Yamaha G14 G11 G16 G19 G20 Service Repair Manual

Yamaha G14 G11 G16 G19 G20 Service Repair Manual

Yamaha Golf Car Manual
G-14A/G14E G11A G16A/G16E G19E G20A
495 Pages

The G14A/G14E is the Main Manual used in concert with the G11A, G16A/G16E, G19E and G20A Supplements

CHAPTER 1
GENERAL INFORMATION
SAFETY PRECAUTIONS
GENERAL SERVICE INFORMATION
FRAME SERIAL NUMBER
WASHING AND CLEANING
THE RIGHT TOOLS
KEEP IT NEAT
TIGHTENING
TORQUE
ALL REPLACEMENT PARTS
GASKETS,OIL SEALS AND
0-RINGS
LOCK WASHERS/PLATES AND
COTTER PINS
BEARINGS AND OIL SEALS
CIRCLIPS
DISASSEMBLY AND ASSEMBLY
SUGGESTIONS
SPECIAL TOOLS
FOR TUNE UP
FOR ENGINE SERVICE
FOR POWER TRAIN
FOR CHASSIS SERVICE
FOR ELECTRICAL COMPONENTS

CHAPTER 2
PERIODIC INSPECTION AND ADJUSTMENT
PERIODIC MAINTENANCE
MAINTENANCE CHART FOR G14-A
MAINTENANCE CHART FOR G14-E
MAINTENANCE CHART FOR
G14-A AND G14-E
INSPECTION AND ADJUSTMENT
ENGINE (FOR G14-Al
VALVE CLEARANCE ADJUSTMENT
ENGINE OIL LEVEL MEASUREMENT
ENGINE OIL REPLACEMENT
OIL DELIVERY HOSE INSPECTION
AIR FILTER CLEANING
ENGINE BRACKET ADJUSTMENT
COMPRESSION PRESSURE
MEASUREMENT
CARBURETOR ADJUSTMENT
ACCELERATOR STOP SWITCH
INSPECTION/ACCELERATOR PEDAL
POSITION ADJUSTING BOLT
HEIGHT ADJUSTMENT
THROTTLE CABLE ADJUSTMENT
SPEED LIMITER
ADJUSTMENT
CHOKE CABLE ADJUSTMENT
FUEL PUMP INSPECTION
FUEL FILTER INSPECTION
FUEL HOSE
INSPECTION
POWER TRAIN
TRANSMISSION OIL LEVEL MEASUREMENT
TRANSMISSION OIL REPLACEMENT
DRIVE BELT INSPECTION (FOR G14-Al PRIMARY SHEAVE LUBRICATION
(FOR G14-A)
SHEAVE INSPECTION
SHIFTING CABLE ADJUSTMENT
(FOR G14-A)
CHASSIS
BRAKE CABLE INSPECTION
PARKING BRAKE ADJUSTMENT
BRAKE SHOE
LINING INSPECTION
BRAKE AND ACCELERATOR PEDALS
STEERING INSPECTION
STEERING LINKAGE INSPECTION
WHEEL ALIGNMENT
TIRE AND WHEEL INSPECTION
FRONT WHEEL BEARING
INSPECTION REAR AXLE BEARING INSPECTION
SHOCK ABSORBER INSPECTION
ELECTRCI AL (FOR G14-A)
SPARK PLUG INSPECTION
STARTER BELT INSPECTION
BATTERY
INSPECTION
BATTERY CHARGING
ELECTRICAL (FOR G14-El
BATTERY CHARGING
BATTERY INSPECTION
CHARGE RECEPTACLE INSPECTION

CHAPTER 3
CHASSIS
FRONT AND REAR BUMPER
REMOVAL
INSTALLATION
BUMPERS
SEAT
REMOVAL
INSTALLATION
FRONT COWLING
REMOVAL
INSTALLATION
FRONT COWLING
REAR COWLING
REMOVAL
INSTALLATION
REAR COWLING FOR
G14-A
REAR COWLING FOR G14-E
FRONT WHEEL
REMOVAL
INSPECTION
INSTALLATION

REAR AXLE WHEEL FOR G14-A
REMOVAL
INSPECTION
INSTALLATION
REAR AXLE WHEEL FOR G14-E
REMOVAL
INSPECTION
INSTALLATION
BRAKE
BRAKE PEDAL
DISASSEMBLY
INSPECTION
ASSEMBLY
ACCELERATOR PEDAL
FOR G14-A
FOR G14-E
STEERING SVSTEM
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
FRONT SUSPENSION
REMOVAL
INSPECTION
INSTALLATION
REAR ARM SUSPENSION
FOR G14-A
FOR G14-E
REMOVAL
INSPECTION
INSTALLATION
CABLE MAINTENANCE
FRAME
FOR G14-A
FOR G14-E

CHAPTER 4
POWER TRAIN
POWER TRAIN FOR G14-A
PRIMARY SHEAVE
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
SECONDARY SHEAVE
DISASSEMBLY
INSPECTION
ASSEMBLY
DRIVE V-BELT
INSPECTION AND REPLACEMENT
TRANSMISSION
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION
POWER TRAIN FOR G14-E
TRANSMISSION
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION

CHAPTER 5
ENGINE OVERHAUL
ENGINE REMOVAL
PREPARATION FOR REMOVAL
DRIVE BELT
CARBURETOR
AIR CLEANER CASE
WIRING AND HOSE
MUFFLER
ENGINE REMOVAL
ENGINE DISASSEMBLY
STARTER-GENERATOR
AIR SHROUD
CYLINDER HEAD
PRIMARY SHEAVE
FLYWHEEL
CRANKCASE COVER
CAMSHAFT
BALANCER SHAFT AND CRANKSHAFT PISTON AND CONNECTING ROD
ENGINE BRACKET
INSPECTION AND REPAIR
CYLINDER HEAD
VALVE
VALVE SEAT
VALVE SPRING
VALVE INSTALLATION
ROCKER ARM
CAMSHAFT
GEARS
CYLINDER AND PISTON
PISTON RING AND PIN
CRANKSHAFT AND CONNECTING ROD
ENGINE ASSEMBLY AND ADJUSTMENT
ENGINE BRACKET
CRANKSHAFT,CAMSHAFT AND BALANCER SHAFT
PISTON AND CONNECTING ROD
CRANKCASE COVER
FLYWHEEL
PRIMARY SHEAVE
CYLINDER HEAD
AIR SHROUD
STARTER-GENERATOR
REMOUNTING ENGINE

CHAPTER 6
CARBURETION
CARBURETOR
SECTION VIEW
REMOVAL
DISASSEMBLY
INSPECTION
ASSEMBLY
INSTALLATION

CHAPTER 7
ELECTRICAL
ELECTRICAL FOR G14-A
G14-A WIRING DIAGRAM
ELECTRICAL COMPONENT LOCATIONS
ELECTRICAL COMPONENTS
STARTING AND CHARGING SYSTEM
TROUBLESHOOTING
THE STARTER DOES NOT TURN
THE BATTERY IS NOT CHARGED
STARTER GENERATOR
SOLENOID RELAY
VOLTAGE REGULATOR
IGNITION SYSTEM
TROUBLESHOOTING
NO SPARK OR WEAK SPARK
SIGNAL SYSTEM
TROUBLESHOOTING
THE OIL LEVEL INDICATOR LIGHT DOES NOT COME ON
THE BACK-UP BUZZER DOES NOT OPERATE
ELECTRICAL FOR G14-E
G14-E WIRING DIAGRAM
ELECTRICAL COMPONENTS
STARTING AND RECHARGING SYSTEM
TROUBLESHOOTING
TRACTION MOTOR
MOTOR
CONTROLLER
SOLENOID RELAY
SIGNAL SYSTEM
TROUBLESHOOTING

CHAPTER 8
TROUBLESHOOTING
TROUBLESHOOTING FOR G14-A/G14-E
SUSPENSION AND STEERING
TROUBLESHOOTING FOR G14-A
TROUBLESHOOTING CHART
ENGINE
ELECTRICAL
STARTER- GENERATOR
TROUBLESHOOTING FOR G14-E
TROUBLESHOOTING CHECKING PROCEDURE
ELECTRICAL
TRACTION MOTOR

CHAPTER 9
SPECIFICATIONS
GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS FOR G14-A
ENGINE
TRANSMISSION
CHASSIS
ELECTRICAL
MAINTENANCE SPECIFICATIONS FOR G14-E
TRANSMISSION
CHASSIS
ELECTRICAL
TIGHTENING TORQUE
ENGINE (FOR G14-A)
CHASSIS
POWER TRAIN
ELECTRICAL
GENERAL TORQUE SPECIFICATIONS
DEFINITION OF UNITS
LUBRICATION POINT AND GRADE OF LUBRICATION
CABLE/WIRE ROUTING
FOR G14-A
FOR G14-E
WIRING DIAGRAM
FOR G14-A
FOR G14-E

G11A UTILITY CAR SERVICE MANUAL SUPPLEMENT
INDEX
TABLE OF CONTENTS
PERIODIC INSPECTION AND ADJUSTMENT
CABLE/WIRE ROUTING FOR G11A

G16A, G16E GOLF CAR SERVICE MANUAL SUPPLEMENT
INDEX
TABLE OF CONTENTS
PERIODIC INSPECTION AND ADJUSTMENT
POWER TRAIN G16A
ENGINE OVERHAUL
CARBURETION
ELECTRICAL FOR G16A
MAINTENANCE SPECIFICATIONS FOR G16A

G19E GOLF CAR SERVICE MANUAL SUPPLEMENT
INDEX
TABLE OF CONTENTS
GENERAL INFORMATION
ELECTRICAL FOR G19E PERIODIC ADJUSTMENT
ELECTRICAL FOR G19E WIRING DIAGRAM
TROUBLESHOOTING FOR G-19E
MAINTENANCE SPECIFICATIONs FOR G19E
CABLE ROUTING FOR G19E

G20A MULTI-PASSENGER SERVICE MANUAL SUPPLEMENT
INDEX
TABLE OF CONTENTS
PERIODIC INSPECTION AND ADJUSTMENT
GENERAL SPECIFICATIONS

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