in the piston grooves.
Hold down the piston rings with your
fingers, and gently slide the cylinder
over the piston while taking care not to
break the piston rings.
8. Place the cylinder head gasket on the
cylinder.
NOTE:
Always use new gaskets.
9. Install the cylinder head.
NOTE:
The cylinder head should be positioned so
that the shroud bolt holes are on the side
nearest the clutch.
10. Gradually tighten the nuts in a crisscross
pattern.
Initial: 20 Nm (2.0 m-kg, 14 ft-Ib)
Second: 25 Nm (2.5 m-kg, 18 ft-Ib)
C. Oil Pump Gear Case

Oil pump drive shaft

Wave washer

1. Place the washer on the oil pump drive
shaft, and insert the drive shaft into the
oil pump. Be sure the worm gear correct-
ly engages the oil pump gear in the
pump.
2. Secure the pump to the gear case. Use a
new gasket. Apply "YAMAHA Bond 4"
to the gear case side of the gasket only.
3. Align the hole in the drive shaft with the
slot in the gear case and install the secur-
ing pin.
4. Thoroughly grease the outer edges of the
drive gear onto the oil pump drive shaft.
Be sure the drive gear correctly engages
the securing pin.
5. Secure the drive gear in place with the
two washers and the snap ring. Be sure
the wave washer is against the drive gear.

I
Tightening torque:
3-5Nm
-
(0.3 0.5 m. kg, 2.2 - 3.6 ft-Ib)
6. Thoroughly grease the teeth and area of
the drive gear, and install the gear case
cover.
7. Install the oil pump gear box onto the
engine. Be sure the drive gear correctly
engages the oil pump drive gear on the
crankshaft. Torque the four securing
bolts to s~ecification.

6.8 Nm (0.68 ma kg, 4.9 ft-lb)

1 1 . Sheave holder

4. Lock the bolt with the lock washer.

E. Flywheel Magneto
1. Feed the magneto leads through the hole
in the crankcase, and install the rubber
sleeve in the case.
2. Install the coil plate onto the crankcase.
Align the pry points on the plate with
the cutout in the crankcase. Apply a
thread-locking compound to both
securing screws.

D. Primary Sheave
1. Bring the Autolube reduction gear to
mesh with the gear on the sheave and
install the sheave on the crankcase.
2. Install the spacer, lock washer and bolt
onto the crankshaft.

3. Place the woodruff key in the crank-

shaft, and install the flywheel magneto.
The keyway in the magneto must align
with the key in the crankshaft. Rap the
magneto with a plastic mallet to seat it
on the crankshaft.
4. Install the flywheel magneto and torque
3. Hold the sheave with the sheave holder
the securing nut to specification.
tool. Tighten the bolt. with a torque
wrench.
Tightening torque:
73 Nm (7.3 m-kg, 53 ftwlb)
Tightening torque:
75 Nm (7.5 m- kg, 54 f t * Ib)
5. Timing adjustment
(Refer to "7-1 7, Ignition Timing".)
3-4. ENGINE INSTALLATION

Rear cush~on

F~rst: 25 Nm (2.5 rn-kg, 18 ftslb)1

Final: 30 Nm (3.0m-kg, 22 ft.lb)l

--

1. Install the engine bracket onto the

crankcase, tighten the four bolts t o spe-
cification.

Tightening torque:
First: 25 IVm (2.5 m*kg, 18 ftalb)
Final: 30 Nm (3.0 m- kg, 22 ft-Ib)

2. Install or connect the remaining compo-

nent, refer t o engine removal section
(page 3-1) for further installation in-
structions.
3-5. E X H A U S T PIPE ASSEMBLY
 CHAPTER 4 CARBURETION .
4.1 . CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
A . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
B. Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
C. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
D. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

4.2 . FUEL PUMP

A . Testing fuel starvation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
B. Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 . REED VALVE

A . Removal and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
 CARBURETION
4-1. CARBURETOR

Throttle stop screw

Pilot adjusting screw (P.S.)

A. Removal 4. Measure the float height.
1. Disconnect the fuel line, oil delivery a. Incline the carburetor approximately 20
line, throttle link and the choke cable. or 30 degrees until the float valve just
2. Loosen the clamp on the carburetor barely closes. The float should be resting
boot and remove the carburetor. on the float needle, but not compressing
the spring.
6. Disassembly b. Measure the distance from the carbure-
1. Carefully remove the jets, float, etc. tor body to the top of the float.
Never, however, disassemble the throttle
valve or throttle shaft, choke valve or Float height:
choke shaft. The threads of the throttle 18 2 1 mm (0.70 k 0.04 in)
shaft have been crimped so the screw
will not come loose. Once the throttle
valve is disassembled, it will be very diffi-
cult to reassemble it correctly. The
original characteristics of this carburetor
will be difficult t o reproduce, thus per-
formance will be adversely affected.
2. Carefully clean all parts. Blow the jets
and passages clear with compressed air.
Use a soft brush to clean the outside sur-
faces so nothing will be scratched or
damaged. Do not use a wire or any such 1. Float height
object to clear a jet. This will deform the
jet and reduce performance. c. If the float height is not within specifica-
3. Remove the carbon from the throttle tion, examine the valve seat and the float
valve and adjacent area. Take care not to needle. If either is worn, replace them
scratch the throttle valve or bore. both. If both are fine, adjust the float
height by bending the tang on the float.
C. Inspection
1. Inspect all jets and passages. They must
be clear.
2. Check the mating surfaces for wear.
Replace jets as required.
3. Check the float valve for damage. If
either the float seat or float needle are
damaged, replace both parts.
4. Check the pilot screw for carbon depos-
its; check the threads for wear. Clean
and replace the jet as required.

