Yamaha G14/G16/G19/G11/G20 Ultima Golf Cars OEM Service & Repair Manual

YAMAHA ULTIMA GOLF CAR SERVICE MANUAL G14 AlE G16 AlE G19 E G11 A G20A

G14-A, G14-E GOLF CAR SERVICE MANUAL G14A,G14E SERVICE MANUAL 1999 by Yamaha Motor Manufacturing Corporation of America 3rd edition, June 1999 Printed in U.S.A. P/N/ LIT-19616-00-00 (Rev. 8/96) (Rev. 6/99)

INTRODUCTION This manual has been written by Yamaha Motor Manufacturing Corporation of America for use by Authorized Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into a manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha golf cars have a basic understanding of the mechanical concepts and procedures inherent to these products. Without such knowledge, attempted repairs or service to this golf car may render it unfit to use and/or unsafe. Yamaha Motor Manufacturing Corporation of America is continually striving to further improve all models manufactured by the company . Modifications are therefore inevitable and will, where applic- able, appear in future editions of this manual. TECHNICAL SERVICE DEPT GOLF CAR SALES GROUP YAMAHA MOTOR MANUFACTURING CORP OF AMERICA HOW TO USE THIS MANUAL Read This Important Information! Particularly important information in this manual is distinguished by the following notations: A WARNING The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to golf car occupants, a bystander, or a person inspecting or repairing the golf car. Imij lf.IQRI Ij\j}jjj This message describes special precautions that must be taken to avoid damage to the golf car. NOTE: This message provides additional key information. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been comp iled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format , the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol , e.g., • Bearings: Pitting/Damage ___,. Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures.

CD ® I~EF~IAI I~JJI&I ® ® lcHAsl~l I~RI®I!01 @ @ I ENG l'-1 lcARBifl <V ® I ELEcl i1iii I IJ~¥~1? I ® lsPEcl P~l @ ~ ® ~ @ ~ @) ~ ® ~ ® § ®) [mJ ® J.. a @) l @ l ® l m m Q @) @ @ ~ ~ ~ ii Symbol Identification Symbols CD to ® are designed as thumb tabs to indicate the contents within a chapter. CD General information ® Periodic inspection and adjustment @ Chassis ® Power train @ Engine overhaul @ Carburetion <V Electrical ® Troubleshooting ® Specifications Symbols @ to ®) are used to identify specifications within the text. @ Filling fluid ® Lubricant @ Special tool @) Tightening torque ® Wear limit, clearance @ Engine speed ®) Q,V,A Symbols ® to @ are used in the exploded diagrams to indicate the grade and location of lubricant. ® Apply locking agent @) Apply engine oil @ Apply gear·oil ® Apply molybdenum disulfide oil @) Apply wheel bearing grease @ Apply lightweight lithium soap base grease @ Apply molybdenum disulfide grease

CARBURETION CARB ELECTRICAL Iii ELEC TROUBLESHOOTING ? • TRBL SHTG SPECIFICATIONS SPEC iii

CHAPTER 1 GENERAL INFORMATION SAFETY PRECAUTIONS ................................... 1-1 GENERAL SERVICE INFORMATION ............... 1-3 FRAME SERIAL NUMBER .......................... 1-3 WASHING AND CLEANING ...................... 1-4 THE RIGHT TOOLS ................................... 1-4 KEEP IT NEAT ............................................. 1-4 TIGHTENING TORQUE .............................. 1-4 ALL REPLACEMENT PARTS ...................... 1-5 GASKETS, OIL SEALS AND O-RINGS ...... 1-5 LOCK WASHERS/PLATES AND COTTER PINS .......................................... 1-5 BEARINGS AND OIL SEALS ...................... 1-5 CIRCLIPS ..................................................... 1-6 DISASSEMBLY AND ASSEMBLY SUGGESTIONS ....................................... 1-6 SPECIAL TOOLS ............................................... 1-7 FOR TUNE UP ............................................. 1-7 FOR ENGINE SERVICE ............................... 1-7 FOR POWER TRAIN ................................... 1-8 FOR CHASSIS SERVICE ............................. 1-9 FOR ELECTRICAL COMPONENTS .......... 1-10 (Rev. 6/99)

Yamaha G14/G16/G19/G11/G20 Ultima Golf Cars OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed