1983-1989 Yamaha G1 Golf Cart Service & Repair Manual

YAMAHA SERVICE MANUAL

@YAMAHA GOLF CAR GI-AM3

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

A. ADJUSTMENTS View in direction of B Fig. 3 1. Locknut 6. Connector arm 11. Lever 2. Joint rod 7. Clamp 12. Butterfly valve 3. Speed adjust screw 8. Connector rod 2 13. Exhaust flange 4. Governor lever 9. Return spring 14. Exhaust pipe 5. Connecter rod 1 10. Shaft NOTE: Before adjusting, installed between remove the return spring connector rod 2 and the exhaust pipe. 1. Setting the governor lever Adjust the length of the joint rod 1 so when the accelerator pedal is fully depressed, and the governor lwer is turned counterclockwise, the carburetor thorttle valve just reaches the fully open position. (To adjust the joint rod length, loosen two locknuts, adjust the length, then tighten the locknuts.) 2. Setting the engine idle speed With the V-belt removed, make sure the engine idles at 1,200 rlmin. (When the V-belt is mounted, the idling speed is 1,000 rlmin.) If not, make an idle speed adjustment by turning the throttle stop screw. While making this idle speed adjustment, the engine speed will not affect the opening of the butterfly valve (exhaust valve).

3. Exhaust valve setting Adjust the length of connector rod so when the governor lever returns t o the closed position, the butterfly valve in the exhaust port closes completely. (To adjust the length of connector rod 1, loosen two locknuts, and after adjusting, tighten the locknuts.) To check that the exhaust valve is completely closed, remove the exhaust pipe. The valve position can be checked by looking into the exhaust flange. As shown in Fig. 1, check the valve position. The screw head should face the exhaust pipe. To facilitate checking the exhaust valve in the full-closed position, prepare a tool as shown in Fig. 4 1. Butterfly valve 2. Shaft 3. Exhaust flange 4. Engine 5. Plate 6. Bolt (or Screw) 7. Locknut 8. Stopper pin distance A = distance A ' = 19 mm (0.75 in) distance B = 20 - 25 mm (0.79 -0.98 in) 4. Adjusting the throttle wire Adjust the throttle wire so when the accelerator pedal is fully depressed, the carburetor throttle just reaches fu II-open position. NOTE: After adjusting the throttle wire, install the return spring between connector rod 2, and the exhaust pipe. 5. Governor adjustment Fig. 5 Adjust the car speed by turning the adjusting screw in either direction. The maximum amount of adjustment is about 4.8 kmlh (* 3 m.p.h.1 Tightening the adjust screw increases the speed; loosening it decreases the speed. Approx. 2,700 r/min at 19.2 kmlh (12 m.p.h.) on hard, level surface. After this operation, check the following points: Check whether both links and butterfly valve move smoothly. Check whether the links move beyond dead center, and become locked. Check for abnormal noise from the butterfly valve and related parts. 1. Adjusting screw 2. Governor lever

6. Rod assembly 2 adjustment Adjust the rod ass'y 2 length by turning the shaft so that when the throttle valve is at a closed (idle) position (by pushing the speed limiter lever slightly), the exhaust valve is at a closed position as illustrated on the next page. Tighten the locknut, keeping the plastic ends at a 90" angle to each other. GOOD Carb. throttle valve position at idling ENGINE

NOTE: Check t o see that when the throttle valve is fully open, the exhaust valve is also fully open. B. DISASSEMBLY AND ASSEMBLY In general, except when links are damaged or the joint is extremely worn, neither removal nor disassembly is necessary. When dismoun- ting the engine from the chassis or reassembl- ing links after replacing parts, the adjustments specified in D, above must be performed. 1. The link adjustment should be made only by adjusting the length of the joint rod and connector rod 1. It is unneces- sary to adjust the length of connector rod 2 because it is already adjusted by the factory. Standard eye-to eye distance of connector rod (2): 179 mm (7 in) 2. As illustrated, the bracket should be installed with the open end facing down- ward, and all joints should be installed squarely facing the ball so that move- ment is free throughout its operating range. Bracket Joint 3. Do not apply grease to the contact surface of the joint.

SPECI FICATIONS A. General Weight: Dry weight Model GI -AM3 Item Performance: Maximum loading limit Maximum speed Starter generator red zone Cranking speed Minimum turning radius Braking distance Seating capacity Hill climbing ability Fuel consumption Oil consumption Model: Code No. Frame I.D. No. & Starting NO. Engine I.D. No. & Starting No. Dimensions: Overall length Overall width Overall height (steering height) Height of floor Height of seat from floor Wheelbase Tread: Front Rear 340 kg (750 Ib) 19 kmlh (12 mph) 4,000 rlmin (25 kmlh) Appx. 800 rlmin 3,000 mm (118 in) 4,500 mm (177 in) at 19 kmlh (12 mph) 2 persons 30" (57%grade) on pavement 20 kmlP at 19 km/h on pavement 4,500 km/P at 19 kmlh on pavement J24 J24-000101 J24-000 101 2,403 mm (94.6 in) 1,140 mm (44.9 in) 1,180 mm (46.5 in) 295 mm (11.6 in) 428 mm (16.9 in) 1,550 mm (61.0 in) 900 mm (35.4 in) 900.mm (35.4 in) 6. Engine Min. ground clearance 1 110 mm ( 4.3 in) - Model - . Description: Engine type Number of cylinder Displacement Bore x Stroke Compression ratio Cooling system Starting system Ignition system Lubrication system Cylinder head: Combustion chamber volume (with spark plug) Compression chamber type Head gasket thickness G1 -AM3 Reversible, 2-stroke, Gasoline, 7-port piston reed valve Forward-inclined, Single 214 cm3 (13.06 cu.in) 68 x 59 mm (2.68 x 2.32 in) 5.7 : 1 Forced air cooled Normal & Reversible starter generator C.D.I. "Autolube" oil injection 31.3 cm3 (1.91 cu.in) Dome + Squish 0.6 mm (0.024 in)