D. Assembly d. Reinstall the float and recheck the float

Be sure all moving parts in the carburetor height.
operate smoothly. 5. Reassemble the float.
1. Install the throttle stop screw with i t s 6. Apply grease to the following areas.
spring. For adjustment (Refer t o 2-10). The wire holder attached t o the choke.
2. Install the main jet and the pilot jet.
3. Install the pilot adjusting screw with i t s
spring. For adjustment (Refer to 2-10).
Insert the float needle into the float
valve and install the float.
 7. Carburetor adjustment
Refer to page 2-11
4-2. FUEL PUMP
A. Testing fuel starvation:
1. Remove the drive V-belt or jack up the
rear of the car to lift the rear wheels off
the ground. Place blocks in front of the
front wheels.
2. Disconnect the fuel line from the carbu-
retor.
3. Start the engine for one minute, keep it
running a t low speed, and make sure that
fuel is discharged from the fuel pipe. If
not, check the pulse pipe, inlet line and
delivery line. If they are good, the fuel
pump must be replaced.
Aim the fuel pipe into a suitable container
and keep away from any spark or flame.
B. Disassembly and assembly
1. Disconnect the fuel inlet line, and the
fuel outlet line.
2. Remove the pulse line.
3. Remove the two pump mounting bolts.
4. Remove the four pump body screws, and
the fuel pump can be disassembled.
5. Assembling the pump,
Before assembling the pump, thoroughly
clean its interior and component parts
with solvent. In assembling, take care
not to damage the diaphragm, valve and
gasket.
6. Installing the pump
After assembling, connect lines to the
pump. Pay attention to the arrow mark
on top of the pump so that lines can be
connected correctly.
4-3. REED VALVE
A. Removal and inspection
With carburetor removed, proceed as follows:
1. Remove the bolts holding the carburetor
joint and reed valve assembly to cylin-
der. Remove assembly.
2. lnspect rubber carburetor joint for signs
of weathering, cracking or other deterio-
ration.
3. lnspect reed petals for signs of fatigue
and cracks. Reed petals should fit flush
or nearly flush against neoprene seats.
If in doubt as to sealing ability, apply
suction to carburetor side of assembly.
Leakage should be slight.
4. Check valve stopper clearance. If beyond
tolerance, replace valve stopper.
Valve stopper clearance:
*
7 0.5 mm (0.28 ? 0.020 in) ,
5. Check reed valve for bending. If beyond
tolerance, replace reed valve.
(at rest maximum opening)
0.3 mm (0.01 2 in)
6. If disassembly of the reed valve assembly
is required, proceed as follows:
a. Remove Phillips screws securing stopper
plate and reed to reed block.
Handle reed carefully. Avoid scratches
and do not bend or crease. Note from
which side of the reed block the reed
and stopper plate were removed. Rein-
stall on same side.
NOTE:
During reassembly, note the cut in the lower
corner of the reed and stopper plate. Use as
aid t o direction of reed installation.

Cut

b. During reassembly, clean block, reed and

stopper plate thoroughly. Apply a hold-
ing agent, such as "~octite@"t o threads
of Phillips screws. Tighten each screw
gradually to avoid warping.

Tightening torque:
0.8 Nm (0.08 ma kg, 0.58 f3-lb)

7. During reassembly of the reed valve as-

sembly and manifold, install new gaskets
and torque the securing bolts gradually
and in a crisscross pattern to the proper
torque.

Tightiqg torque:
Reed valve securing bolt
 CHAPTER 5. POWER TRAIN
5.1 . PRIMARY SHEAVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
A . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
B . Checking and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
C. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2 . SECONDARY SHEAVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

A . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
B . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
C. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3 . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

A . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
B . Disassembly and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
C .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
 POWER TRAIN
5-1. PRIMARY SHEAVE

Primary sheave bolt

Plastic washer

A. Removal
1. Remove the drive bolt. Sheave holder:
2. Hold the fixed sheave with the primary 9089001 701
sheave holder and remove the clutch (YS-01880)
bolt. Remove the primary sheave from Primary sheave puller:
the crankshaft with the primary sheave 9 0 8 9 0 0 1898
puller.
 2. Check the compression spring.

Free length: 75 mm (2.95 in)

Minimum limit: 70 mm (2.76 in)

1 75 mm (2.95 in)

1
1. Sheave holder 2. Primary sheave puller

3. Remove the sheave cap.

4. Push in the sliding sheave with your
hand.
5. Remove the circlip using a circlip plier.
Slowly release your hand from the slid-
ing sheave. (The sheave is forced out by 3. Check the weight pivot pin and hole.
the spring.) (lubricate with grease)

1 . Circlip 2. Circlip plier

4. Check the slider for wear, and replace

as necessary.
B. Checking and Repair
1. Check the O-ring
I t shouldbe replaced if damaged.
( ~ubricat'e
with grease)
C. Assembly
1. Install the collar, bearing, spring seat,
compression spring and the primary
sliding sheave into the primary fixed
sheave.
2. Install the cam. Be sure it is correctly
seated in the sheave cap.
3. Push on the primary sliding sheave with
your hand, and install the circlip using
circlip pliers.
1 . Circlip 2. Circlip pliers
4. Install the sheave cap. Be sure the "Y-1"
on the sheave cap aligns with the "Y-1"
on the sliding sheave.
5. Check the movement of the sliding
sheave. I f it is not smooth, disassemble
the primary sheave and reassemble it
correctly.
6. Clean the tapered portions of crankshaft
and fixed sheave.
7. Fit the fixed sheave to the tapered por-
tion of crankshaft.
8. Apply engine oil t o the threaded portion
of primary sheave bolt and its contact
surface with lock washer.
9. Hold the primary fixed sheave with the
primary sheave holder, and torque the
sheave bolt t o specification.
Tightening torque:
Tighten the bolt t o A t o properly seat
the primary sheave on the crankshaft.
Loosen the bolt, then torque it t o B,
the final torque.
A: 100Nm(10m.kg,72ft.lb)
B: 75 Nm (7.5 m. kg, 54 ft-Ib)
5-2. SECONDARY SHEAVE

Secondary spring

(White)

A. Removal 2. Using the 2-way puller or 3-way puller,

1. Lock the brake, and install the second- remove the fixed sheave.
ary sheave holder or rotor holding tool.
Fit the tool behind the spring seat so it 2-Way Puller Ass'y: 90890-01888
will hold the sliding sheave in place when 1. 2-Way Puller Body:
the fixed sheave is removed. Remove the 2. 2-Way Puller Attachment:
cotter pin and securing nut.

Secondary sheave holder:

9089001 705

3. Remove the key from the input shaft.

4. Very carefully remove the secondary
sheave holder. The spring will force the
1 . Secondary sheave holder sheave out.
5-4
 5. Remove the sliding sheave, the spring,
and the spring seat. The spring seat has a
spline.

6. Inspection
1. l nspect both sheaves. I f either is warped,
replace it.
2. Inspect the ramp shoes on the sliding
sheave and spring seat. Replace as neces-
sary.
3. Check the sheave bushings for wear;
replace the bushing as required.
4. Check the spring. If it is fatigued or
damaged, replace it.

C. Assembly 4. Starting from the free position, rotate

1. lnstall the spring seat onto the input
shaft.
2. Be sure the spring is in one of the holes.
NOTE:
The three holes in the spring seat are for con-
venience only. Seating the spring in a differ-
ent hole will not change the spring preload.
the sliding sheave clockwise to preload
the spring, and push the sheave towards
the transmission case. Lock the sliding
sheave in place with the secondary
sheave holder.
Secondary sheave holder:
90890-01 705

5. lnstall the key in the input shaft, and

install the fixed sheave. Grease the indi-
cated point.

3. lnstall the sliding sheave onto the input-

shaft. Be sure the spring engages the hole
in the sheave.
6. lnstall the washer and securing nut.
NOTE: Torque the nut to specification.
Clean all from the input-shaft and fixed-
-
Tightening torque: 40 80 Nm
sheave tapers.
- -
(4.0 8.0 mekg, 29 58 ft*Ib)

7. lnstall the cotter pin.

NOTE:
Always use a new cotter pin.

8. Wipe both sheaves. They should be free

from oil and grease.
5-5
5-3. TRANSMISSION

First:
20 Nm (2.0 m-kg, 14 ft-lb)
Final:
25 Nm (2.5 mskg, 18ft.Ib)

Differential side gear

Counter gear 1
A. Removal 10. Remove the four bolts holding the brake
1. Remove the V-belt. back plate t o the rear axle housing.
2. Remove the carburetor assembly and air
cleaner assembly.

11. Pull the rear axle and brake back plate

1 . Throttle cable 2. Speed limiter outwards, the rear axle will come away
completely but the brake back plate can
3. Remove the throttle cable from the
remain suspended by i t s cable.
speed limiter.
12. Remove the fuel pump.
4. Remove the secondary sheaves. (Refer
13. Remove the oil tank vent line from the
to page 5-4).
transmission case.
5. Remove the bolt and copper washer t o
14. Remove the oil line from i t s clip on the
drain the transmission oil.
transmission case.
6. Release the parking brake by depressing
15. Unscrew the four bolts on the axle
the accelerator pedal.
housing from the rear arm.
7. Jack up the rear of the golf car and
block the front wheels.
8. Tap the brake drum lightly with a
plastic-tip hammer and loosen.

16. Remove the six bolts on the right and

left sides of the axle housing.
Pull the rear axle housing straight out.
9. Pull the brake drum out and remove.
17. Remove the two transmission mounting
bolts and lift the transmission case out
of the car.
18. Using the clip pliers, remove the circlip
frnm t h innttt
~ chaft
B. Disassembly and Inspection
1. When the transmission case is disas-
sembled, i t s inner parts can be seen as
described in (10) above. To disassemble,
remove the differential gear assembly
first, and other parts can be disassembled
in order.
2. Checking the transmission gears
Check each gear for worn or chipped
teeth. Replace gears if excessive1y worn
or chipped.
3. Disassembling the differential gear as-
sembly.
Remove the bolts (M8x 4).
Remove the differential case, and all
pinion gears can be removed.

19. Disassembling the transmission case

cover. B O I ~ S(MS x 4)
Remove the M 8 nuts.
Hold the transmission case right side
cover with both your hands, and remove
by moving it in the direction parallel t o
the transmission case.

4. Checking the differential gears

As in the case of transmission gears,
"I% check the differential gears for worn or
1. Governor assembly 5. Final drive gear
chipped teeth.
(for speed limiter) 6. Crown gear
2. Secondary shaft 7. Pinion gear (a, a')
3. Forward gear 8 . Pinion gear (b, b')
4. Counter gear shaft 9. Differential case

Do not drive chisels, screwdrivers, etc, be-

tween the case halves.
C. Assembly
1. Assembling the differential gear
Set the two side gears on the ring gear,
and assemble the four pinion gears as
shown in the photo above. Be sure that
the pinion gears (a-a', b-b') are position-
ed diametrically opposite. If not, the
gears will not turn. Place the differential
case over this sub-assembly of ring gear
and pinion gears.
Install lock washers and bolts, and
tighten.

Tightening torque:
M8 bolt:
20 Nm (2.0 m. kg, 14 ft. Ib)

2. Assembling the transmission

Install the differential gear assembly,
other gears and shafts in the transmis-
sion case.

1. Thrust washer 3. Collar

2. Thrust bearing 4. Fork
Insert the limiter fork under the thrust
bearing and washer from the bottom.
While taking care so that the fork does
not slip off, align the stud bolts and bolt
holes and assemble the cases.
Tighten the transmission case nuts
(12M8 nuts) in a crisscross pattern,
starting from the center of the case.

1 . Weight assembly 3. Secondary shaft

2. Thrust bearing & washer
Take care that speed limiter parts are
installed in the correct order. Don't
install them left side right or vice versa.
Particularly, if the weight assembly is
positioned incorrectly, the speed limiter
will not operate.
Hook the weight claws onto the collar.

Tightening torque:
Transmission case nut
25 Nm (2.5 m-kg, 18 ft-lb)
 3. To assemble the rear axle housing and
secondary sheave, reverse the procedure
for disassembly.

Tightening torque:
Transmission case mounting bolts:
25 Nm (2.5 m-kg, 18 ft-lb)
Rear axle:
25 Nm (2.5 m-kg, 18 ftelb)
Rear arm:
40 Nm (4.0 ma kg, 29 ftmlb)

Sparingly grease the outer race of the bearing

into which the rear axle shaft is force-fitted
in assembly. The 6 bolts securing the axle
housings to the transmission case must be
tighten before the 4 bolts that secure the
housing to the swing arm.
 CHAPTER 6. CHASSIS
6 1. BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
A . Brake Shoe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
B. Checking Brake Shoe Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
C. BrakeDrum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
D. Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
E. Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
F. Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.2 . STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

A . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
B. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
C. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.3 . WHEEL ALIGNMENT ..................................... 6-9

6 4. STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-6-10

A . TieRod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
B. Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6.5 . KNUCKLE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6.6 . REARAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

.
A . Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
B . Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
C. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13

6.7 . FRONT SHOCK ABSORBER AND SPRING ASSEMBLY . . . . . . . . . . 6.14

A . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
B. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6.8 . REAR SHOCK ABSORBER AND SPRING ASSEMBLY . . . . . . . . . . . 6-14

A . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
B. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6.9 . REAR ARM BUSHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15

A . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
B. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
C. Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15

6 1 0. O I L T A N K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
6-11. FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6.12 . BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

A . Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
B. Body Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
C. FrontIRear Bumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
D. FrontIRear Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
E. Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
F. Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
 CHASSIS
6-1. BRAKE
-

Brake arm complete

Brake cable ( R I H )

Brake cable ( L I H )
Brake pawl

(REAR DRUM BRAKE)

A. Brake shoe removal NOTE:
Manuever the axle plate t o position access
NOTE:
holes.
1. Raise the rear of the car and remove rear
wheels. Refer t o 1-24.
5. Pull the axle and brake shoe plate out-
2. They can be removed in the same way
ward. The axle will come away corn
as the front wheels.
pletely but the brake shoe plate can
remain suspended by i t s cable.
1. Release the parking brake by depressing
6. Temporarily replace the brake shoe plate
the accelerator removal.
on the axle housing. Finger-tighten two
2. Tap the brake drum lightly with a
bolts t o hold it in position.
plastic-tip hammer and loosen.

3. Pull the brake drum outward t o remove. 7. With pliers push the "U" clip in and turn

4. Remove the four bolt holding the brake

shoe plate to the axle housing.
NOTE:
This will release the brake shoes and springs.
The spring assembly position should be noted.

Do not turn the pins as their rear seal may be

broken.
6. Checking Brake Shoe Wear 2. Hold the front shoe and attach the lower
1. Measure the brake lining thickness with spring to both shoes.
slide calipers.

4 mm (0.16 in)
Replacement limit:
2 mm (0.08 in)

3. Temporarily install the rear shoe and

attach the upper spring to both shoes.

Make sure the springs are fitted exactly as

shown.
2. Remove any glazed areas from brake
shoes using coarse sand paper. 4. Push the rear shoe into the brake back
plate.
C. Brake Drum
Oil or scratches on the inner surface of the
brake drum will impair braking performance
or result in abnormal noises.
Remove oil by wiping with a rag soaked in
lacquer thinner or solvent.
Remove scratches by lightly and evenly
polishing with emery cloth.

D. Brake Assembly
1. First-fit the brake shoe in the slot in the
adjusting bolt head.
5. Unscrew the two bolts holding the brake
back plate to the axle housing.
6. Clean and lightly grease the axle bearing
cover and replace the axle.
 7. Bring the axle plate access holes to align
with the four holding bolts.
Make sure that no grease or water comes in
contact with the brake drum or shoe surfaces.
11. Turn wheel unit as so far assembled.
12. If the wheel rubs and doesn'tturn easily
replace the brake drum and check brake
shoe.
13. Lower the car and tighten the wheel nuts
completely.

Tightening torque:
80 Nm (8.0 m. kg, 58 ft. Ib)

E. Cable Replacement
1. Disconnect the cable from the back of
the rear wheel.

- -

Tightening torque:
30 Nm (3.0 m-kg, 22 ft-lb)

8. Lightly sand paper the contact surfaces

of the shoes and brake drum. 1. Brake cable 2. Pin clevis

2. Disconnect the cable from the under side

of the floor board.

1. Split pin 2. Clevis pin 3. Circlip

3. l nstal l the new cable in reverse order. Be

sure that the new cable is placed in the
same location as the original, and pro-
tected from damage or interference.

9. Install the brake drum.

10. Check that the adjusting arm i s in mesh
with the ratchet. (Refer to the brake
shoe adjustment on page 2-18.) Adjust if
necessary.
64
 F. Cable Routing Starter wire (engine component)

Se
-
To solenoid relay
6-2. STEERING

Steering wheel nut

(Nylon nut)

lotted adjusting screw

(4.3 m-kg, 31 ft-lb)

68 -108 N m
(6.8 - 1 0.8 m-kg, 49 - 7 5 ft-Ib)
A. Removal 7. Remove the drain plug, and drain the
1. Remove the steering wheel nut and steering gear box oil.
steering wheel.
2. Remove the main switch, choke wire and
instrument panel screws.
3. Disconnect the main switch connector
and remove the instrument panel.
4. Remove the front cowl; See the illustra-
tion below.

8. Remove the steering gear cover, pitman

arm, lock nut and bolt.
9. Remove the steering shaft and taper-
roller bearing.

5. Straighten the lock washer, then remove

the lock nut from the pitman arm.

B. lnspection
1. Check the taper-roller bearing for exces-
sive wear or damage. Check the rollers
for flat spots. If such wear is found, re-
place the bearing.
2. Check the steering worm gear and
pitman shaft pin for wear or damage. If
6. Remove the steering gear box bolts and
such wear is found, replace the gear and
remove the steering gear box.
pin.
 NOTE:
Keep the golf car in a horizontal position and
front wheels steered straight. Fill oil until it
overflows the oil inlet.

6. Align the mark on the lower end of the

pitrnan shaft with the marks on the idler
arm as shown, and ins21 the idler arm
onto the pitrnan shaft. Install and
tighten the lock nut on the end of the
pitrnan shaft.
Then, to secure the lock nut, bend the
C. Assembly washer lock tab so that the bent tab is in
1. Install the taper-roller bearing and steer- close contact with the lock nut side. (See
ing shaft into the steering column. the following illustration.)
2. Install the lock nut, bolt and pitrnan
arm.
3. Install the steering gear cover and the
four cover bolts.
NOTE:
Use two gaskets.

,
Tightening torque:
25 Nrn (2.5 m-kg, 18 ft-Ib)

4. Install the steering gear box, and secure

with the four washer head bolts.
Tightening torque:
Tightening torque: 85 Nrn (8.5 rn-kg, 61 ft-lb)
29 Nrn (2.9 rn. kg, 21 f t - Ib)

5. Fill with steering gear oil.

Don't forget t o lock the lock nut with lock
SAE 90: washer tab after tightening the lock nut.
150 crn3 (0.13 Imp qt, 0.16 US qt)
7. Back lash adjustment:
In installation, first carefully retighten
the worm gear tightening adjustment
bolt (1) to the farthest extent that will
permit no more steering wheel move-
ment, then loosen this bolt. After this
proceudre comes the final adjustment, in
which the same bolt must be screwed in
just enough not t o allow axial looseness
t o occur and then be locked with the
lock nut. The same sequence should be
followed in the case of the pitman shaft
adjustment bolt (2).

12. Apply a small amount of grease to the

taper and spline and install the wheel in
the position shown by pushing it gently
onto the shaft. Secure the wheel to the
shaft with the plain washer and nut.

8. Install the front cowl. Tightening torque:

9. Install the instrument panel on the steer-
ing column, then connect the main
switch wire.
10. Install the main switch, choke wire and
instrument panel screws.
63 Nm (6.3 m. kg, 45 ft* Ib)
13. Snap the score card holder onto the
steering wheel.
6-3.WHEEL ALIGNMENT
Measure the wheel alignment with the vehicle
parked on level ground and with the front
wheels placed in the straight-ahead position.
Front suspension, steerirlg system, wheels and
tires should be serviced t o normal condition
prior to measurement of wheel adjustment.

Toe-in (at centre of tire tread B-A):

-
10 20 mm (Unloaded)
0 mm (Fully loaded)

11. Position the front wheels straight ahead.

Position the steering wheel symmetrical-
ly as shown below and align it with the
serrations on the steering shaft.
NOTE:
Be careful not to misalign the wheel to steer-
ing wheel relationship.
Make adjustment of the toe-in with the turn-
buckle of the left tie rod. Toe-in increases
when the turnbuckle is turned in the forward
direction. The difference in the length b e
tween right and left tie rods should not
exceed 5 mm (0.2 in). If the difference
exceeds 5 mm (0.2 in), remove the right tie
rod from the knuckle and adjust i t s length so
that the difference is within 5 mm (0.2 in).
Then make adjustment of toe-in. Toe-in
changes by about 7.5 mm (0.29 in) when the
turnbuckle of the left tie rod is turned once.

