Page 1 SERVICE MANUAL UTILITY VEHICLE YUM1A YUM2A YUM2E LIT-19616-A0-37 J0F-F8197-E1...
Page 3 This manual was produced by the Yamaha Motor Powered Products Co., Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a me- chanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Page 4 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium-soap-based grease...
Page 7: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE (YUM1A/YUM2A) FUEL SYSTEM (YUM1A/YUM2A) DRIVE TRAIN ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION .................... 1-1 UTILITY VEHICLE SERIAL NUMBER ............1-1 ENGINE SERIAL NUMBER (YUM1A/YUM2A) ......... 1-1 TRACTION MOTOR SERIAL NUMBER (YUM2E)........1-1 MOTOR CONTROL UNIT SERIAL NUMBER (YUM2E) ......1-1 SAFETY PRECAUTIONS................1-2 SAFETY LOCKOUT PROCEDURE ............1-2 DISCHARGE THE MOTOR CONTROL UNIT CAPACITOR..... 1-2 RECOMMENDED JACK POINTS .............
Page 10: Identification
IDENTIFICATION IDENTIFICATION UTILITY VEHICLE SERIAL NUMBER The utility vehicle serial number “1” is affixed to the frame under the cargo bed. ENGINE SERIAL NUMBER (YUM1A/YUM2A) The engine serial number “1” is affixed to the cyl- inder head cover. TRACTION MOTOR SERIAL NUMBER (YUM2E) The traction motor serial number “1”...
Page 11: Safety Precautions
SAFETY PRECAUTIONS SAFETY PRECAUTIONS RECOMMENDED JACK POINTS Jack up the vehicle at the indicated jacking points. SAFETY LOCKOUT PROCEDURE 1. Turn the main switch to “OFF” position. 2. Apply the parking brake. 3. Move the shift lever to the neutral position. In- sert a screwdriver “1”...
Page 12: Important Information
5. Keep all parts away from any source of fire. REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 13: Bearings And Oil Seals
IMPORTANT INFORMATION BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.
Page 14: Basic Service Information
BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
Page 15: Electrical System
BASIC SERVICE INFORMATION NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
Page 16 BASIC SERVICE INFORMATION NOTICE Checking the electrical system Handle electrical components with special care, and do not subject them to strong Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V (YUM1A/YUM2A) or 6V (YUM2E). NOTICE Electrical components are very sensitive to NOTICE...
Page 17 BASIC SERVICE INFORMATION 2. Check: • Lead • Coupler • Connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect sev- eral times. Checking the connections Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1.
Page 18 BASIC SERVICE INFORMATION Digital circuit tester (CD732) Intake air temperature sensor re- 90890-03243 sistance Model 88 Multimeter with ta- 2.21–2.69 kΩ at 20 °C (2.21–2.69 chometer kΩ at 68 °F) YU-A1927 Intake air temperature sensor re- sistance 0.322 kΩ at 80 °C (0.322 kΩ...
Page 19 SPECIAL TOOLS SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 20: Special Tools
SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Valve spring compressor 5-12, 5-16 90890-04019 Valve spring compressor YM-04019 Valve guide remover (ø6) 5-13 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6) 5-13 90890-04065 Valve guide installer (6.0 mm)
Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-29 90890-01304 Piston pin puller YU-01304 YU-01304 Pressure gauge 90890-03153 Pressure gauge YU-03153 Fuel pressure adapter 90890-03186 Fuel pressure adapter YM-03186 Primary fixed sheave puller 90890-01876 Primary clutch puller YG-01876 Bolt 7-5, 7-6...
Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Dynamic spark tester 8-55 90890-06754 Oppama pet–4000 spark checker YM-34487 Test harness S– pressure sensor 5S7 (3P) 8-58 90890-03207 Test harness S– pressure sensor 5S7 (3P) YU-03207 PC GENIUS2 diagnostic tool 90890-J0CDC-00 DISCHARGE TESTER 36/48V 8-73 LES-DISCH-AR-GE...
Page 23: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS (YUM1A/YUM2A)..........2-3 CHASSIS SPECIFICATIONS ................2-6 DRIVE TRAIN SPECIFICATIONS (YUM1A/YUM2A) ........2-7 DRIVE TRAIN SPECIFICATIONS (YUM2E) ........... 2-8 ELECTRICAL SPECIFICATIONS (YUM1A/YUM2A)........2-9 ELECTRICAL SPECIFICATIONS (YUM2E) ..........2-11 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUE (YUM1A/YUM2A) ......2-13 FUEL SYSTEM TIGHTENING TORQUE (YUM1A/YUM2A)....
Page 24: General Specifications
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Model code J0F2 (YUM1A) J0G2 (YUM2A) J0H2 (YUM2E) Frame serial number J0F-100101 (YUM1A) J0G-100101 (YUM2A) J0H-100101 (YUM2E) Dimensions Overall length 2830 mm (111.5 in) (YUM1A) 3030 mm (119.4 in) (YUM2A/YUM2E) Overall width 1255 mm (49.3 in) Overall height (Steering height) 1235 mm (48.5 in) Height of floor...
Page 25 GENERAL SPECIFICATIONS 1174 kg (2589 lb) (YUM2E) Hill claiming ability 20° (YUM1A) 15° (YUM2A/YUM2E)
Page 26: Engine Specifications (Yum1A/Yum2A)
ENGINE SPECIFICATIONS (YUM1A/YUM2A) ENGINE SPECIFICATIONS (YUM1A/YUM2A) Engine Engine type 4-stroke, Gasoline, 60° inline OHV Number of cylinders Single Displacement 402 cm³ Bore × stroke 85 × 70.8 mm (3.30 × 2.79 in) Compression Ratio 8.2:1 Compression Pressure 700–900 kPa (7.0–9.0 kgf/cm², 102–131 psi) Starting system Electric starter/generator Gross output...
Page 27 ENGINE SPECIFICATIONS (YUM1A/YUM2A) Valve, valve seat, valve guide Valve clearance cold Intake and exhaust side 0.05–0.09 mm (0.0020–0.0035 in) Valve dimensions Valve seat contact width (intake) 0.7–0.9 mm (0.0276–0.0354 in) Valve seat contact width (intake) limit 1.6 mm (0.063 in) Valve seat contact width (exhaust) 0.7–0.9 mm (0.0276–0.0354 in) Valve seat contact width (exhaust) limit...
Page 28 ENGINE SPECIFICATIONS (YUM1A/YUM2A) Air filter Type Oil spread over pleated paper + urethane foam pre filter Fuel pump Pump type Electrical Fuel line pressure 246–254 kPa (2.46–2.54 kgf/cm², 35.7–36.8 psi) Fuel injector Model/quantity J0B1 00/1 12.0 Ω Resistance...
Page 29: Chassis Specifications
CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Chassis Toe-in (with tires touching the ground) 0–10 mm (0–0.4 in) Wheel Tire size 20 × 10.00-10/4-ply turf type Front 20 × 10.00-10/4-ply turf type Rear Rim size 7.00–9.968 (Offset 1) Tire pressure Recommended Front 137 kPa (1.37 kgf/cm²,20 psi) Rear 151 kPa (1.57 kgf/cm², 22 psi) Minimum...
Page 30: Drive Train Specifications (Yum1A/Yum2A)
DRIVE TRAIN SPECIFICATIONS (YUM1A/YUM2A) DRIVE TRAIN SPECIFICATIONS (YUM1A/YUM2A) Primary and secondary sheave Type V-belt automatic centrifugal engagement 31.0 × 1010 mm (1.22 × 39.75 in) V-belt width and outer line length V-belt wear limit 28.0 mm (1.10 in) Secondary sheave torque cam angle Transmission Governor type Oil bath flyweight...
Page 31: Drive Train Specifications (Yum2E)
DRIVE TRAIN SPECIFICATIONS (YUM2E) DRIVE TRAIN SPECIFICATIONS (YUM2E) Transmission Secondary reduction system Helical gear Secondary reduction ratio 15.31:1 Differential type Bevel gear Transmission oil Type SAE 80W-90 or SAE 90 gear oil Quantity 355 cm³ (0.38 US qt, 0.31 Imp.qt) Traction motor Model AMT7179...
Page 32: Electrical Specifications (Yum1A/Yum2A)
ELECTRICAL SPECIFICATIONS (YUM1A/YUM2A) ELECTRICAL SPECIFICATIONS (YUM1A/YUM2A) Voltage System voltage 12 V Ignition System Ignition System Ignition timing (B.T.D.C.) 16°/3000 r/min Ignition coil Minimum ignition spark gap 6 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.69 kΩ Spark plug cap Resistance 3.75–6.25 kΩ...
Page 33 ELECTRICAL SPECIFICATIONS (YUM1A/YUM2A) USB fuse 2-10...
Page 34: Electrical Specifications (Yum2E)
ELECTRICAL SPECIFICATIONS (YUM2E) ELECTRICAL SPECIFICATIONS (YUM2E) Voltage System voltage 48 V Throttle position sensor Resistance 0.66–1.54 kΩ Battery Model Trojan - golf car type 48 V (6 V × 8), T-105: 225 Ah at 20 h rate/115 Voltage, capacity minutes at 75 A Fuses Main fuse 10 A...
Page 35: Tightening Torques
TIGHTENING TORQUES TIGHTENING TORQUES GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 36: Engine Tightening Torque (Yum1A/Yum2A)
TIGHTENING TORQUES ENGINE TIGHTENING TORQUE (YUM1A/YUM2A) Thread Item Q’ty Tightening torque Remarks size Muffler nut 17 N·m (1.7 kgf·m, 13 lb·ft) Muffler mount bolt 17 N·m (1.7 kgf·m, 13 lb·ft) Muffler bracket bolt 25 N·m (2.5 kgf·m, 18 lb·ft) Exhaust pipe bolt 25 N·m (2.5 kgf·m, 18 lb·ft) Exhaust pipe stay bolt 25 N·m (2.5 kgf·m, 18 lb·ft)
Page 37 TIGHTENING TORQUES Cylinder head bolt Tighten the cylinder head bolts to 50 N·m (5.0 kgf·m, 37 lb·ft) in the proper tightening sequence. Crankcase cover bolt Tighten the crankcase cover bolts to 30 N·m (3.0 kgf·m, 22 lb·ft) in the proper tightening sequence. 2-14...
Page 38: Fuel System Tightening Torque (Yum1A/Yum2A)
TIGHTENING TORQUES FUEL SYSTEM TIGHTENING TORQUE (YUM1A/YUM2A) Thread Item Q’ty Tightening torque Remarks size Fuel tank bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Fuel tank retainer bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Fuel pump nut 7 N·m (0.7 kgf·m, 5.2 lb·ft) Air filter case bolt 14 N·m (1.4 kgf·m, 10 lb·ft) Air filter case nut...
Page 39: Drive Train Tightening Torque (Yum1A/Yum2A)
TIGHTENING TORQUES DRIVE TRAIN TIGHTENING TORQUE (YUM1A/YUM2A) Thread Item Q’ty Tightening torque Remarks size Primary sheave assembly bolt 85 N·m (8.5 kgf·m, 63 lb·ft) Primary sheave cup bolt 5 N·m (0.5 kgf·m, 3.7 lb·ft) Spider roller nut 6 N·m (0.6 kgf·m, 4.4 lb·ft) Spider roller collar set bolt 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Primary sliding sheave weight nut...
Page 40: Chassis Tightening Torque
TIGHTENING TORQUES CHASSIS TIGHTENING TORQUE Thread Item Q’ty Tightening torque Remarks size Engine mounting nut 54 N·m (5.4 kgf·m, 40 lb·ft) Baffle plate bolt (YUM2A) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Seat back bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Seat frame bolt 16 N·m (1.6 kgf·m, 12 lb·ft) Cargo bed pivot nut...
Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel hub nut 162 N·m (16.2 kgf·m, 116 lb·ft) Rear wheel nut 102 N·m (10.2 kgf·m, 75 lb·ft) Rear wheel hub nut 210 N·m (21 kgf·m, 155 lb·ft) Front brake plate nut (YUM2A/ 41 N·m (4.1 kgf·m, 30 lb·ft) YUM2E) Rear brake plate nut...
Page 42 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Connecting rod nut 100 N·m (10 kgf·m, 74 lb·ft) Rear suspension arm nut 90 N·m (9.0 kgf·m, 66 lb·ft) Bushing bolt 53 N·m (5.3 kgf·m, 39 lb·ft) Bottom panel bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) USB plug bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2-19...
Page 43 TIGHTENING TORQUES 2-20...
Page 44: Cable Routing
CABLE ROUTING CABLE ROUTING YUM1A Frame (top view) 2-21...
Page 45 CABLE ROUTING 1. Wire harness 2. Fuel hose 3. Fuel pump coupler 4. Intake air temperature sensor 5. Plastic band 6. Voltage regulator 7. Fuel pump relay 8. Positive battery lead 9. Negative battery lead 10. Accelerator switch coupler 11. Main switch 12.
Page 46 CABLE ROUTING YUM1A Front and rear 2-23...
Page 47 CABLE ROUTING 1. Wire harness 2. USB port 3. Starter generator 4. Negative battery lead 5. USB plug 6. Sub-wire harness A. Route the headlight leads through the clamps. B. Fasten the wire harness at the white tape with a plastic band.
Page 48 CABLE ROUTING YUM1A Left side 2-25...
