2019 Yamaha DRIVE2 PTV (QUIETECH EFI) Service & Repair Manual

CommonServiceManual LIT-19616-29-16. 4-MS»im;‘7

DR2A/DR2E SERVICEMANUAL ©2016byYamahaMotorPowered ProductsCo.,Ltd. 1stEdition,November2016 Allrightsreserved.Anyreprintingor unauthorizedusewithoutthewritten permissionofYamahaMotor PoweredProductsCo.,Ltd. isexpresslyprohibited. LIT-19616-29-16

@YAMAHA Chapter1-GENERALINFORMATION Chapter2-—SPECIFICATIONS Chapter3-PERIODICMAINTENANCE Chapter4-BATTERIES Chapter5—-ENGINE Chapter6—-DRIVETRAIN Chapter7-—CHASSIS Chapter8-ELECTRICAL Chapter9-TROUBLESHOOTING Chapter10—-PTVSPEEDCODEKIT BHBOOMAOAAA NA &

DR2A,DR2E GOLFCARSERVICEMANUAL 1GENERALINFORMATION SAFETYPRECAUTIONS.. GeneralInformation. PrepareforEmergencies SafetyLockoutProcedure... DischargetheMotorControlUnitCapacitor-DCModels. DischargetheMotorControlUnitCapacitor-ACModels RecommendedJackPoints. GENERALSERVICEINFORMATION SerialNumbers DR2AEngine DR2ETractionMotor. DR2EMotorControlUnit WashingandCleaning CorrectTools. Neatness... TighteningTorque.. ReplacementPart: Gaskets,OilSealsandO-rings LockWashers/PlatesandCotterPins. BearingsandOilSeals. RetainingRings.....1-11 DisassemblyandAssemblySuggestion:1-11 SPECIALTOOLS... ForTune-Up... ForEngineService. ForPowerTrain... ForChassisService ForElectricalComponents... VEHICLESTORAGE. GasolineModels PreparationforStorage ReturningCartoService. BatteryModel: PreparationforStorage ReturningCartoService.. 2SPECIFICATIONS GENERALSPECIFICATION Chassis PaintCodes.....

TORQUESPECIFICATIONS... Engine... SERVICESPECIFICATIONS(DR2A) Engine... CABLEROUTING—DR2A... CABLEROUTING—DR2A—BRAKEANDTHROTTLE SERVICESPECIFICATIONS(DR2E) CABLEROUTING—DR2E —-DCMODELS... CABLEROUTING—DR2E—ACMODELS..... BRAKECABLEROUTING—DR2E PERIODICMAINTENANCE —PeriodicMaintenanceProgram— INSPECTIONANDADJUSTMENTSCHEDULE DR2A—GasolineModels DR2E—BatteryModels. DAILYCHECKS—GASOLINEMODELS OperationalInspection ChecktheEngineOil... CleantheEngineCoolingInletDuct. InspecttheFuelLines. ChecktheFuelLeve' ChecktheBattery. ChecktheBrakes. ChecktheSteerin: InspecttheWheelsandTires InspecttheTires. ChecktheTirePressurt InspecttheWheels... ChecktheBodyandChassisforDamage..... ChecktheTightnessofBolts,Nuts,ScrewsandRivets. ChecktheReverseBuzzerOperation MONTHLYSERVICE—GASOLINEMODELS InspecttheFuelFilterandHoses DriveBelt. InspecttheDriveBel ReplacetheDriveBelt AdjusttheShiftCable...... ChecktheShiftCableAdjustment. AdjusttheShiftCableAdjustment. CheckthePedalGroup SIX-MONTHSERVICE—GASOLINEMODELS. CleanthePre-Filter/AirFilter..... ChecktheEngineCompressionPressure

CheckandAdjusttheValveClearanceandSparkPlug ChecktheValveClearanceandSparkPlug AdjusttheValveClearance.... InspecttheShockAbsorbers YEARLYSERVICE—GASOLINEMODELS ChangetheEngineOil... ReplacetheFuelFilter—CarburetorModels AdjusttheThrottleCables AdjusttheFreePlay... RemovetheUnderCover1—EFIModels. InstalltheUnderCover1—EFIModels. RemovetheUnderCover2—EFIModels. InstalltheUnderCover2—EFIModels. AdjusttheThrottleCables—EFlModels Introduction AdjustmentProcedures StarterBelt InspecttheStarterBelt AdjusttheStarterBelt. CheckandAdjusttheSpeedLimiter ChecktheSpeedLimiter. AdjusttheSpeedLimiter InspecttheWireHarnessandElectricalCable: InspecttheRearAxleBearing.. InspecttheRadial InspecttheBearing InspecttheSteeringKnuckle. WheelAlignment InspecttheFrontWheelBearin: ChecktheRearAxleOil(CarburetorModels) ChecktheTransmissionOil(EFIModels). AdjusttheParkingBrake AdjusttheBrakePedalFreePlay .. TWO-YEARSERVICE —GASOLINEMODELS InspecttheStarter/Generator. FOUR-YEARSERVICE —GASOLINEMODELS ChangetheAxleOil(CarburetorModels). ChangetheTransmissionOil(EFIModels) InspecttheBrakeDrumsandShoes. DAILYCHECKS—BATTERYMODELS OperationalInspection InspecttheBatteries InspecttheBrakes.... InspecttheSteeringSystem . InspecttheWheelsandTires InspecttheTires. ChecktheTirePressure