6-4. STEERING LINKAGE

(5.8-7.8 m.kg.42-56 ft-lb)

Front lower arm comp.

A. Tie Rod Removal:
Removal and Replacement: 1. Remove the cotter pin and remove the
1. Disconnect the tie rod ends from the hub nut.
knuckle arm and idler arm.

1. Cotter pin 2 . Hub nut

2. Check the ball joints for cracks, damage 2. Using a hammer, remove the hub from
and deformation. the knuckle arm.
3. Tighten the t i e rod to the knuckle arm
and idler arm.

Tightening torque:
85 Nm (8.5 m-kg, 61 ft-lb)

NOTE:
Make adjustment of the toein.

6. Wheel Bearings
Check and Adjustment:
1. By turning the bearing in the direction 3. Removal of bearings from the hub.
of (1), check for abnormal noise.
2. By moving it in the direction of ( 2 ) ,
check for looseness or excessive play.
3. If necessary tighten the hub nut to speci-
fication. Perform checks 1 and 2 again.

Tightening torque:
140 Nm (14 m-kg, 100 ft-lb)

Replacement:
For assembly, reverse the for disassemblv.

6-5. KNUCKLE ARM

Separate the following parts from the knuckle

arm.
Tire
Front hub
Tie rod
6-11
 1. Remove the king pin nut. Pull out 2. Check the knuckle arm for damage and
the king pin. bends.

Tightening torque:
King pin:
87 Nm (8.7 m. kg, 65 ft. Ib)

6-6. REAR AXLE

Rear axle housing comp.

Rear axle shaft comp.

A. Removal and Replacement
1. Place a jack under the rear arm and jack
up the rear of the car.
2. Remove the rear wheel nuts.
3. Remove the brake drum.
B. Inspection and Repair
1. To check the axle shaft for bends, block
it at both its ends, and read the dial
gauge positioned at the center of the
axle shaft. A bent axle shaft adversely
affects riding comfort (or machine
stability). I f bent more than specific*
tion, it should be replaced.

4. Remove the bolt securing the brake shoe

plate to the rear axle housing. Runout limit: 0.3 mm (0.012 in)

Bolts (M6 x 4)

5, Pull the brake shoe plate in the axial

direction, and both the brake shoe plate
and rear axle can be removed. 2. The splined portion may tend to twist or
crack. Check it visually, and replace the
axle shaft, i f necessary.

C. Replacement
For assembly, reverse the procedure for dis-
assembly.

Tightening torque:
30 Nm (3.0 mekg, 22 ft-Ib)
6-7. SHOCK ABSORBER AND SPRING AS-
SEMBLY

A. Removal
1. Place a jack under the frame and jack up
the car.
2. For safety, place blocks under the car.
3. Remove the wheel nuts, and remove the
wheels.
4. Loosen the 2 bolts securing the shock
absorber and spring assembly. While 1. Bolts
supporting the lower arm, remove the B. Replacement
shock absorber spring assembly. For assembly, reverse the procedure for dis-
assembly.

6-8. REAR SHOCK ABSORBER SPRING

ASSEMBLY

Engine bracket

Rear cushion
A. Removal
1. Place a jack under the rear bumper and
jack up the rear of the car.
2. For operation safety, place blocks under
the car.
3. Remove the 2 bolts securing each shock
absorber and spring assembly. While
supporting the rear arm assembly, r e
move the shock absorber and spring.
4. Remove the bolts from the front of the
arm and allow it to swing down free of
the chassis.
Support the front of the rear arm to avoid
damage to wiring cables, etc., by dropping
downward too far.
5. Remove both right and left bushings
and replace with new ones.

C. Disassembly
For assembly, reverse the procedure for
disassembly.

6-10. OIL TANK

B. Replacement
For assembly, reverse the procedure for dis-
assembly.

6-9. REAR ARM BUSHING

A. Checking
Free play of shaft and bushing.

1. Check the oil line from the tank to the

pump. I t should be free from all obstruc-
tions and should not be pinched or
1 . Bushings
damaged in any way. Replace as neces-
sary.
B. Replacement
1. Support the rear of the golf car and
block the front wheels.
2. Release the wiring harness and cables
from their clips on the rear arm and
chassis near the front of the rear arm.
3. Remove the muffler.
6-11. FUEL TANK

Fuel line t o carburetor

Fuel pump ass'y

Fuel filter ass'

1. Check all lines. If any are cracked,
crimped, or damaged in any way, replace
them.
2. Be sure all lines are secured in place by a
retaining clip.
3. Be sure that all lines are routed as shown
in the Cable Routing Diagram in the
appendix.
4. Replace the fuel filter each season.
5. When reinstalling the fuel tank, torque
the four securing bolts to specification.
Tightening torque:
10 Nm (1.0 m-kg, 7.2 ft-Ib)
6-12. BODY

A. Frame

-
6. Body Fitting

Floor mat

@
C. FrontIRear Bumper

Front

Rear

20 N m
(2.0 rn-kg, 14 ftelb)

25 Nm
(2.5 m-kg,1 8 ftelb)
D. FrontIRear Cowl

Front

Plastic panhead screw

lastic washer (Black)