Page 49 CABLE ROUTING 1. Fuse box 2. FI diagnostic tool coupler 3. ECU (Engine Control Unit) 4. Wire harness 5. Reverse buzzer 6. Horn 7. Voltage regulator 8. Fuel pump relay 9. USB couplers A. 0–45° B. Fasten the wire harness at the white tape with a plastic band.
Page 50 CABLE ROUTING YUM1A Brake and throttle cables 2-27...
Page 51 CABLE ROUTING 1. Throttle cable 1 2. Rear brake cable (right) 3. Rear brake cable (left) 4. Shift control cable (reverse) 5. Shift control cable (forward) A. Route the throttle cable 1 above the frame and rear suspension arm. B. Yellow ring 2-28...
Page 52 CABLE ROUTING YUM1A Shift cables 2-29...
Page 53 CABLE ROUTING 1. Shift control cable (forward) 2. Shift control cable (reverse) 3. Plastic band 4. Reverse switch 2-30...
Page 54 CABLE ROUTING YUM2A Frame (top view) 2-31...
Page 55 CABLE ROUTING 1. Wire harness 2. Fuel hose 3. Intake air temperature sensor 4. Voltage regulator 5. Fuel pump relay 6. Positive battery lead 7. Negative battery lead 8. Accelerator switch coupler 9. Main switch 10. Ground lead 11. Main relay 12.
Page 56 CABLE ROUTING YUM2A Front and rear 2-33...
Page 57 CABLE ROUTING 1. Wire harness 2. USB port 3. Starter generator 4. Negative battery lead 5. USB plug 6. Sub-wire harness 7. Ground lead A. Route the headlight leads through the clamps. B. Fasten the wire harness at the white tape with a plastic band.
Page 58 CABLE ROUTING YUM2A Left side 2-35...
Page 59 CABLE ROUTING 1. Fuse box 2. FI diagnostic tool coupler 3. ECU (Engine Control Unit) 4. Wire harness 5. Reverse buzzer 6. Reverse buzzer lead 7. Horn 8. Voltage regulator 9. Fuel pump relay 10. USB couplers A. 0–45° B. Fasten the wire harness at the white tape with a plastic band.
Page 60 CABLE ROUTING YUM2A Brake, throttle and shift cables 2-37...
Page 61 CABLE ROUTING 1. Front brake cable (right) 2. Shift lever 3. Throttle cable 1 4. Shift control cable (reverse) 5. Shift control cable (forward) 6. Front brake cable (left) 7. Rear brake cable (left) 8. Rear brake cable (right) 9. Reverse switch A.
Page 62 CABLE ROUTING YUM2E Frame (top view) 2-39...
Page 63 CABLE ROUTING 1. Speed sensor coupler 2. Traction motor temperature sensor coupler 3. Traction motor leads 4. Traction motor 5. Taillight lead 6. Wire harness 7. Accelerator switch coupler 8. TPS (throttle position sensor) 9. Accelerator switch 10. Horn switch lead 11.
Page 64 CABLE ROUTING YUM2E Front and rear 2-41...
Page 65 CABLE ROUTING 1. USB port 2. Battery gauge/warning light 3. Shift switch 4. USB plug A. Route the headlight leads through the clamps. 2-42...
Page 66 CABLE ROUTING YUM2E Left side 2-43...
Page 67 CABLE ROUTING 1. Reverse buzzer lead 2. Reverse buzzer 3. Horn 4. Tow switch 5. Negative battery lead 6. MCU (motor control unit) 7. Positive battery lead 8. Main relay 9. Wire harness 10. Voltage regulator 11. USB couplers A. Pass the wire harness through the hole of the footrest.
Page 68 CABLE ROUTING YUM2E Brake cable 2-45...
Page 69 CABLE ROUTING 1. Front brake cable (right) 2. Front brake cable (left) 3. Rear brake cable (right) 4. Rear brake cable (left) A. Pass the front brake cable through the guide. Align the guide with the white tape on the front brake cable.
Page 70 CABLE ROUTING 2-47...
Page 71: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHARTS (YUM1A/YUM2A) ......3-1 PERIODIC MAINTENANCE CHARTS (YUM2E) ........3-3 PRE-OPERATION CHECKS ................3-4 CHECKING THE ENGINE OIL LEVEL (YUM1A/YUM2A) ......3-4 CHECKING THE ENGINE COOLING INLET DUCT (YUM1A/YUM2A)..3-4 CHECKING THE FUEL LINE (YUM1A/YUM2A) ........3-4 CHECKING THE FUEL LEVEL (YUM1A/YUM2A)........3-5 CHECKING THE BATTERY (YUM1A/YUM2A).........
Page 72 ANNUAL CHECKS..................3-12 CHANGING THE ENGINE OIL (YUM1A/YUM2A) ........3-12 ADJUSTING THE THROTTLE CABLES (YUM1A/YUM2A)....3-12 CHECKING THE EXHAUST SYSTEM (YUM1A/YUM2A) ......3-14 LUBRICATING THE PRIMARY SHEAVE (YUM1A/YUM2A) ....3-14 LUBRICATING THE SECONDARY SHEAVE (YUM1A/YUM2A)....3-15 CHECKING AND ADJUSTING THE STARTER GENERATOR BELT (YUM1A/YUM2A) ...................3-15 CHECKING THE DRIVE BELT (YUM1A/YUM2A) ........3-16 CHECKING THE SPEED LIMITER OPERATION (YUM1A/YUM2A)..
Page 74: Periodic Maintenance
PERIODIC MAINTENANCE PERIODIC MAINTENANCE INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon- ger service life and reduce the need for costly overhaul work. This information applies to vehicles al- ready in service as well as to new vehicles that are being prepared for sale.
Page 75 PERIODIC MAINTENANCE CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Daily 160 km 1000 km 2000 km 4000 km 8000 km Remarks...
Page 76: Periodic Maintenance Charts (Yum2E)
PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHARTS (YUM2E) CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Daily 160 km 1000 km 2000 km 4000 km...
Page 77: Pre-Operation Checks
PRE-OPERATION CHECKS PRE-OPERATION CHECKS 130 °F CHECKING THE ENGINE OIL LEVEL (YUM1A/YUM2A) SAE 10W-30 1. Park the vehicle on a level surface and apply the parking brake. SAE 10W-40 2. Remove the under-seat panel (YUM1A). Refer to “GENERAL CHASSIS (1)” on page 4-1.
Page 78: Checking The Fuel Level (Yum1A/Yum2A)
PRE-OPERATION CHECKS Terminal nut 10 N·m (1.0 kgf·m, 7.4 lb·ft) 4. Check: • Battery hold down plate Loose → Tighten. Bolt 6 N·m (0.6 kgf·m, 4.4 lb·ft) 5. Charge: CHECKING THE FUEL LEVEL (YUM1A/ • Battery YUM2A) Refer to “CHECKING AND CHARGING THE 1.
Page 79: Checking The Steering Operation
The tires listed below have been and left. Excessive play → Check that the steering approved by Yamaha Motor Powered Prod- ucts Co., Ltd. for this model. If other tire com- column bolts or steering wheel nut are tight- binations are used, they can adversely affect ened to specification.
Page 80: Checking The Body And Chassis
PRE-OPERATION CHECKS Front WARNING 250 kPa (2.5 kgf/cm²) (36 psi) It is dangerous to ride with a worn-out tire. Rear When the tire tread reaches the wear limit, re- 250 kPa (2.5 kgf/cm²) (36 psi) place the tire immediately. Higher pressures and fast inflation may cause a tire to burst.
Page 81: Monthly Checks
MONTHLY CHECKS MONTHLY CHECKS CHECKING THE DRIVE BELT (YUM1A/ YUM2A) 1. Park the vehicle on a level surface and apply the parking brake. 2. Remove the under-seat panel (YUM1A). Refer to “GENERAL CHASSIS (1)” on page 4-1. 3. Lift up the cargo bed. b.
Page 82: Checking The Battery Electrolyte (Yum2E)
MONTHLY CHECKS b. Insert screwdriver into locking hole “1”. Internal: Drink large quantities of water or c. Loosen both locknuts “2”. milk. Follow with milk of magnesia, beaten d. Turn the adjusting nuts “3” until the correct egg, or vegetable oil. Call physician immedi- adjustment is obtained.
Page 83: 6-Month Checks
6-MONTH CHECKS 6-MONTH CHECKS CHECKING THE AIR FILTER (YUM1A/ YUM2A) 1. Remove: • Air filter • Air filter element Refer to “AIR FILTER CASE” on page 6-4. NOTICE c. Properly dispose of the used solvent. The engine should never be run without the d.
Page 84: Checking The Wire Harness (Yum2E)
6-MONTH CHECKS 2. Remove: 8. Connect: • Spark plug • Spark plug cap Refer to “CYLINDER HEAD AND ROCKER ARMS” on page 5-6. CHECKING THE WIRE HARNESS (YUM2E) NOTICE 1. Check: • Wire harness Before removing the spark plug, blow away Cracks/frayed/corrosive →...
Page 85: Annual Checks
ANNUAL CHECKS ANNUAL CHECKS Engine oil drain plug 27 N·m (2.7 kgf·m, 20 lb·ft) CHANGING THE ENGINE OIL (YUM1A/ 7. Fill: YUM2A) • Crankcase 1. Start the engine, warm it up for several min- (with the specified amount of the recom- utes, and then turn it off.
Page 86 ANNUAL CHECKS • There are two separate throttle cables. Each cable requires adjustment for free play and full throttle operation. 1. Turn the main switch to the “OFF” position. 2. Remove the under-seat panel (YUM1A). Refer to “GENERAL CHASSIS (1)” on page 4-1.
Page 87: Checking The Exhaust System (Yum1A/Yum2A)
ANNUAL CHECKS a. Loosen the locknut “1”. b. Turn the adjusting nut “2” in or out until the clearance is obtained. 4. Check: • Exhaust pipe tail screen Dirt/clogging/damage → Clean or replace. c. Tighten the locknut. 5. Install: 10.Remove: •...
Page 88: Lubricating The Secondary Sheave (Yum1A/Yum2A)
ANNUAL CHECKS 4. Install: 4. Check: • Driver seat frame (YUM1A) • Starter generator belt tension “a” Refer to “GENERAL CHASSIS (1)” on page Apply 100 N (10 kg, 22 lb) of force to the cen- 4-1. ter of the starter generator belt. Out of specification →...
Page 89: Checking The Drive Belt (Yum1A/Yum2A)
ANNUAL CHECKS 1. Check: Starter generator mounting bolt • Standard speed limiter setting 66 N·m (6.6 kgf·m, 49 lb·ft) Out of specification → Adjust. f. Tighten the nut to specification. Standard speed limiter setting 28 km/h (17.5 mph) Starter generator mounting nut 25 N·m (2.5 kgf·m, 18 lb·ft) 2.
Page 90: Checking The Wire Harness (Yum1A/Yum2A)
ANNUAL CHECKS • Battery terminal Yamaha battery terminal cleaner & protector ACC-BATTC-LN-PR CHECKING THE STEERING KNUCKLES 1. Park the vehicle on a level surface and apply the parking brake. 2. Raise the front end of the vehicle so that there is no weight on the front wheels.
Page 91: Checking The Front Wheel Bearing
ANNUAL CHECKS f. Calculate the toe-in using the formula giv- en below. Toe-in = “B” – “A” g. If the toe-in is incorrect, adjust it. d. Tighten the tie-rod end locknuts to specifi- cation. Tie-rod end locknut 45 N·m (4.5 kgf·m, 33 lb·ft) 4.
Page 92: Checking The Transmission Oil Level
ANNUAL CHECKS CHECKING THE TRANSMISSION OIL LEVEL a. Apply pressure to the parking brake pedal 1. Park the vehicle on a level surface and apply “1” until the brake nail “2” catches the first the parking brake. latch position on the sector “3”. 2.
Page 93: 4-Year Checks
4-YEAR CHECKS 4-YEAR CHECKS c. Paint alignment marks “a” on the primary sheave assembly and crankcase. CHECKING THE STARTER GENERATOR BRUSHES AND COMMUTATOR (YUM1A/ YUM2A) 1. Check: • Brush length • Commutator diameter Refer to “CHECKING THE STARTER GEN- ERATOR” on page 5-19. CHECKING THE CYLINDER HEAD BOLTS d.
Page 94: Changing The Transmission Oil
4-YEAR CHECKS Tappet adjusting tool 90890-01311 Six piece tappet set YM-A5970 c. Tighten the locknut to specification. Locknut 7 N·m (0.7 kgf·m, 5.2 lb·ft) 6. Install: A. YUM1A/YUM2A • Cylinder head cover B. YUM2E • Spark plug 4. Install: Refer to “CYLINDER HEAD AND ROCKER ARMS”...
Page 95: Checking The Brake Shoes
4-YEAR CHECKS B. YUM2E 6. Fill: • Transmission case (with the specified amount of the recom- mended transmission oil) Type SAE 80W-90 or SAE 90 gear oil NOTICE Take care not to allow foreign material to en- ter the transmission case. 7.
Page 96 4-YEAR CHECKS 3-23...
Page 97: Chassis
CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE SEATS ................4-2 INSTALLING THE SEATS................. 4-2 GENERAL CHASSIS (2) ................. 4-3 GENERAL CHASSIS (3) ................. 4-6 REMOVING THE MUDGUARD..............4-8 INSTALLING THE MUDGUARD ............... 4-8 GENERAL CHASSIS (4) ................. 4-9 GENERAL CHASSIS (5) ................4-10 REMOVING THE HOOD .................4-12 GENERAL CHASSIS (6) ................
Page 98 FRONT SUSPENSION COMPONENTS ............4-32 CHECKING THE FRONT LOWER ARMS ..........4-34 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ..... 4-34 CHECKING THE STEERING KNUCKLES..........4-34 INSTALLING THE FRONT LOWER ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ..............4-34 REAR SUSPENSION COMPONENTS............4-36 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES....
Page 100: General Chassis (1)
GENERAL CHASSIS (1) GENERAL CHASSIS (1) Removing the seats m (0.7 kgf m, 5.2 lb • • • 16 N m (1.6 kgf m, 12 lb • • • Order Job/Parts to remove Q’ty Remarks Cargo bed Lift up. Seat cushion Under-seat panel Driver seat frame Passenger seat frame...
Page 101: Removing The Seats
GENERAL CHASSIS (1) REMOVING THE SEATS The following procedure applies to both of the seats. 1. Remove: • Seat cushion “1” a. Lift the front of the seat cushion. b. Pull the cushion off. INSTALLING THE SEATS The following procedure applies to both of the seats.
Page 102: General Chassis (2)
GENERAL CHASSIS (2) GENERAL CHASSIS (2) Removing the cargo bed 30 N m (3.0 kgf m, 22 lb • • • 16 N m (1.6 kgf m, 12 lb • • • 16 N m (1.6 kgf m, 12 lb •...
Page 103 GENERAL CHASSIS (2) Disassembling the cargo bed 32 N m (3.2 kgf m, 24 lb 12 13 • • • m (0.7 kgf m, 5.2 lb • • • m (0.8 kgf m, 5.9 lb • • • 32 N m (3.2 kgf m, 24 lb •...
Page 104 GENERAL CHASSIS (2) Disassembling the tailgate m (0.8 kgf m, 5.9 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.8 kgf m, 5.9 lb • • • m (0.8 kgf m, 5.9 lb • •...
Page 105 GENERAL CHASSIS (3) GENERAL CHASSIS (3) Removing the rear covers m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)”...
Page 106 GENERAL CHASSIS (3) Removing the inner covers m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Tail inner cover for YUM1A Tail inner cover for YUM2A Rear inner cover (left) for YUM1A Rear inner cover (left) for YUM2A/YUM2E Rear inner cover (right) for YUM1A...
Page 107: Removing The Mudguard
GENERAL CHASSIS (3) REMOVING THE MUDGUARD The following procedure applies to both of the mudguards. 1. Remove: • Rear inner cover (With mudguard) 2. Remove: • Mudguard “1” Unhook the projections “a” on the mudguard from the rear inner cover. INSTALLING THE MUDGUARD The following procedure applies to both of the mudguards.
Page 108: General Chassis (4)
GENERAL CHASSIS (4) GENERAL CHASSIS (4) Removing the front and side panels m (0.7 kgf m, 5.2 lb • • • m (0.8 kgf m, 5.9 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Seat frames (driver and passenger) 4-1.
Page 109 GENERAL CHASSIS (5) GENERAL CHASSIS (5) Removing the floor mat and instrument panel assembly 1.0 N m (0.10 kgf m, 0.73 lb 1.5 N m (0.15 kgf m, 1.1 lb • • • • • • 4.0 N m (0.40 kgf m, 3.0 lb •...
Page 110 GENERAL CHASSIS (5) Disassembling the instrument panel assembly 2.5 N m (0.25 kgf m, 1.8 lb • • • Order Job/Parts to remove Q’ty Remarks Hinge cover Hinge Hood Hood stopper Nut plate Circlip Handle 4-11...
Page 111: Removing The Hood
GENERAL CHASSIS (5) REMOVING THE HOOD 1. Remove: • Hinge cover When removing the hinge cover “1”, use a flat- head screwdriver to push the cover outward and release the projection “a”. 2. Remove: • Screws • Hood 4-12...
Page 112: General Chassis (6)
GENERAL CHASSIS (6) GENERAL CHASSIS (6) Removing the dashboard 35 N m (3.5 kgf m, 26 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (5)” on page Instrument panel assembly 4-10. Scorecard holder Steering wheel Steering grommet Storage compartment mat (left) Storage compartment mat (right)
Page 113: Installing The Steering Wheel
GENERAL CHASSIS (6) INSTALLING THE STEERING WHEEL 1. Install: • Steering grommet “1” • Steering wheel “2” • Scorecard holder “3” With the front wheels pointing straight ahead, install the steering wheel as shown in the illustration. Steering wheel nut 35 N·m (3.5 kgf·m, 26 lb·ft) 4-14...
Page 114: General Chassis (7)
GENERAL CHASSIS (7) GENERAL CHASSIS (7) Removing the front grille and front fender m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • 1.8 N m (0.18 kgf m, 1.3 lb • •...
Page 115: Front And Rear Wheels
FRONT AND REAR WHEELS FRONT AND REAR WHEELS Removing the front wheels (YUM1A) 162 N m (16.2 kgf m, 116 lb • • • 102 N m (10.2 kgf m, 75 lb • • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front wheels.
Page 116 FRONT AND REAR WHEELS Removing the front wheels (YUM2A/YUM2E) 162 N m (16.2 kgf m, 116 lb • • • 102 N m (10.2 kgf m, 75 lb • • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front wheels.
Page 117 FRONT AND REAR WHEELS Removing the rear wheels 210 N m (21 kgf m, 155 lb • • • 102 N m (10.2 kgf m, 75 lb • • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the rear wheels.
Page 118: Remove The Wheels
FRONT AND REAR WHEELS REMOVE THE WHEELS 1. Park the vehicle on a level surface and apply the parking brake. 2. Elevate: • Wheels Place the vehicle on a suitable stand so that the wheels are elevated. CHECKING THE WHEELS The following procedure applies to all of the wheels.
Page 119: Front And Rear Brakes
FRONT AND REAR BRAKES FRONT AND REAR BRAKES Removing the front brake (YUM2A/YUM2E) 41 N m (4.1 kgf m, 30 lb • • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brakes. Refer to “FRONT AND REAR WHEELS”...
Page 120 FRONT AND REAR BRAKES Removing the rear brakes 42 N m (4.2 kgf m, 31 lb • • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the rear wheels. Refer to “FRONT AND REAR WHEELS” on Rear wheel hub page 4-16.
Page 121: Checking The Brakes
FRONT AND REAR BRAKES Oil deposits → Clean. CHECKING THE BRAKES 1. Check: Remove the oil with a rag soaked in lacquer • Brake shoe lining thinner or solvent. Glazed areas → Repair. Scratches → Repair. Sand the glazed areas with coarse sandpa- Lightly and evenly polish the scratches with per.
Page 122: Pedal Assembly
PEDAL ASSEMBLY PEDAL ASSEMBLY Removing the pedal assembly (YUM1A) 16 N m (1.6 kgf m, 12 lb • • • 17 N m (1.7 kgf m, 13 lb • • • * Yamashield™ or LPS 3® Premier Rust Inhibitor Order Job/Parts to remove Q’ty Remarks...
Page 123 PEDAL ASSEMBLY Removing the pedal assembly (YUM2A/YUM2E) 16 N m (1.6 kgf m, 12 lb • • • 17 N m (1.7 kgf m, 13 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (5)” on page Service lid 4-10.
Page 124 PEDAL ASSEMBLY Disassembling the accelerator pedal 3.8 N m (0.38 kgf m, 2.8 lb • • • 16 N m (1.6 kgf m, 12 lb • • • 3.6 N m (0.36 kgf m, 2.7 lb • • • 10 N m (1.0 kgf m, 7.4 lb •...
Page 125 PEDAL ASSEMBLY Disassembling the brake pedal 10 N m (1.0 kgf m, 7.4 lb 23 N m (2.3 kgf m, 17 lb m (0.7 kgf m, 5.2 lb • • • • • • • • • m (0.6 kgf m, 4.4 lb •...
Page 126: Assembling The Accelerator Pedal
PEDAL ASSEMBLY ASSEMBLING THE ACCELERATOR PEDAL 1. Install: • Oil seal Before install the oil seal, cover the accelerator pedal shaft with a plastic bag to protect. INSTALLING THE PEDAL ASSEMBLY 1. Install: • Throttle cable (YUM1A/YUM2A) • Brake cables 2.
Page 127 PEDAL ASSEMBLY Test harness– TPS (3P) 90890-03204 Test harness– TPS (3P) YU-03204 Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe blue (wire harness color) • Negative tester probe orange (wire harness color) c.
Page 128: Steering System
STEERING SYSTEM STEERING SYSTEM Removing the steering assembly 45 N m (4.5 kgf m, 33 lb • • • 22 N m (2.2 kgf m, 16 lb • • • 52 N m (5.2 kgf m, 38 lb • • •...
Page 129: Removing The Tie-Rod
STEERING SYSTEM REMOVING THE TIE-ROD 1. Straighten the lock washer “a”. 2. Check: • Tie-rod end Bends/damage → Replace. 2. Loosen: Rubber boot damage → Replace the tie-rod • Tie-rod “1” end. INSTALLING THE STEERING SYSTEM 1. Install: • Lock washer “1” Align the tabs “a”...
Page 130: Lubricating The Steering Shaft
STEERING SYSTEM 3. Bends the lock washer “a”. Refer to “INSTALLING THE STEERING WHEEL” on page 4-14. 8. Adjust: • Toe-in Refer to “ADJUSTING THE WHEEL ALIGN- MENT” on page 3-17. LUBRICATING THE STEERING SHAFT Lubricate the pivoting point and metal-to-metal moving parts of the shaft.
Page 131: Front Suspension Components
FRONT SUSPENSION COMPONENTS FRONT SUSPENSION COMPONENTS Removing the front suspension 73 N m (7.3 kgf m, 54 lb 47 N m (4.7 kgf m, 35 lb • • • • • • 80 N m (8.0 kgf m, 59 lb •...
Page 132 FRONT SUSPENSION COMPONENTS Removing the front under bracket 47 N m (4.7 kgf m, 35 lb • • • 47 N m (4.7 kgf m, 35 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (7)” on page Skid plate 4-15.
Page 133: Checking The Front Lower Arms
FRONT SUSPENSION COMPONENTS CHECKING THE FRONT LOWER ARMS • Bushings Wear/damage → Replace. The following procedure applies to both of the front lower arms. 1. Check: • Front lower arm free play a. Check the front arm side play “A” by mov- ing it from side to side.
Page 134 FRONT SUSPENSION COMPONENTS 4-35...
Page 135: Rear Suspension Components
REAR SUSPENSION COMPONENTS REAR SUSPENSION COMPONENTS Removing the rear suspension 125 N m (12.5 kgf m, 92 lb 73 N m (7.3 kgf m, 54 lb • • • • • • 53 N m (5.3 kgf m, 39 lb •...
Page 136 REAR SUSPENSION COMPONENTS Removing the rear suspension 125 N m (12.5 kgf m, 92 lb 73 N m (7.3 kgf m, 54 lb • • • • • • 53 N m (5.3 kgf m, 39 lb • • • 30 N m (3.0 kgf m, 22 lb...
Page 137: Checking The Rear Shock Absorber Assemblies
REAR SUSPENSION COMPONENTS CHECKING THE REAR SHOCK ABSORBER INSTALLING THE CONNECTING ROD ASSEMBLIES 1. Install: The following procedure applies to both of the • Connecting rod “1” rear shock absorber assemblies. 1. Check: Install the connecting rod to the upper hole “a” in •...
Page 138 REAR SUSPENSION COMPONENTS 4-39...
Page 139: Engine (Yum1A/Yum2A)
ENGINE (YUM1A/YUM2A) ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL (1) ................... 5-2 ENGINE REMOVAL (2) ................... 5-3 INSTALLING THE ENGINE............... 5-5 CYLINDER HEAD AND ROCKER ARMS............5-6 REMOVING THE CYLINDER HEAD............5-8 CHECKING THE CYLINDER HEAD ............5-8 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..5-9 CHECKING THE PUSH RODS ..............5-9 INSTALLING THE CYLINDER HEAD ............5-9 VALVES AND VALVE SPRINGS..............
Page 140: Engine Inspection
ENGINE INSPECTION ENGINE INSPECTION 7. Measure: • Compression pressure Out of specification → Refer to steps (b) and MEASURING THE COMPRESSION (c). PRESSURE Compression pressure 700–900 kPa (7.0–9.0 kgf/cm², Insufficient compression pressure will result in a 102–131 psi) loss of performance. 1.
Page 141: Engine Removal (1)
ENGINE REMOVAL (1) ENGINE REMOVAL (1) Removing the muffler and exhaust pipe m (0.7 kgf m, 5.2 lb • • • 25 N m (2.5 kgf m, 18 lb • • • 17 N m (1.7 kgf m, 13 lb •...
Page 142 ENGINE REMOVAL (2) ENGINE REMOVAL (2) Disconnect the couplers and leads Order Job/Parts to remove Q’ty Remarks Refer to “ENGINE REMOVAL (1)” on page Muffler 5-2. Intake manifold Refer to “THROTTLE BODY” on page 6-5. Refer to “STARTER GENERATOR” on page Starter generator 5-17.
Page 143 ENGINE REMOVAL (2) Removing the engine 54 N m (5.4 kgf m, 40 lb 54 N m (5.4 kgf m, 40 lb • • • • • • Order Job/Parts to remove Q’ty Remarks Engine mounting nut Engine mounting bolt Engine...
Page 144: Installing The Engine
ENGINE REMOVAL (2) INSTALLING THE ENGINE 1. Install: • Engine “1” • Engine mounting bolts • Engine mounting nuts 2. Tighten: • Engine mounting nuts Before tightening the nuts, push the engine to- ward left side “a” of frame. Engine mounting nut 54 N·m (5.4 kgf·m, 40 lb·ft)
Page 145: Cylinder Head And Rocker Arms
CYLINDER HEAD AND ROCKER ARMS CYLINDER HEAD AND ROCKER ARMS Removing the cylinder head cover 20 N m (2.0 kgf m, 15 lb • • • 11 N m (1.1 kgf m, 8.1 lb • • • 11 N m (1.1 kgf m, 8.1 lb •...
Page 146 CYLINDER HEAD AND ROCKER ARMS Removing the cylinder head and rocker arms 50 N m (5.0 kgf m, 37 lb • • • m (0.7 kgf m, 5.2 lb • • • 2.3 N m (0.23 kgf m, 1.7 lb •...
Page 147: Removing The Cylinder Head
CYLINDER HEAD AND ROCKER ARMS REMOVING THE CYLINDER HEAD 1. Remove: • Flywheel cover Refer to “FLYWHEEL” on page 5-21. 2. Align: • Piston (to top dead center [TDC] on the compres- sion stroke) a. Carefully insert a dial indicator into the spark plug hole until it contacts the top of the piston.
Page 148: Checking The Rocker Arms And Rocker Arm Shafts
CYLINDER HEAD AND ROCKER ARMS b. Measure the warpage. c. If the limit is exceeded, resurface the cylin- der head as follows. d. Place a 400–600 grit wet sandpaper on the surface plate and resurface the cylin- der head using a figure-eight sanding pat- tern.
Page 149 CYLINDER HEAD AND ROCKER ARMS 2. Install: • Rocker arm shafts “1” • Rocker arm shaft set bolt Rocker arm shaft set bolt 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) When installing a rocker arm shaft set bolt, be sure to fit the bolt into the groove “a” in the rocker arm shaft.
Page 150: Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Refer to “CYLINDER HEAD AND ROCKER Cylinder head ARMS” on page 5-6. Valve cotter Valve spring retainer Valve spring Intake valve Exhaust valve Valve stem seal Intake side only.
Page 151: Removing The Valves
VALVES AND VALVE SPRINGS REMOVING THE VALVES 3. Remove: The following procedure applies to all of the • Valve spring retainer “1” valves and related components. • Valve spring “2” • Valve “3” • Valve stem seal “4” (intake side only) Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.
Page 152 VALVES AND VALVE SPRINGS 2. Replace: • Valve guide After replacing the valve guide, reface the valve seat. To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder Valve guide remover (ø6) head to 100 °C (212 °F) in an oven. 90890-04064 Valve guide remover (6.0 mm) a.
Page 153: Checking The Valve Seats
VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. CHECKING THE VALVE SEATS c. Press the valve through the valve guide The following procedure applies to all of the and onto the valve seat to make a clear valves and valve seats.
Page 154: Checking The Valve Springs
VALVES AND VALVE SPRINGS 1. Measure: • Valve spring free length “a” For the best lapping results, lightly tap the valve Out of specification → Replace the valve seat while rotating the valve back and forth be- spring. tween your hands. Free length (intake) 36.2 mm (1.43 in) Limit...
Page 155 VALVES AND VALVE SPRINGS 3. Install: 5. To secure the valve cotter onto the valve stem, lightly tap the valve tip with a soft-face • Valve stem seal “1” (intake side only) hammer. • Valve “2” • Valve spring “3” NOTICE •...
Page 156: Starter Generator
STARTER GENERATOR STARTER GENERATOR Removing the starter generator 66 N m (6.6 kgf m, 49 lb • • • m (0.5 kgf m, 3.7 lb • • • 25 N m (2.5 kgf m, 18 lb • • • Order Job/Parts to remove Q’ty Remarks...
Page 157 STARTER GENERATOR Disassembling the starter generator m (0.7 kgf m, 5.2 lb • • • 4.2 N m (0.42 kgf m, 3.1 lb m (0.5 kgf m, 3.7 lb • • • • • • 2.0 N m (0.20 kgf m, 1.5 lb •...
Page 158: Checking The Starter Generator
STARTER GENERATOR CHECKING THE STARTER GENERATOR b. If there is no continuity, replace the starter 1. Check: generator. • Commutator Dirt → Clean with 600-grit sandpaper. 2. Measure: • Commutator diameter “a” Out of specification → Replace. Commutator diameter limit 39 mm (1.54 in) 5.
Page 159: Assembling The Starter Generator
STARTER GENERATOR 2. Install: • Rear bracket “1” Starter generator 7 N·m (0.7 kgf·m, 5.2 lb·ft) Align the pin hole of the rear bracket with the sta- tor pin “2” to assemble. b. Limit mark 8. Measure: • Brush spring force “a” Out of specification →...
Page 160: Flywheel
FLYWHEEL FLYWHEEL Removing the flywheel 10 N m (1.0 kgf m, 7.4 lb • • • m (0.8 kgf m, 5.9 lb • • • 120 N m (12 kgf m, 89 lb • • • 2.0 N m (0.20 kgf m, 1.5 lb •...
Page 161: Removing The Flywheel
FLYWHEEL REMOVING THE FLYWHEEL 1. Remove: • Flywheel nut • Washer Hold the flywheel “1” with the rotor holding tool “2” while loosening the flywheel nut. Rotor holding tool 90890-04166 Rotor holding tool INSTALLING THE FLYWHEEL YM-04166 1. Install: • Flywheel “1” •...
Page 162 FLYWHEEL 2. Install: • Flywheel cover “1” Flywheel cover bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Install the flywheel cover bolts in the 4 locations “a”, but do not install a bolt in the 1 location “b”. 5-23...
Page 163: Camshaft
CAMSHAFT CAMSHAFT Removing the camshaft 10 N m (1.0 kgf m, 7.4 lb • • • m (0.5 kgf m, 3.7 lb • • • New New 30 N m (3.0 kgf m, 22 lb • • • 27 N m (2.7 kgf m, 20 lb •...
Page 164: Removing The Crankcase Cover
CAMSHAFT REMOVING THE CRANKCASE COVER Camshaft journal dimensions 1. Remove: 15.965–15.990 mm • Crankcase cover (0.6285–0.6295 in) • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. 4.
Page 165: Checking The Decompression System
CAMSHAFT 6. Calculate: CHECKING THE VALVE LIFTERS • Camshaft-to-crankcase clearance 1. Check: Out of specification → Replace the defective • Valve lifters Damage/wear → Replace the valve lifter. part(s). Calculate the clearance by subtracting the cam- INSTALLING THE CAMSHAFT shaft journal diameter (crankcase side) from the 1.
Page 166 CAMSHAFT Route the oil level switch lead as shown in the il- lustration. 3. Install: • Crankcase cover Crankcase cover bolt 30 N·m (3.0 kgf·m, 22 lb·ft) Tighten the bolts in the proper sequence as shown. 5-27...
Page 167: Crankshaft And Piston
CRANKSHAFT AND PISTON CRANKSHAFT AND PISTON Removing the crankshaft and piston 20 N m (2.0 kgf m, 15 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “CYLINDER HEAD AND ROCKER Cylinder head ARMS” on page 5-6. Flywheel Refer to “FLYWHEEL”...
Page 168: Removing The Connecting Rod And Piston
CRANKSHAFT AND PISTON REMOVING THE CONNECTING ROD AND Piston pin puller set PISTON 90890-01304 1. Remove: Piston pin puller • Connecting rod cap bolts “1” YU-01304 • Connecting rod cap “2” Loosen the connecting rod cap bolts and re- move the connecting rod cap while the parts are in the crankcase.
Page 169: Checking The Piston Rings
CRANKSHAFT AND PISTON f. If out of specification, rebore or replace the Bore crankcase, and replace the piston and pis- 85.000–85.020 mm ton rings as a set. (3.3465–3.3472 in) Wear limit CHECKING THE PISTON RINGS 85.050 mm (3.3484 in) 1. Measure: •...
Page 170: Checking The Piston Pin
CRANKSHAFT AND PISTON 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring 4.
Page 171: Checking The Balancer
CRANKSHAFT AND PISTON Crankshaft pin outside diameter 35.969–35.984 mm (1.4161–1.4167 in) e. Tighten the connecting rod cap bolts to the specified torque in two stages. Connecting rod cap bolt 20 N·m (2.0 kgf·m, 15 lb·ft) 4. Measure: • Crankshaft pin to connecting rod clearance f.
Page 172 • Apply engine oil onto the piston pin. • Piston • Make sure that the arrow mark “a” on the piston • Piston rings head and the “YAMAHA” mark “b” on the con- • Cylinder necting rod are positioned as shown when as- (with the recommended lubricant) sembling the piston to the connecting rod.
Page 173 CRANKSHAFT AND PISTON • Make sure that the arrow mark “a” on the piston head faces toward the push rod cavity. Make sure that the “YAMAHA” mark “b” on the connecting rod faces toward the crankcase cover. 7. Install: • Connecting rod cap “1”...
Page 174 CRANKSHAFT AND PISTON 5-35...
Page 175: Fuel System (Yum1A/Yum2A)
FUEL SYSTEM (YUM1A/YUM2A) FUEL TANK..................... 6-1 REMOVING THE FUEL TANK ..............6-2 REMOVING THE FUEL PUMP ..............6-2 CHECKING THE FUEL PUMP BODY............6-2 INSTALLING THE FUEL PUMP..............6-2 INSTALLING THE FUEL TANK..............6-2 CHECKING THE FUEL PRESSURE ............6-3 AIR FILTER CASE ..................6-4 THROTTLE BODY................... 6-5 REMOVING THE THROTTLE BODY............6-6 CHECKING THE FUEL INJECTOR ............
Page 176: Fuel Tank
FUEL TANK FUEL TANK Removing the fuel tank m (0.7 kgf m, 5.2 lb • • • m (0.7 kgf m, 5.2 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Seat frames (driver and passenger) 4-1.
Page 177: Removing The Fuel Tank
FUEL TANK REMOVING THE FUEL TANK INSTALLING THE FUEL PUMP 1. Extract the fuel in the fuel tank through the 1. Install: fuel tank cap with a pump. • Fuel pump gasket “1” 2. Remove: • Fuel hose • Always use a new fuel pump gasket. WARNING •...
Page 178: Checking The Fuel Pressure
FUEL TANK Fuel tank bolt Pressure gauge 7 N·m (0.7 kgf·m, 5.2 lb·ft) 90890-03153 Fuel tank retainer bolt Pressure gauge 7 N·m (0.7 kgf·m, 5.2 lb·ft) YU-03153 Fuel pressure adapter 2. Install: 90890-03186 Fuel pressure adapter • Fuel hose YM-03186 •...
Page 179: Air Filter Case
AIR FILTER CASE AIR FILTER CASE Removing the air filter case 14 N m (1.4 kgf m, 10 lb • • • 15 N m (1.5 kgf m, 11 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Seat frames (driver and passenger) 4-1.
Page 180: Throttle Body
THROTTLE BODY THROTTLE BODY Removing the throttle body and intake manifold 12 N m (1.2 kgf m, 8.9 lb 3.5 N m (0.35 kgf m, 2.6 lb • • • • • • Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “AIR FILTER CASE”...
Page 181: Removing The Throttle Body
THROTTLE BODY REMOVING THE THROTTLE BODY CHECKING THE THROTTLE BODY 1. Disconnect: 1. Check: • Fuel hose • Throttle body Cracks/damage → Replace the throttle body. WARNING Cover fuel hose connections with a cloth when disconnecting them. Residual pres- CHECKING THE INTAKE MANIFOLD sure in the fuel lines could cause fuel to 1.
Page 182 THROTTLE BODY 3. Install: 5. Adjust: • Fuel injector “1” • Throttle cable Refer to “ADJUSTING THE THROTTLE CA- Fuel injector bolt BLES (YUM1A/YUM2A)” on page 3-12. 12 N·m (1.2 kgf·m, 8.9 lb·ft) Fit the projection “a” on the fuel injector into the hole “b”...
Page 183: Drive Train
DRIVE TRAIN PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) ......7-1 REMOVING THE PRIMARY SHEAVE............7-4 REMOVING THE SECONDARY SHEAVE ..........7-4 DISASSEMBLING THE SECONDARY SHEAVE........7-5 CHECKING THE PRIMARY SHEAVE ............7-5 CHECKING THE SECONDARY SHEAVE ..........7-5 ASSEMBLING THE PRIMARY SHEAVE ..........7-6 ASSEMBLING THE SECONDARY SHEAVE..........7-6 TRANSMISSION (YUM1A/YUM2A) ..............7-8 DISASSEMBLING THE TRANSMISSION..........
Page 184 PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) Removing the primary and secondary sheave 30 N m (3.0 kgf m, 22 lb • • • 85 N m (8.5 kgf m, 63 lb • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”...
Page 185 PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) Disassembling the primary sheave m (0.5 kgf m, 3.7 lb • • • m (0.6 kgf m, 4.4 lb • • • 3.5 N m (0.35 kgf m, 2.6 lb • • • m (0.6 kgf m, 4.4 lb •...
Page 186 PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) Disassembling the secondary sheave 2.0 N m (0.20 kgf m, 1.5 lb • • • Order Job/Parts to remove Q’ty Remarks Circlip Spring collar Spring seat Secondary sheave spring Secondary sliding sheave Secondary fixed sheave Washer Grease nipple Oil seal...
Page 187: Primary And Secondary Sheave (Yum1A/Yum2A)
PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) REMOVING THE PRIMARY SHEAVE 1. Park the vehicle on a level surface and apply the parking brake. 2. Remove: • Driver seat frame (YUM1A) Refer to “GENERAL CHASSIS (1)” on page 4-1. • Battery plate “1” (YUM1A) •...
Page 188: Disassembling The Secondary Sheave
PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) DISASSEMBLING THE SECONDARY 3. Remove: SHEAVE • Circlip “1” 1. Attach: • Bolt “1” • Remove by tightening the nut until the drive (to the secondary sheave “2”) shaft clip groove is visible. • Put a mark “a” before disassembling the sec- Bolt ondary sheave to make assembly work later JY2-SECND ST-1...
Page 189: Assembling The Primary Sheave
PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) 2. Check: • Secondary sheave spring “1” Cracks/damage → Replace. ASSEMBLING THE PRIMARY SHEAVE 1. Install: • Slider “1” • Face the gap “a” in the spring pin “2” outward within the range shown. • Position the spring pin “2” so that the spaces ASSEMBLING THE SECONDARY SHEAVE between the pin and the slider “1”...
Page 190 PRIMARY AND SECONDARY SHEAVE (YUM1A/YUM2A) After tightening the nut to a certain extent, press down the secondary sheave, hold the handle “1” of tool and turn it clockwise, align to the align- ment mark made when it was removed, and fur- ther tighten the nut.
Page 191: Transmission (Yum1A/Yum2A)
TRANSMISSION (YUM1A/YUM2A) TRANSMISSION (YUM1A/YUM2A) Removing the shift lever and shift cables m (0.7 kgf m, 5.2 lb • • • 16 N m (1.6 kgf m, 12 lb • • • 2.0 N m (0.20 kgf m, 1.5 lb • •...
Page 192 TRANSMISSION (YUM1A/YUM2A) Removing the transmission assembly 210 N m (21 kgf m, 155 lb • • • 73 N m (7.3 kgf m, 54 lb • • • 73 N m (7.3 kgf m, 54 lb • • • 210 N m (21 kgf m, 155 lb •...
Page 193 TRANSMISSION (YUM1A/YUM2A) Disassembling the transmission 42 N m (4.2 kgf m, 31 lb 55 N m (5.5 kgf m, 41 lb 28 N m (2.8 kgf m, 21 lb • • • • • • • • • (10) 81 N m (8.1 kgf m, 60 lb •...
Page 194 TRANSMISSION (YUM1A/YUM2A) Disassembling the transmission 42 N m (4.2 kgf m, 31 lb 55 N m (5.5 kgf m, 41 lb 28 N m (2.8 kgf m, 21 lb • • • • • • • • • (10) 81 N m (8.1 kgf m, 60 lb •...
Page 195: Disassembling The Transmission
TRANSMISSION (YUM1A/YUM2A) DISASSEMBLING THE TRANSMISSION 1. Remove: • Set screw “1” Before loosening the set screw “1”, measure the installed length “a” so that the screw can be in- stalled in the same position. 4. Check: • Bearings Damage → Replace. ASSEMBLING THE TRANSMISSION 1.
Page 196 TRANSMISSION (YUM1A/YUM2A) Refer to “CHECKING THE SHIFT LEVER (YUM1A/YUM2A)” on page 3-8. 7-13...
Page 197: Transmission (Yum2E)
TRANSMISSION (YUM2E) TRANSMISSION (YUM2E) Removing the transmission assembly 12 N m (1.2 kgf m, 8.9 lb m (0.8 kgf m, 5.9 lb • • • • • • 73 N m (7.3 kgf m, 54 lb • • • 210 N m (21 kgf m, 155 lb •...
Page 198 TRANSMISSION (YUM2E) Disassembling the transmission 3 (2) (10) 42 N m (4.2 kgf m, 31 lb • • • F W F W 28 N m (2.8 kgf m, 21 lb 55 N m (5.5 kgf m, 41 lb 81 N m (8.1 kgf m, 60 lb •...
Page 199: Checking The Transmission
TRANSMISSION (YUM2E) CHECKING THE TRANSMISSION 1. Check: • Ring gear • Counter gear • Input gear Blue discoloration/pitting/wear → Replace. 2. Check: • Counter shaft • Input shaft Bend/pitting → Replace. 3. Check: • Bearings Damage → Replace. 7-16...
Page 200: Traction Motor (Yum2E)
TRACTION MOTOR (YUM2E) TRACTION MOTOR (YUM2E) Disassembling the traction motor 3.3 N m (0.33 kgf m, 2.4 lb • • • m (0.6 kgf m, 4.4 lb • • • 3.3 N m (0.33 kgf m, 2.4 lb • • •...
Page 201: Assembling The Traction Motor
TRACTION MOTOR (YUM2E) ASSEMBLING THE TRACTION MOTOR 1. Install: • End bracket “1” Align the match mark “a” on the stator with the slot “b” on the end bracket. 2. Install: • Front bracket “1” Align the match mark “a” on the stator with the slot “b”...
Page 202 TRACTION MOTOR (YUM2E) 7-19...
Page 203: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM (YUM1A/YUM2A)............8-1 CIRCUIT DIAGRAM .................. 8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM (YUM1A/YUM2A) ........8-5 CIRCUIT DIAGRAM .................. 8-5 TROUBLESHOOTING ................8-7 CHARGING SYSTEM (YUM1A/YUM2A) ............8-9 CIRCUIT DIAGRAM .................. 8-9 TROUBLESHOOTING ................8-11 CHARGING SYSTEM (YUM2E) ..............8-13 CIRCUIT DIAGRAM ................8-13 TROUBLESHOOTING ................8-14 LIGHTING SYSTEM (YUM1A/YUM2A)............
Page 204 CHECKING THE SWITCHES ..............8-61 ADJUSTING THE HEADLIGHT BEAMS..........8-63 CHECKING THE FUSES ................8-63 CHECKING AND CHARGING THE BATTERY........8-63 BATTERY CHARGER (YAMAHA PROVIDED CHARGER)....8-65 REMOVING AND REPLACING THE BATTERY........8-77 CHECKING THE RELAYS ..............8-77 CHECKING THE REVERSE BUZZER............8-78 CHECKING THE THROTTLE POSITION SENSOR .......8-78...
Page 206: Ignition System (Yum1A/Yum2A)
IGNITION SYSTEM (YUM1A/YUM2A) IGNITION SYSTEM (YUM1A/YUM2A) CIRCUIT DIAGRAM...
Page 207 IGNITION SYSTEM (YUM1A/YUM2A) 5. Main switch fuse 6. Main fuse 18.Main switch 19.Accelerator switch 25.ECU (engine control unit) 29.Crankshaft position sensor 31.Frame ground 35.Battery 36.Spark plug 37.Ignition coil 38.Engine ground...
Page 208: Troubleshooting
IGNITION SYSTEM (YUM1A/YUM2A) TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Under-seat panel 2. Service lid 3. Instrument panel assembly NG → 1. Check the fuses. (Main and Main switch) Replace the fuse(s).
Page 209 IGNITION SYSTEM (YUM1A/YUM2A) NG → 8. Check the accelerator switch. Refer to “CHECKING THE Replace the accelerator switch. SWITCHES” on page 8-48. OK ↓ NG → 9. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-48. OK ↓...
Page 210: Electric Starting System (Yum1A/Yum2A)
ELECTRIC STARTING SYSTEM (YUM1A/YUM2A) ELECTRIC STARTING SYSTEM (YUM1A/YUM2A) CIRCUIT DIAGRAM...
Page 211 ELECTRIC STARTING SYSTEM (YUM1A/YUM2A) 5. Main switch fuse 6. Main fuse 18.Main switch 19.Accelerator switch 31.Frame ground 33.Starter generator 34.Main relay 35.Battery 38.Engine ground...
Page 212: Troubleshooting
ELECTRIC STARTING SYSTEM (YUM1A/YUM2A) TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Under-seat panel 2. Cargo bed (lift up) 3. Service lid 4. Instrument panel assembly NG → 1. Check the fuses. (Main and Main switch) Replace the fuse(s).
Page 213 ELECTRIC STARTING SYSTEM (YUM1A/YUM2A) NG → 8. Check the entire starting system wir- ing. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-5. OK ↓ The electric starting system circuit is...
Page 214: Charging System (Yum1A/Yum2A)
CHARGING SYSTEM (YUM1A/YUM2A) CHARGING SYSTEM (YUM1A/YUM2A) CIRCUIT DIAGRAM...
Page 215 CHARGING SYSTEM (YUM1A/YUM2A) 5. Main switch fuse 6. Main fuse 18.Main switch 19.Accelerator switch 32.Voltage regulator 33.Starter generator 35.Battery 8-10...
Page 216: Troubleshooting
CHARGING SYSTEM (YUM1A/YUM2A) TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Under-seat panel 2. Cargo bed (lift up) 3. Service lid 4. Instrument panel assembly NG → 1. Check the fuse. (Main and main switch) Replace the fuse.
Page 217 CHARGING SYSTEM (YUM1A/YUM2A) 8-12...
Page 218: Charging System (Yum2E)
CHARGING SYSTEM (YUM2E) CHARGING SYSTEM (YUM2E) CIRCUIT DIAGRAM 27.Battery 28.Charging receptacle 8-13...
Page 219: Troubleshooting
CHARGING SYSTEM (YUM2E) TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Under-seat panel NG → 1. Check the battery. Refer to “CHECKING AND • Clean the battery terminals. CHARGING THE BATTERY” on • Recharge or replace the battery. page 8-63.
Page 220: Lighting System (Yum1A/Yum2A)
LIGHTING SYSTEM (YUM1A/YUM2A) LIGHTING SYSTEM (YUM1A/YUM2A) CIRCUIT DIAGRAM 8-15...
Page 221 LIGHTING SYSTEM (YUM1A/YUM2A) 3. Lighting fuse 6. Main fuse 15.Headlight (right) 16.Headlight (left) 17.Light switch 18.Main switch 35.Battery 38.Engine ground 8-16...
Page 222: Troubleshooting
LIGHTING SYSTEM (YUM1A/YUM2A) TROUBLESHOOTING Any of the following fail to light: headlight. • Before troubleshooting, remove the following part(s): 1. Under-seat panel 2. Instrument panel assembly 3. Front grill NG → 1. Check the fuses. (Main and lighting) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 223 LIGHTING SYSTEM (YUM1A/YUM2A) 8-18...
Page 224: Lighting System (Yum2E)
LIGHTING SYSTEM (YUM2E) LIGHTING SYSTEM (YUM2E) CIRCUIT DIAGRAM 8-19...
Page 225 LIGHTING SYSTEM (YUM2E) 4. Headlight (right) 5. Headlight (left) 6. Light switch 9. Voltage regulator 12.Tow switch 24.Main fuse 27.Battery 8-20...
Page 226: Troubleshooting
LIGHTING SYSTEM (YUM2E) TROUBLESHOOTING Any of the following fail to light: headlight. • Before troubleshooting, remove the following part(s): 1. Under-seat panel 2. Cargo bed (lift up) 3. Front grill NG → 1. Check the fuses. (Main) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 227 LIGHTING SYSTEM (YUM2E) 8-22...
Page 228: Signaling System (Yum1A/Yum2A)
SIGNALING SYSTEM (YUM1A/YUM2A) SIGNALING SYSTEM (YUM1A/YUM2A) CIRCUIT DIAGRAM 8-23...
Page 229 SIGNALING SYSTEM (YUM1A/YUM2A) 5. Main switch fuse 6. Main fuse 8. Reverse switch 9. Reverse buzzer 10.Horn switch 11.Horn 18.Main switch 19.Accelerator switch 21.Engine oil level switch 22.Meter assembly 23.Fuel pump assembly 25.ECU (engine control unit) 31.Frame ground 35.Battery 38.Engine ground 8-24...
Page 230: Troubleshooting
SIGNALING SYSTEM (YUM1A/YUM2A) TROUBLESHOOTING • The fuel gauge fails to come on. • The hour meter fails to come on. • The reverse buzzer fails to sound. • The horn fails to sound. • Before troubleshooting, remove the following part(s): 1.
Page 231 SIGNALING SYSTEM (YUM1A/YUM2A) NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-23. OK ↓ Replace the meter assembly. The hour meter fails to come on. NG →...
Page 232 SIGNALING SYSTEM (YUM1A/YUM2A) NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-23. OK ↓ Replace the horn. The engine oil level warning light fails to come on. NG →...
Page 233 SIGNALING SYSTEM (YUM1A/YUM2A) 8-28...
Page 234: Signaling System (Yum2E)
SIGNALING SYSTEM (YUM2E) SIGNALING SYSTEM (YUM2E) CIRCUIT DIAGRAM 8-29...
Page 235 SIGNALING SYSTEM (YUM2E) 7. Horn 8. Horn switch 9. Voltage regulator 10.Main switch 11.Battery gauge/warning light 12.Tow switch 14.Reverse buzzer 15.Shift switch 20.MCU (motor control unit) 21.MCU fuse 24.Main fuse 27.Battery 8-30...
Page 236: Troubleshooting
SIGNALING SYSTEM (YUM2E) TROUBLESHOOTING • The reverse buzzer fails to sound. • The horn fails to sound. • Before troubleshooting, remove the following part(s): 1. Under-seat panel 2. Cargo bed (lift up) 3. Front grill 4. Instrument panel assembly 1. Check the fuses. NG →...
Page 237 SIGNALING SYSTEM (YUM2E) Checking the signaling system The reverse buzzer fails to sound. NG → 1. Check the shift switch. Refer to “CHECKING THE Replace the shift switch. SWITCHES” on page 8-61. OK ↓ NG → 2. Check the reverse buzzer. Refer to “CHECKING THE RE- Replace the reverse buzzer.
Page 238: Fuel Injection System (Yum1A/Yum2A)
FUEL INJECTION SYSTEM (YUM1A/YUM2A) FUEL INJECTION SYSTEM (YUM1A/YUM2A) CIRCUIT DIAGRAM 8-33...