Material Bore size Taper limit Out of round limit Model Item Cylinder: Cast iron sleeved aluminum 68 mm (2.677 in) 0.05 mm (0.0020 in) 0.01 mm (0.0004 in) GI-AM3 Piston: Piston skirt clearance (measuringpoint) Std. Max. Piston oversize Piston pin outside diameter x Length Piston ring: Piston ring design (Top)/l.D. mark Piston ring design (2nd)ll.D. mark Ring end gap (installed)(Top) (2nd) 0.030 - 0.035 mm (0.0012 - 0.0014 in) (10 mm (0.39 in) from piston skirt end) 0.1 mm (0.0039 in) 1st. 68.25 mm (2.687 in) 2nd. 68.50 mm (2.697 in) 418x 55 mm (40.709 x 2.165in) Kevstonel" RN" Keystone1"R" 0.2 - 0.4 rnrn (0.008 - 0.016 in) 0.2 - 0.4 mm (0.008 - 0.016 in) I Type I Needle bearing Small end bearing: Big end bearing: Crankshaft: I Needle bearing Crankshaft assembly width (A) Crankshaft deflection (0 Connecting rod big end side clearnace (C) Connecting rod small end deflection (P Max. CLUTCH SIDE 40 rnrn +O 56 TE.05mm (2.20 -0.002 in) 0.02 mm (0.008 in) 0.25- 0.75 rnm (0.010 - 0.030 in) 2.0 mm (0.079 in) Crank pin outside diameter x Length (1.57 in) x 2.1652: in) 1 00'945-0.0005 Crankpin type Crank bearing type (Left) x Q'ty Crank bearing type (Right) x Q'ty Crank oil seal type (Left) x Q'ty Crank oil seal type (Right) x Q'ty Solid shaft #6306 c3 (Nylon retainer) x 1 pc #6306 c3 (Nylon retainer) x 1 pc FPJSO 72 8 x 1 PC FPJ-30 48 8 x 1 PC

Air cleaner: Model - Element type Element assembly PIN Element cover PIN Intake reed valve: GI -AM3 Type At rest open limit Valve lift Choke cable: Free play Carburetor: ModelIMaker PINO I.D. mark Venturi diameter (Ven. T.) Main jet (M.J.) Air jet (A.J.) Main nozzle. (M.N.) Pilot jet (P.J.) Pilot air jet (P.A.J.) Throttle valve (Th.V.) Valve seat (V.S.) By-pass (1 ) (B.P.-1 By-pass (2) (B.P.-2) Pilot outlet (P.O.) Pilot screw (P.S.) Float height (F.H.) Engine idling speed" Fuel pump: Part No. ManufacturerIType Fuel tank: Fuel grade Fuel tank capacity Fuel tank position MaterialIColor Gauge position 1 Lubrication system: Autolube pump - Type - Color code - Minimum stroke - Maximum stroke - Reduction ratio Max. output (690 mmAg exhaust pipe 111) Max. output (0 mmAg exhaust pipe Min.) Mixing ratio Wet paper with element cover J10-14450-10 J10-14417-00 "V" type 0.3 mm (0.012 in) 10.4 f 0.2 mm (0.409 f 0.0078 in) 1 mm (0.04 in) BV21-161MIKUN J24-14101-00 J2400 4 16 #97.5 41.2 2B #42.5 4 1 .o # 100 41.0 4 0.8 $0.7 41.1 1 and 318 turn out 18 mm (0.7 in) 1,200 rlmin J10-24410-02 MIKUNIIDF-36 (Diaphragm) Any grade gasoline 25.5 L (5.6 Imp gal, 6.7 US gal) Front of left rear wheel PolyethyleneIBlack Side of filler cap Separated lubrication YAMAHA Automatic oil injection system (controlled by exhaust pressure) Pink 0.50 - 0.55 mm (0.020 - 0.022 in) 1.80 - 1.85 mm (0.071 - 0.073 in) 111.9 x 1/84 Approx. 21 . cm3/h at 3,250 rlmin Approx. 5.9 cm3/h at 3,250 r/min 150 : 1 at Max. Dower

1983-1989 Yamaha G1 Golf Cart Service & Repair Manual

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