Rear
E. Seat

k"

Seat ass'y (right)

F. Carrier
 CHAPTER 7. ELECTRICAL SYSTEM
7.1 . MAIN PARTS AND FUNCTIONS ............................ 7-1

7.2 . CHARGINGSYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

A . Operation of voltage regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
B. Route of charging current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
C. Voltage regulator - Measuring and adjustment . . . . . . . . . . . . . . . 7-4
D. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.3 . STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

A . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
B. Checking the starter system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
C. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
D. Performance of starter generator . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
E. Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
F . Inspection while disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

7.4 . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

A . Basic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
B. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
C. Checking the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
D. Ignition timing - Inspection and adjustment . . . . . . . . . . . . . . . .7-16
E. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 .

7.5 . SIGNAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19

A . Back-up buzzer circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
B. l nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19

7.6 . NOTES ON THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19

A . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
B. Check items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19.
C. Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

7.7 . CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21

7.8 . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Ea
 ELECTRICAL SYSTEM
7-1. MAIN PARTS AND FUNCTIONS

Back-up buzzer
v

1. Main switch assembly
2. Accelerator stop switch
3. Battery
4. Starter generator assembly
1. Main switch:
Changes the direction of car from For-
ward to Reverse or vice versa. Locks the
ignition. After starting the engine, it
allows current to flow to the solenoid.
2. Accelerator stop switch:
When the accelerator pedal is depressed,
the magneto circuit is opened to allow
the engine to start. When released, cur-
rent from charge is grounded t o the
chassis, thus stopping the engine.
3. Battery:
Supplies power to starter and back-up
buzzer.
4. Starter generator:
Serves as starter when receiving current
from battery to start the engine, and acts
as generator after the engine starts.
FWD
5. Forward solenoid relay 8. Back-up buzzer
6. Reverse solenoid relay 9. CDI unit assembly
7. Voltage regulator assembly 10. Ignition coil ass'y
5. Forward solenoid relay:
Current flows from battery to starter.
6. Reverse solenoid relay:
Current flows from battery to starter in
the reverse direction.
7. Voltage regulator:
Controls charging current flowing from
shunt coil in starter generator.
8. Back-up buzzer:
Gives an alarm when backing the car.
9. CDl unit:
Stores current from the CDI magneto
charge coil in condenser, and discharges
stored current to the primary winding of
the ignition coil when triggered by the
pulser coil.
10. Ignition coil:
Produces a high voltage in the secondary
side when current flows to the primary
side from CDI unit.
7-2. CHARGING SYSTEM
A. Operation of voltage regulator
1. When the main switch is turned to For-
ward or Reverse and the accelerator
pedal is depressed and the engine is run-
ning current flows from the battery to
the starter generator shunt coil.
Battery - Accelerator stop switch -
Main switch - Shunt coil - a - b -
Earth (ground)
2. When the engine speed is low, current
flows as shown in 1 above; that is, the
current flowing to the shunt coil in-
creases without being controlled, and the
generator voltage also increases.
3. When the engine speed increases from
low to medium, the generator voltage
further increases, and the voltage coil
- 9. Battery
B. Route of charging current
1. Forward
When the main switch i s turned to "For-
ward" and the accelerator pedal is de-
pressed, the current from the battery
flows t o the coil in the forward solenoid
relay, thus turning on the switch. When
the engine speed exceeds 1,500 rlmin,
the generator starts to generate power,
and when the voltage rises to 12 volts,
charging to the battery starts.
causes "b" to separate from "a" by its
attraction. As a result, the current pas-
sing through the shunt coil must flow to
resistor "R", and the current flow is de-
creased. Battery charging current is de-
creased because the shunt coil magnetic
field is decreased.
4. When the engine speed increases from
medium to high, the generator voltage
further increases, thus making the attrac-
tion of the voltage coil much stronger.
This brings "b" to contact "c" and the
current from the battery bypasses the
shunt coil and flows through the route
of b - c. The shunt coil i s short circuited
and very l i t t l e charging current flows to
the battery.
5. By repeating the steps, 2, 3 and 4 above,
the generator voltage i s regulated.
1. Series coil
2. Armature
3. Solenoid relay
4. Shunt coil
5. Main switch
6. Accelerator stop
switch
7. Voltage coil
8. Voltage regulator
The charging voltage i s regulated by the
voltage regulator, which controls the
magnetic field produced by the shunt
coil.
4. To check the function of brush spring,
hook a spring scale to brush spring and
pull. When spring comes off brush, read
the scale.
1. Brush spring 3. Spring scale
2. Steel-wire-made spring puller
New brush
If the reading is less than specified, the
brush spring should be replaced.
Commutator
1. Inspection and maintenance
The commutator is the most important
component of the motor. An oil-stained
or dusty commutator will cause brushes
to wear fast, and the motor becomes in-
operative. It is advisable to check the
commutator for roughness, pits, uneven
wear, or grooves in the brush track.
a. If roughness and wear are present only
t o a minor degree, or i f contact surfaces
are dirty with carbon dust, sandpapering
is required in the manner as illustrated.
Wrap armature in protective covering
and lightly grip i t s core with a vise. Use a
sandpaper strip to smooth the surface.
8-20
Place an aluminium or copper sheet
between core and vise to protect the
core against damage.
Clean the surface with compressed air or
with a clean, dry cloth.
NOTE:
Partial polishing will only deform commuta-
tor and shorten brush life. Take care to main-
tain the roundness of commutator while sand-
papering.
b. If commutator is deeply pitted o t
grooved, commutator must be refinished
by mounting in a lathe. Limit the depth
of cut to 0.13 mm (0.005 in) or less and
repeat cut as require.
Service spec. of commutator
Diameter 29 mm (1.14 in)
Do not reduce the diameter to less than 27
mm (1.06 in).
2. Eccentricity
After refinishing, it should not exceed
0.025 mm (0.001 in) runout.
When the difference between the maxi-
mum and minimum diameter exceeds
0.1 mm (0.004 in), refinishing is re-
quired.
Mica undercut
If the depth of mica undercut between seg-
ments is less than specified below, the mica
should be undercut with saw blade. All the
mica undercuts must be the same in depth
and parallel to each other and to the center
line of the shaft. (See Fig. A)
NOTE:
Correction should be made by moving saw Standard: -
0.8 1 .O mm
blade parallel to the shaft. -
(0.03 0.04 in)
Minimum: 0.2 mm (0.006 in)