Page 239 FUEL INJECTION SYSTEM (YUM1A/YUM2A) 5. Main switch fuse 6. Main fuse 18.Main switch 19.Accelerator switch 20.Fuel pump relay 22.Meter assembly 23.Fuel pump assembly 24.Diagnostic tool coupler 25.ECU (engine control unit) 26.Engine temperature sensor 27.Intake air pressure sensor 28.Fuel injector 29.Crankshaft position sensor 30.Intake air temperature sensor 31.Frame ground 35.Battery...
Page 240: Reading Error Codes - Fuel Injection System
FUEL INJECTION SYSTEM (YUM1A/YUM2A) READING ERROR CODES – FUEL 5. The screen will display “Waiting for Connec- INJECTION SYSTEM tion...”. Reading Codes Using the FI Diagnostic Tool The accelerator pedal must be pushed down WARNING and the engine rotated, to read error codes, Lock out the vehicle when you perform this even if the engine will not start.
Page 241 FUEL INJECTION SYSTEM (YUM1A/YUM2A) 6. The screen should now display “DIAG” “2”. POWER WARNING FI Diagnostic Tool POWER WARNING FI Diagnostic Tool 1500rpm 114˚F DIAG MODE DOWN MODE DOWN Setting FI Tool to Diagnostic Mode 7. Press and release the “MODE” button. The The FI Tool can be set to Diagnostic Mode to screen will now display the diagnostic code view the sensors’...
Page 242 FUEL INJECTION SYSTEM (YUM1A/YUM2A) If the engine is not start in the diagnostic mode, turn the main switch to “OFF” and disconnect the negative battery lead to release the diagnostic mode. 8-37...
Page 243 FUEL INJECTION SYSTEM (YUM1A/YUM2A) 8-38...
Page 244: Fuel Pump System (Yum1A/Yum2A)
FUEL PUMP SYSTEM (YUM1A/YUM2A) FUEL PUMP SYSTEM (YUM1A/YUM2A) CIRCUIT DIAGRAM 8-39...
Page 245 FUEL PUMP SYSTEM (YUM1A/YUM2A) 5. Main switch fuse 6. Main fuse 18.Main switch 19.Accelerator switch 20.Fuel pump relay 23.Fuel pump assembly 25.ECU (engine control unit) 31.Frame ground 35.Battery 38.Engine ground 8-40...
Page 246: Troubleshooting
FUEL PUMP SYSTEM (YUM1A/YUM2A) TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Under-seat panel 2. Service lid 3. Instrument panel assembly NG → 1. Check the fuses. (Main, and main switch) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 247 FUEL PUMP SYSTEM (YUM1A/YUM2A) 8-42...
Page 248: Drive System (Yum2E)
DRIVE SYSTEM (YUM2E) DRIVE SYSTEM (YUM2E) CIRCUIT DIAGRAM 8-43...
Page 249 DRIVE SYSTEM (YUM2E) 10.Main switch 12.Tow switch 13.Accelerator switch 15.Shift switch 17.Motor temperature sensor 18.Motor speed sensor 19.Traction motor 20.MCU (motor control unit) 21.MCU fuse 24.Main fuse 25.TPS (throttle position sensor) 26.Main relay 27.Battery 8-44...
Page 250: Troubleshooting
DRIVE SYSTEM (YUM2E) TROUBLESHOOTING • The drive system fails to operate. • Before troubleshooting, remove the following part(s): 1. Under-seat panel 2. Cargo bed 3. Service lid 4. Instrument panel assembly NG → 1. Check the fuses. (Main, and MCU) Replace the fuse(s).
Page 251 DRIVE SYSTEM (YUM2E) NG → 9. Check the entire drive system wiring. Properly connect or replace the drive sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-43. OK ↓ Replace the traction motor or MCU. 8-46...
Page 252: Electrical Components (Yum1A/Yum2A)
ELECTRICAL COMPONENTS (YUM1A/YUM2A) ELECTRICAL COMPONENTS (YUM1A/YUM2A) 1. Meter assembly 20.Fuel pump assembly 2. Light switch 21.Reverse switch 3. Main switch 22.Accelerator switch 4. Main switch fuse 23.Horn switch 24.Reverse buzzer 5. Main fuse 6. Lighting fuse 25.Horn 7. Fuel pump relay 26.USB fuse 8.
Page 253: Checking The Switches
ELECTRICAL COMPONENTS (YUM1A/YUM2A) CHECKING THE SWITCHES R/Y G B WIRE COLOR Br R ON/(H/L SW.) R/YG 1. Light switch 2. Main switch 3. Reverse switch 4. Accelerator switch 5. Horn switch 8-48...
Page 254 ELECTRICAL COMPONENTS (YUM1A/YUM2A) Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 255: Adjusting The Headlight Beams
ELECTRICAL COMPONENTS (YUM1A/YUM2A) ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: • Headlight beam (vertically) a. Turn the adjusting screw “1”. a. Connect the digital circuit tester to the fuse and check the continuity. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta-...
Page 256: Checking And Charging The Battery
ELECTRICAL COMPONENTS (YUM1A/YUM2A) CHECKING AND CHARGING THE BATTERY Therefore, the charge of the battery has to be checked by measuring the voltage at the battery WARNING terminals. Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- 1.
Page 257 ELECTRICAL COMPONENTS (YUM1A/YUM2A) • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
Page 258: Checking The Relays
ELECTRICAL COMPONENTS (YUM1A/YUM2A) c. Make sure that the current is higher than CHECKING THE RELAYS the standard charging current written on Check each switch for continuity with the digital the battery. circuit tester. If the continuity reading is incor- rect, replace the relay. If the current is lower than the standard charging Digital circuit tester (CD732) current written on the battery, this type of battery...
Page 259: Checking The Spark Plug Cap
ELECTRICAL COMPONENTS (YUM1A/YUM2A) • Positive tester probe → Result red “1” Continuity • Negative tester probe → (between “3” and “4”) orange “2” CHECKING THE SPARK PLUG CAP 1. Check: • Spark plug cap resistance Out of specification → Replace. Resistance 3.75–6.25 kΩ...
Page 260: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS (YUM1A/YUM2A) Out of specification → Perform the ignition a. Connect the digital circuit tester to the system troubleshooting, starting with step 5. crankshaft position sensor coupler as Refer to “TROUBLESHOOTING” on page shown. 8-3. Digital circuit tester (CD732) 90890-03243 Minimum ignition spark gap Model 88 Multimeter with ta-...
Page 261: Checking The Voltage Regulator
ELECTRICAL COMPONENTS (YUM1A/YUM2A) CHECKING THE FUEL SENDER 1. Disconnect: • Fuel pump coupler (from the wire harness) 2. Remove: • Fuel pump assembly (from the fuel tank) 3. Check: • Fuel sender resistance Out of specification → Replace the fuel pump b.
Page 262: Checking The Reverse Buzzer
ELECTRICAL COMPONENTS (YUM1A/YUM2A) CHECKING THE REVERSE BUZZER Digital circuit tester (CD732) 1. Check: 90890-03243 • Reverse buzzer Model 88 Multimeter with ta- Does not sound → Replace. chometer a. Disconnect the reverse buzzer coupler YU-A1927 from the wire harness. b. Connect the battery to the reverse buzzer b.
Page 263: Checking The Intake Air Temperature Sensor
ELECTRICAL COMPONENTS (YUM1A/YUM2A) b. Connect the digital circuit tester to the test Intake air temperature sensor re- harness S– pressure sensor 5S7 (3P). sistance 2.21–2.69 kΩ at 20 °C Test harness S– pressure sensor (2.21–2.69 kΩ at 68 °F) 5S7 (3P) Intake air temperature sensor re- 90890-03207 sistance (reference data)
Page 264: Checking The Oil Level Switch
ELECTRICAL COMPONENTS (YUM1A/YUM2A) Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe Fuel injector terminal “1” • Negative tester probe Fuel injector terminal “2” O/W R/L c. Measure the fuel injector resistance. CHECKING THE OIL LEVEL SWITCH 1.
Page 265: Electrical Components (Yum2E)
ELECTRICAL COMPONENTS (YUM2E) ELECTRICAL COMPONENTS (YUM2E) 1. Battery gauge/warning light 20.Reverse buzzer 2. Light switch 21.Horn 3. Shift switch 4. Main switch 5. Battery 6. Tow switch 7. Voltage regulator 8. Main relay 9. MCU (motor control unit) 10.Motor temperature sensor 11.Motor speed sensor 12.Traction motor 13.USB fuse...
Page 266: Checking The Switches
ELECTRICAL COMPONENTS (YUM2E) CHECKING THE SWITCHES R/Y G B REV FWD R/YG OFF ON 1. Light switch 2. Main switch 3. Shift switch 4. Tow switch 5. Accelerator switch 6. Horn switch 8-61...
Page 267 ELECTRICAL COMPONENTS (YUM2E) Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 268: Adjusting The Headlight Beams
ELECTRICAL COMPONENTS (YUM2E) ADJUSTING THE HEADLIGHT BEAMS b. If the digital circuit tester indicates “∞”, re- The following procedure applies to both of the place the fuse. headlights. 3. Replace: 1. Adjust: • Blown fuse • Headlight beam (vertically) a. Turn the main switch to “OFF”. a.
Page 269 The 48 V Battery Charger regulates charge. these values and ensures adequate charge Refer to “BATTERY CHARGER (YAMAHA during extended storage. Before charging the PROVIDED CHARGER)” on page 8-65. batteries, read and understand the owner’s 6.
Page 270: Battery Charger (Yamaha Provided Charger)
ELECTRICAL COMPONENTS (YUM2E) BATTERY CHARGER (YAMAHA PROVIDED CHARGER) Charger Safety Read the following label located on the top of the charger before operating or using the charger and promptly replace the label if it becomes damaged. 8-65...
Page 271 Features and Benefits Keep the charger plugged into the AC outlet Yamaha has developed a state-of-the-art bat- and the Yamaha vehicle while in storage. Af- tery/charger combination. The battery charger is ter 14 days from the last charge, if the voltage...
Page 272 ELECTRICAL COMPONENTS (YUM2E) Grounding WARNING The battery charger must be grounded to reduce To reduce the risk of an electric shock, keep the risk of electric shock. The charger is the charger dry. Do not expose it to rain. For equipped with an AC cord set having an equip- storage, keep the charger indoors.
Page 273 ELECTRICAL COMPONENTS (YUM2E) • The DC cord set plug or charging recepta- The charger will start automatically. cle contacts are bent, corroded, or are dark Upon connection to AC power source, the lower or bluish in appearance. four LEDs come on as a Power-On Self-Test, •...
Page 274 ELECTRICAL COMPONENTS (YUM2E) Under normal charge circumstances, the LEDs operate as follows: Comes on Blinking Ammeter “a” Displays approximate scale of current out- High internal charger temperature. Current (Amber) put during Step 2. output reduced. With no battery connected, indicates algo- 80% Charge “b”...
Page 275 ELECTRICAL COMPONENTS (YUM2E) Troubleshooting 1. LED Error Codes (For Battery Condition) WARNING Incorrect reassembly may result in a risk of electric shock or fire. The following procedures are intended only to determine if a malfunction may exist in the charger. WARNING To reduce the risk of electric shock, always disconnect the charger’s AC cord set plug from AC power and its DC cord set plug from batteries before attempting any maintenance or cleaning.
Page 276 ELECTRICAL COMPONENTS (YUM2E) Problem Description Cause Remedy Charger does not start charging Incorrect wiring or disconnection Ensure polarity for wiring is correct when DC cord set is plugged into from DC cord, receptacle and bat- from DC cord, receptacle and bat- the receptacle and the Amber AC teries.
Page 277 ELECTRICAL COMPONENTS (YUM2E) Battery Charging 3. With the charger properly connected and grounded (see charger’s owner’s manual), in- WARNING sert the DC output into the golf car recepta- Read and understand the owner’s manual cle. provided with your golf car’s battery charger before charging batteries.
Page 278 When you are load testing, you will need a load from service. tester and a high-quality digital voltmeter capa- ble of reading at least 55 V DC. Yamaha recom- Open-Circuit Voltage Test mends using the Lester 17770 Battery For accurate voltage readings, batteries must Discharge Unit.
Page 279 Con- measurement after the discharge tester shuts sult your Yamaha service representative for help off. with schedule adjustments. Once the weaker batteries are identified, they...