InspecttheWheels...eee ChecktheBodyandChassisforDamage..... ChecktheTightnessofBolts,Nuts,ScrewsandRivets. ChecktheReverseBuzzerOperation MONTHLYSERVICE—BATTERYMODELS. ChecktheBatteryElectrolyteLevel.... InspecttheChargeReceptacle InspecttheElectricalConnectors. CheckthePedalGroup SIX-MONTHSERVICE—BATTERYMODELS... InspecttheWireHarnessandElectricalCable: InspecttheShockAbsorbers. YEARLYSERVICE—-BATTERYMODELS PerformtheDischargeTest ApplyBatteryTerminalProtectant InspecttheControllerConnector. InspecttheRearAxleBearing.. InspecttheRadial. InspecttheBearing InspecttheSteeringKnuckle. WheelAlignment... InspecttheFrontWheelBearing ChecktheAxleOilLevel....... AdjusttheParkingBrake... AdjusttheBrakePedalFreePlay. FOUR-YEARSERVICE—BATTERYMODELS ChangetheAxleOil BATTERIES INTRODUCTION... RecommendedEquipment. GeneralCare. BatteryType.. BatteryCycleLife .. —ServiceProcedures— PREVENTIVEMAINTENANCE BatteryCleaning... BatteryInspection ElectrolyteLevels. BatteryWatering. WateringProcedures BATTERYCHARGING ChargingGuidelines ChargingProcedure

BATTERYCHARGER(Delta-Q). ChargerSafety FeaturesandBenefits Installatior Mounting Grounding Charging. Troubleshooting BatteryCharging SpecificGravityTest... Open-CircuitVoltageTest DischargeLoadTest... SchedulingDischargeLoadTest BatteryDischargeChart... BATTERYCHARGER(JW9-CHARGER) ChargerSafety...... FeaturesandBenefits .. Installatior Grounding Charging(forWesternHemisphereMarkets) Five-StepChargingCycle Step1-Pre-Test..... Step2-ConstantCurrentCharg Step3-ConstantVoltageCharge Step4—ToppingOff Step5-Storage.. Troubleshooting... HardwareSystemFaults...wee Charging(forAllMarketsOutsideoftheWesternHemisphere) Troubleshooting LEDErrorCodes(forbatterycondition BatteryStorage. REMOVEANDREPLACETHEBATTERY. 5ENGINE —Engine— ENGINETESTSANDADJUSTMENTS, ChecktheEngineCompressionPressure TesttheFuelPump(CarburetorModels) SparkOutputTest.. TestandAdjustTransistorControlIgnition(TCI. AdjusttheChokeCable(CarburetorModels). —EngineRepair— PREPARATIONFORENGINEREPAIR... CARBURETOR........

AirFilterHousing...eas RemovetheAirFilterHousing InstalltheAirFilterHousing.... RemovetheCarbureto: RepairtheCarburetor... DisassembletheCarburetor... CleanandInspecttheCarburetor AssembletheCarburetor InstalltheCarburetor. RemovetheFuelLineClamps... InstalltheFuelLineClamp: FuelPumpPressureTest RemovetheFuelPum| InstalltheFuelPump AirFilterHousing... RemovetheAirFilterHousingandAirIntakeDuct InstalltheAirFilterHousingandAirIntakeDuc! RemovetheFuelInjector InstalltheFuelInjector... RemovetheThrottleBody. InstalltheThrottleBody. MUFFLER—CARBURETORMODELS MUFFLER—EFIMODELS Removal.. Installatior REMOVETHEENGINE—CARBURETORMODELS REMOVETHEENGINE—EFIMODELS DISASSEMBLETHEENGINE CylinderHeadandRockerArmComponents RemovetheCylinderHead DisassembletheCylinderHead... RemovetheFlywheelMagneto/Pickup RemovetheCamshaftComponents RemovethePistonandCrankshaft. INSPECTTHEENGINECOMPONENTS.. InspecttheCylinderHeac ChecktheCylinderHead InspecttheCamshat ChecktheValveLifte: ChecktheBalancerShaft. ChecktheBearings ChecktheCylinderandPiston. CheckthePistonRings vi

vii CheckthePistonPin ChecktheCrankshaft. ASSEMBLETHEENGINE AssemblethePiston... InstallthePistonandCrankshaft.. InstalltheCamshaftComponents InstalltheFlywheelMagneto. AssembletheCylinderHead. InstalltheCylinderHead INSTALLTHEENGINE—CARBURETORMODELS.. INSTALLTHEENGINE—EFIMODELS. DRIVETRAIN —DriveTrainRepair— FORWARDANDREVERSESHIFTINGASSEMBLY— CARBURETORMODELS.. FORWARDANDREVERSESHIFTINGASSEMBLY—EFIMODELS SHIFTCABLES—GASOLINEMODELS RemovetheShiftCables. InstalltheShiftCables. REPLACETHEDRIVEBELT PRIMARYSHEAVEASSEMBLY... RemovethePrimarySheaveAssembly DisassembleandInspectthePrimarySheaveAssembly .. AssemblethePrimarySheaveAssembly. InstallthePrimarySheaveAssembly SECONDARYSHEAVEASSEMBLYar RemovetheSecondarySheaveAssembly DisassembleandInspecttheSecondarySheaveAssembly AssembletheSecondarySheave InstalltheSecondarySheaveAssembly REARAXLE—-CARBURETORMODELS AxleShafts RemovetheRearAxleon InstalltheRearAxle—CarburetorModels DisassembletheRearAxle AssembletheRearAxle.... TRANSMISSION—EFIMODELS AxleShafts........ RemovetheTransmissio1 InstalltheTransmission—EFIModels DisassembletheTransmission. AssembletheTransmission DriveShaft.

2019 Yamaha DRIVE2 PTV (QUIETECH EFI) Service & Repair Manual

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