0 X

Commutator

0 X
Chamfer
Segment M lca

CORRECT INCORRECT
Fig. A

2. After undercutting, chamfer the edges the yoke. (See Fig. C) There should be
segments lightly using a fine file, and no continuity.
finish with fine sandpaper.
Fig. B
Ball bearing
The bearings should be removed and re-
placed only when they are faulty. For re-
moval, refer to page 8-18 ((2-8).
Insulation resistance
Using a 500 Volt insulating resistance tester
(Megger), measure the resistance.
The tester readings below should be more
than 1 M a . If less than 1Ma, blow off the
carbon dust with compressed air or with a hot
air dryer.

Insulation resistance measurement

The insulation resistance between the
armature and brush holder can be mea-
sured by measuring the insulation resist-
ance between the A1 or A2 terminal and
the yoke. (See Fig. B) There should be
no continuity.
The insulation resistance of the field coil
can be measured by measuring the resist-
ance between the F 1 or F2 terminal and
8-5. ELECTRIC WIRE ROUTING
-I - - -- . - --
8 ,

V i e w i n direction o f C:
Main switch section

stall the tube so that Minus fuse holder

re does n o t contact A 1 assembly
d l o r F 1 terminal.

Switch c o r d band

Plus fuse holder

, - - ~ -- ~ ~ - -
,.. --.- ~ ~

8 Rear fender section

Lead wire

N o t e 1:
When connecting lead wires
t o t h e relay assembly,
be careful so that terminals
d o n o t contact each other.

N o t e 2: Place the tube

0FWD
Positive lead wire

8attery@ Receptacle
Relay ass'y section
View i n direction of A
8-7. ACCELERATOR

qj \

Accelerator rod
8-8. SOLENOID RELAY ASSEMBLY

Controller cover

@
8-9. SPEED CONTROLLER

Lead wire
 CHAPTER 9 . TROUBLESHOOTING
9.1 . GI-A3 ...................................................9-1
A . Troubleshooting Chart ..................................9.1
B. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
C. Suspension and Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2

9-2 . G1.E3 ................................................... 9.4

A . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.4
B. Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
 TROUBLESHOOTING

A. Troubleshooting Chart

POOR IDLE OR LOW POOR MIDRANGE OR HIGH

SPEED PERFORMANCE SPEED PERFORMANCE

TURN OFF Ie)

n -1 -
REPLACE PLUG

RESETTIMING ADJUST
I
REPLACE I T

READJUST BRAKES

Ft LEVEL I T 1- E:F":.":N
CIRCUITS
I
MAIN JET COMPRESSION
C'EC" w""
COMPRESS1ON
TESTER

PILOT SCREW

CARE LOW REPAIR AS

REPLACE OR
t
INCORRECT
PILOT JET
BUILDUP

NECESSARY

1 1 - REPAIR AS
NECESSARY

e~ REPAIR

B. Engine

I I 1 1
Condition
ENGINE WILL NOT
START.
1 Possible Cause
1. Weak battery.
Correction
1. Test battery specific gravity.
Recharge or replace as necessarv.
2. Corroded or loose battery connec- 2. Clean and tighten battery connec-
tions. tion. Apply a coat of grease to
terminals.
3. Faulty starter. 3. Repair starter motor.
4. Moisture on ignition wires and spark 4. Wipe wires and cap clean and dry.
plug cap.
5. Faulty ignition cables. 5. Replace any cracked or shorted
1 cables.
1 6. Open or shorted primary ignition cir-
cuit.
6. Trace primary ignition circuit and
repair as necessary.
1 7. Faulty coil. i 7. Test and re~laceif necessarv. 1
1
-
8. Incorrect mark ~ l u aap.
a 1
-
8. Set a a correctlv.
~ 1
9. Incorrect ignition timing. 9. Reset timing.
10. Dirt or water in fuel line or carbure- 10. Clean lines and carburetor. Replace
tor. filter.
1 11. Carburetor flooded. I 11. Adjust float level - check seats. I
12. Incorrect carburetor float setting. 12. Adjust float level - check seats.
13. Faulty fuel pump. 13. Install new fuel pump.
14. Carburetor percolating. No fuel in 14. Measure float level. Check bowl
the carburetor. vent.