Page 280 ELECTRICAL COMPONENTS (YUM2E) 2. Record surface voltage from the discharge unit readout panel. 3. Record the ambient temperature using the thermometer. 4. Turn the discharge unit “ON” and wait at least three minutes. If you have a bad connection or reverse polarity, the discharge unit will au- tomatically shut off in three minutes.
Page 281 ELECTRICAL COMPONENTS (YUM2E) Battery Discharge Chart Discharge Minutes Adjusted for Temperature Temperature °C 15.5 °F Adjusted Discharge Minutes = Discharge Minutes 1-(((80-temp)/100)*.64) 8-76...
Page 282: Removing And Replacing The Battery
ELECTRICAL COMPONENTS (YUM2E) REMOVING AND REPLACING THE BATTERY WARNING • Secure the vehicle and discharge the con- troller capacitor. Refer to “SAFETY LOCK- OUT PROCEDURE” on page 1-2. • Always remove the negative (-) battery ca- bles first and ensure they are stowed in a manner to prevent arching.
Page 283: Checking The Reverse Buzzer
ELECTRICAL COMPONENTS (YUM2E) Main relay • Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it. 2. Check: • Throttle position sensor maximum resistance Out of specification → Replace the throttle position sensor. Resistance 0.66–1.54 kΩ...
Page 284 ELECTRICAL COMPONENTS (YUM2E) 8-79...
Page 285: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING (YUM1A/YUM2A) ............9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES................9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-1 FAULTY GEAR SHIFTING................ 9-1 SHIFT LEVER DOES NOT MOVE ............9-2 FAULTY DRIVE TRAIN PERFORMANCE ..........9-2 OVERHEATING ..................9-2 POOR BRAKING PERFORMANCE............9-2 FAULTY SHOCK ABSORBER ASSEMBLY..........9-2 UNSTABLE HANDLING ................9-2 FAULTY LIGHTING SYSTEM ..............9-3 DIAGNOSTIC/ERROR CODE IDENTIFICATION CHART...
Page 286: Troubleshooting (Yum1A/Yum2A)
TROUBLESHOOTING (YUM1A/YUM2A) TROUBLESHOOTING (YUM1A/ Electrical system 1. Battery YUM2A) • Discharged battery • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse • Improperly installed fuse The following guide for troubleshooting does not 3. Spark plug cover all the possible causes of trouble. It should •...
Page 287: Shift Lever Does Not Move
TROUBLESHOOTING (YUM1A/YUM2A) SHIFT LEVER DOES NOT MOVE 3. Engine oil • Incorrect oil level Shift shaft and shift forks • Incorrect oil viscosity • Bent shift shaft • Inferior oil quality • Seized shift fork Cooling system Transmission 1. Cooling system •...
Page 288: Faulty Lighting System
TROUBLESHOOTING (YUM1A/YUM2A) • Bent tie-rods • Deformed steering knuckles 3. Shock absorber assembly(-ies) • Faulty shock absorber spring • Leaking oil 4. Tire(s) • Uneven tire pressures (left and right) • Incorrect tire pressure • Uneven tire wear 5. Wheel(s) •...
Page 289: Diagnostic/Error Code Identification Chart (Yum1A/Yum2A)
DIAGNOSTIC/ERROR CODE IDENTIFICATION CHART (YUM1A/ YUM2A) DIAGNOSTIC/ERROR CODE IDENTIFICATION CHART (YUM1A/YUM2A) Diagnostic Error Engine Description Symptom Possible cause code code starts — Crankshaft position No signal from the Crankshaft position sensor sensor crankshaft position open or short circuit sensor Pickup rotor Wire harness Incorrectly installed sensor Intake air pressure...
Page 290 DIAGNOSTIC/ERROR CODE IDENTIFICATION CHART (YUM1A/ YUM2A) Diagnostic Error Engine Description Symptom Possible cause code code starts — Number of error Indicate the number — — history and clear of the kind of error error history history. History will be clear when press the mode button with mode.
Page 291: Troubleshooting (Yum2E)
TROUBLESHOOTING (YUM2E) TROUBLESHOOTING (YUM2E) • Leaking oil UNSTABLE HANDLING GENERAL INFORMATION 1. Steering wheel • Bent or improperly installed steering wheel The following guide for troubleshooting does not 2. Steering components cover all the possible causes of trouble. It should •...
Page 292: Mcu Main Harness Coupler (Yum2E)
TROUBLESHOOTING (YUM2E) b. There may be a poor or intermittent con- nection. MCU MAIN HARNESS COUPLER (YUM2E) Shows the open end of a disconnected coupler. Position Wire color Function Red/Yellow Tow switch Not used Not used Blue Throttle position sensor Red/Blue Main relay Red/Black...
Page 293: Pc Genius Diagnostic System (Yum2E)
PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) PC GENIUS DIAGNOSTIC SYSTEM CONNECTING THE PC GENIUS 1. CAN-BUS device is must be connected with (YUM2E) wire harness before use the PC genius. 2. Remove the cap “1” from the wire harness INTRODUCTION connector “2” connector is located on the in- The PC genius diagnostic system is a software side of rear access panel beside the MCU.
Page 294 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) System performance is continually monitored 4. The PC genius diagnostic screen will appear. and fault codes identified for troubleshooting Help button purposes. The fault codes identify the problem The Help screen will appear with the following area and any necessary corrective action.
Page 295 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) “Set Car#” button Sets car number stored in MCU within a range of 0 to 511. If the communication method is CAN, you can set car serial number. (less than 20 characters) “Erase” button Fault codes stored in MCU are erased. “Save”...
Page 296: Troubleshooting Using Pc Genius
PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) TROUBLESHOOTING USING PC GENIUS This section identifies the diagnostic codes/display names used in the PC Genius diagnostic tool. Check and service the items or components that are the probable cause of the malfunction according to the following table. Fault code No.
Page 297 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. Display name Over current Over current (Short circuit between motor and MCU) Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Short circuit → Properly Cable continuity Connect the PC Genius connect or replace the cable.
Page 298 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. 23, 24, 25 Fault code No. 23, 24, 25 [23] Power circuit overheated Display name [24] Control circuit overheated [25] Internal circuit overheated [23] Main circuit overheated [24] Circuit board overheated Symptom [25] Condenser overheated Vehicle stopped Confirmation steps after...
Page 299 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. 27 Fault code No. Display name MCU temperature too low Temperature too low (MCU temperature too low) Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Resetting the MCU Cycle the TOW switch off and Connect the PC Genius on (RUN →...
Page 300 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. 32 Fault code No. Display name MCU internal error Defective motor temperature sensor Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Resetting the MCU Cycle the TOW switch off and Connect the PC Genius on (RUN →...
Page 301 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. Display name TPS signal too high Throttle position sensor voltage failure high side Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Open or short circuit → Properly Wire harness continuity Connect the PC Genius connect or replace the wire...
Page 302 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. Display name Invalid logic for TPS and switch Mismatch between the accelerator switch and throttle position sensor Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Open or short circuit → Properly Wire harness continuity Connect the PC Genius connect or replace the wire...
Page 303 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. Display name Invalid logic for shift switch Shift switch mismatch Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure OK → Maintenance job Operation check Set the TOW switch to RUN, the main switch to ON, depress the completion.
Page 304 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. Display name Low voltage Low voltage failure (IV determination) Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Battery Check the battery. Connect the PC Genius Refer to “CHECKING AND diagnostic tool, and check if any CHARGING THE BATTERY”...
Page 305 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. 41 Fault code No. Display name Low voltage Low voltage failure (battery low voltage) Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Resetting the MCU Cycle the TOW switch off and Connect the PC Genius on (RUN →...
Page 306 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. 43 Fault code No. Display name Motor overheated Motor overheated Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Resetting the MCU Cycle the TOW switch off and Connect the PC Genius on (RUN →...
Page 307 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code No. Display name Speed sensor error Motor speed sensor malfunction Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure OK → Maintenance job Operation check Set the TOW switch to RUN, the main switch to ON, depress the completion.
Page 308 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Vehicle stopped Fault code No. None Display name None Symptom Vehicle stopped Confirmation steps after Step Inspection items Diagnostic procedure diagnostic procedure Resetting the MCU Cycle the TOW switch off and Connect the PC Genius on (RUN →...
Page 309: Fault Code Table
PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code table Fault code Display name Item Symptom Possible cause Main relay drive Main relay drive Motor output • Main relay drive short fault fault shut-off, vehicle circuit stopped (no • Short circuit in the regeneration) harness between the MCU and relay drive...
Page 310 PC GENIUS DIAGNOSTIC SYSTEM (YUM2E) Fault code Display name Item Symptom Possible cause Invalid logic for TPS Accelerator Vehicle stopped Accelerator sensor failure and switch mismatch (with regeneration) Invalid logic for shift Shift switch Vehicle stopped • Defective shift switch switch mismatch (with regeneration)
Page 311: Pc Genius Golf Car Programming System (Yum2E)
PC GENIUS GOLF CAR PROGRAMMING SYSTEM (YUM2E) PC GENIUS GOLF CAR 3. Enter your password. The generic password is 13121. then click “LOGIN” button. PROGRAMMING SYSTEM (YUM2E) GOLF CAR PROGRAMMING MODE User selects either MCU type and enters a pass- word to login to change the top speed and re- generative brake settings.
Page 312 PC GENIUS GOLF CAR PROGRAMMING SYSTEM (YUM2E) Topics: Set mode button • Check adapter before connection 1. The user selects the intended mode number. • Communicating dialog The number will flash green for the intended • Password setting “1”. • Select MCU type 2.
Page 313 PC GENIUS GOLF CAR PROGRAMMING SYSTEM (YUM2E) 9-28...
Page 314 WIRING DIAGRAM YUM2E 1. Tail light (left) (option) YUM1A/YUM2A 2. Tail light (right) (option) 1. Auxiliary DC jack (option) 3. Deluxe lighting kit (option) 2. Deluxe lighting kit (option) 4. Headlight (right) 3. Lighting fuse 5. Headlight (left) 4. Auxiliary DC jack fuse (option) 6.
Page 317 YUM1A/YUM2A WIRING DIAGRAM G/W P WIRE COLOR Br R ON/(H/L SW.) R/Y O/W G/W P B/W W/R B/W W/R Br/W P B/W B/Y R R/W Br R/W R R R/Y L R G G/W Br/W B/W B/W W/R Br/W Br/W Br R/W G R/W G R/W...
Page 318 YUM1A/YUM2A WIRING DIAGRAM WIRE COLOR Br R ON/(H/L SW.)
Page 319 YUM2E WIRING DIAGRAM REV FWD OFF ON OFF ON Br R/W W B/W L/W O/W R/W Br R/W B R/Y W O R/Y B Br R/B R/L...
Page 320 YUM2E WIRING DIAGRAM REV FWD OFF ON OFF ON...

This manual is also suitable for:

Umx Yum1a Yum2a Yum2e

Yamaha UMAX Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Pre-Operation Checks

Monthly Checks

6-Month Checks

Annual Checks

4-Year Checks

Chassis

General Chassis (1)

General Chassis (2)

General Chassis (3)

General Chassis (4)

General Chassis (5)

General Chassis (6)

General Chassis (7)

Front and Rear Wheels

Front and Rear Brakes

Pedal Assembly

Steering System

Front Suspension Components

Rear Suspension Components

Engine (Yum1A/Yum2A)

Engine Inspection

Engine Removal (1)

Engine Removal (2)

Cylinder Head and Rocker Arms

Valves and Valve Springs

Starter Generator

Flywheel

Camshaft

Crankshaft and Piston

Fuel System (Yum1A/Yum2A)

Fuel Tank

Air Filter Case

Throttle Body

Drive Train

Primary and Secondary Sheave (Yum1A/Yum2A)

Transmission (Yum1A/Yum2A)

Transmission (Yum2E)

Traction Motor (Yum2E)

Electrical System

Ignition System (Yum1A/Yum2A)

Electric Starting System (Yum1A/Yum2A)

Charging System (Yum1A/Yum2A)

Charging System (Yum2E)

Lighting System (Yum1A/Yum2A)

Lighting System (Yum2E)

Signaling System (Yum1A/Yum2A)

Signaling System (Yum2E)

Fuel Injection System (Yum1A/Yum2A)

Fuel Pump System (Yum1A/Yum2A)

Drive System (Yum2E)

Electrical Components (Yum1A/Yum2A)

Electrical Components (Yum2E)

Troubleshooting

Troubleshooting (Yum1A/Yum2A)

Diagnostic/Error Code Identification Chart (Yum1A/Yum2A)

Troubleshooting (Yum2E)

Pc Genius Diagnostic System (Yum2E)

Pc Genius Golf Car Programming System (Yum2E)

Quick Links

Chapters

Troubleshooting

Related Manuals for Yamaha UMAX

Summary of Contents for Yamaha UMAX