YAMAHA

SERVICE MANUAL

G9-AJ/EJ
G9-AG/AH
G9-EG/EH1
G9-EH2
G2-A1E .

L1T-19616-G9 -93
 NOTICE

This manual has been written by Yamaha Motor Company for use by Authorized Yamaha Dealers
and their qualified mechanics. In light of this purpose it has been assumed that certain basic mecha-
nical precepts and procedures inherent to our products are already known and understood by the
mechanic. Without such basic knowledge, repairs or service to this model may render the machine
unsafe, and forthis reason we must advise that all repairs and/or service be performed by an Authorized
Yamaha Dealer who is in possession of the requisite basic product knowledge.
Yamaha Motor Company, Ltd. is continually striving to further improve all models manufactured by
the company. Modifications are therefore inevitable and changes in specifications or procedures will
be forwarded to all Authorized Yamaha Dealers and will, where applicable, appear in future editions
of this manual.
SERVICE DEPT.
LEISURE VEHICLE AND POWER
PRODUCTS OPERATIONS
YAMAHA MOTOR CO., LTD.

HOW TO USE THIS MANUAL

PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notations.

NOTE: A NOTE provides key information to make procedures easier or clearer.

A CAUTION indicates special procedures that must be followed to avoid

damage to the vehicle.

g,WARNING: A WARNING indicates special procedures that must be followed to avoid

injury to a vehicle operator or person inspecting or repairing the vehicle.

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled 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.
ill

I~EF~I~I ISPECI p~1

®
@

@
ILLUSTRATED SYMBOLS
(Refer to the illustration)

Illustrated symbols ill to ® are designed as

thumb tabs to indicate the chapter's number and
content.
•
B~rfJI~1 ••
CD General information
ENG ® Specifications
® Periodic inspection and adjustment
@ Engine
® ® ® Cooling system
® Carburetion
ICOOll ~I ICARBI fI (j) Power train
® Chassis
® Electrical
(J) ® @ Troubleshooting

Ip<t~RI~1 ICHAsl~1
® ®

IElEcl E
(j})
I ITRBll?
SHTG •
@
I Illustrated symbols (j}) to lID are used to

~ ~
identify the specifications appearing in the text
(j}) Filling fluid
@ Lubricant
@ Special tool
@ @ @ Tightening

~ ~
@ Wear limit, clearance
@ Engine speed
lID n, V, A

@ @

~ ~
lID

[mJ
@

a
.1
Illustrated symbols @ to @ in the exploded
diagram indicate grade of lubricant and location
of lubrication point.
@Apply locking agent ILOCTITE®)
•
@
l
Dl
®
l
~
@

e
1
@ Apply engine oil
® Apply gear oil
® Apply molybdenum disulfide
@ Apply wheel bearing grease
oil

@ Apply lightweight lithium-soap base grease

@ Apply molybdenum disulfide grease
•
®

•
® @

~ ~ ~
 INDEX
~
GENERAL INFORMATION GEN
INFO

SPECIFICATIONS SPEC

PERIODIC INSPECTION 1----

If!a
INSP
AND ADJUSTMENT

ENGINE OVERHAUL
....
ADJ

1-----=

CARBURETION I---.,;f
CARS

®I!0
POWER TRAIN 1---
POWR
TR

CHASSIS
~=========================~
ICHAS~
ELECTRICAL
IHEeD
TROUBLESHOOTING
 CONTENTS
CHAPTER 1.
GENERAL INFORMATION

CAR IDENTIFiCATION 1-1

FRAME SERIAL NUMBER 1-1
ENGINE SERIAL NUMBER (FOR G2-Al 1-1

IMPORTANT INFORMATION 1-2

NO FLAME SOURCES 1-2
WASHING AND CLEANING 1-2
RIGHT TOOLS 1-2
MAKING IT NEAT 1-2
TIGHTENING TORQUE 1-2
ALL REPLACEMENT PARTS 1-3
GASKETS, OIL SEALS, AND O-RINGS 1-3
LOCK WASHERS/PLATES AND COTTER PINS _ 1-3
BEARINGS AND OIL SEALS 1-3
CIRCLlPS _ 1-4
NOTES ON DISASSEMBLY AND ASSEMBLY 1-4

SPECIAL TOOLS _ 1-5

FOR TUNE UP 1-5
FOR ENGINE SERVICE 1-5
FOR POWER TRAIN 1-6
FOR CHASSIS SERVICE , 1-7
FOR ELECTRICAL COMPONENTS 1-8

CHAPTER 2.
SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1

FOR G2-A. 2-1
FOR G2-E , _ 2-1

MAINTENANCE SPECIFICATIONS 2-2

ENGINE 2-2
TRANSMISSION 2-7
CHASSIS _ 2-9
ELECTR ICAL. 2-12

GENERAL TORQUE SPECIFICATIONS 2-17

DEFINITION OF UNITS , 2-17

CABLE ROUTING (FOR G2-Al. 2-18

CABLE ROUTING (FOR G2-El 2-20

 CHAPTER 3.
PERIODIC INSPECTION AND ADJUSTMENT

INTRODUCTION _ 3-1
.( '"£.
I---=-
PERIODIC MAINTENANCE TABLE 3-1
GEN
FOR G2-A " ., 3-1 INFO
FOR G2-E " 3-4

JACK-UP _ 3-6
FRONT SIDE _ , 3-6
REAR SIDE 3-6 SPEC

COWLING BODY 3-7

SEAT COWLING OPENING " 3-7
REAR COWLING REMOVAL " 3-7

ENGINE (FOR G2-A) 3-8

VALVE CLEARANCE ADJUSTMENT ' 3-8
ENGINE OIL LEVEL MEASUREMENT 3-10
ENGINE OIL REPLACEMENT 3-10
OIL DELIVERY HOSE INSPECTION __ 3-11
ENG
AIR FILTER CLEANING _ " _ " .3-12
ENGINE BRACKET ADJUSTMENT _ 3-13
COMPRESSION PRESSURE MEASUREMENT _ 3-13
CARBURETOR ADJUSTMENT. _ _. _ _ _ 3-15
CARB
THROTTLE CABLE ADJUSTMENT _ 3-15
SPEED LIMITER ADJUSTMENT 3-17
CHOKE CABLE ADJUSTMENT.. _ , " .3-18
FUEL PUMP INSPECTION _.. _ 3-19
f--_®I---,C!0
FUEL FILTER INSPECTION _ _ 3-21 POWR
FUEL HOSE INSPECTION _ _ 3-21 TR

POWER TRAIN. _ _ 3-22

TRANSMISSION 01 L LEVEL MEASUREMENT _ 3-22
TRANSMISSION OIL REPLACEMENT _ _ _.3-22 CHAS
DRIVE BELT INSPECTION (FOR G2-A) _ 3-23
PRIMARY SHEAVE LUBRICATION (FOR G2-A) 3-24
SHEAVE INSPECTION , 3-25
SHIFTING CABLE ADJUSTMENT (FOR G2-A) 3-25
ELEC
CHASSIS 3-26
BRAKE CABLE INSPECTION 3-26
PARKING BRAKE ADJUSTMENT _ 3-27
1----.;-
?
I SHOE LINING INSPECTION , _ , 3-27
TRBL
i
I
BRAKE AND ACCELERATOR PEDALS
STEERING INSPECTION .. "
STEERING LINKAGE INSPECTION
_ ,
, ., '"
3-29
3-30
. 3-33
SHTG

I
WHEEL ALIGNMENT 3-33
TIRE AND WHEEL INSPECTION , 3-34

I
 FRONT WHEEL BEARING INSPECTION 3-35
REAR AXLE BEARING INSPECTION 3-35
SHOCK ABSORBER INSPECTION " 3-35

ELECTRICAL (FOR G2-A) 3-36

SPARK PLUG INSPECTION 3-36
STARTER BELT INSPECTION _" ' 3-37
BATTERY INSPECTION " 3-38
BATTERY CHARGING " 3-39
ACCELERATOR STOP SWITCH ADJUSTMENT 3-40

ELECTRICAL (FOR G2-E) 3-41

BATTERY CHARGING .. , , '" 3-41
BATTERY INSPECTION 3-44
SPEED CONTROLLER INSPECTION 3-46
SOLENOID RELAY INSPECTION 3-49
TRACTION MOTOR INSPECTION _.. 3-51
CABLE ROUTING INSPECTION ," " 3-51
FUSE 3-51

CHAPTER 4.
ENGINE OVERHAUL

ENGINE REMOVAL , " .. , 4-1

PREPARATION FOR REMOVAL , 4-1
DRIVE BELT 4-2
CARBURETOR , 4-2
AIR CLEANER CASE 4-2
LEAD AND HOSE 4-3
MUFFLER '" 4-3
ENGINE REMOVAL 4-3

ENGINE DISASSEMBLY , 4-4

STARTER-GENERATOR. ," 4-4
AI R SHOUD 4-4
CYLINDER HEAD , 4-5
PRIMARY SHEAVE , .. , .. , ' 4-6
FLYWHEEL (Cooling Fan) 4-7
CRANKCASE COVER , , " , .4-7
CAMSHAFT 4-8
BALANCER SHAFT AND CRANKSHAFT , '" 4-8
PISTON AND CONNECTING ROD 4-8
ENGINE BRACKET 4-9

INSPECTION AND PREPAIR 4-9

CYLINDER HEAD " ., , '" 4-9
VALVE 4-11
VALVE SEAT " ., 4-12
VALVE INSTALLATION 4-16
 ROCKER ARM, ROCKER ARM SHAFT AND
ROCKER ARM SHAFT SUPPORT 4-17
CAMSHAFT 4-18
GEARS 4-19
CYLINDER AND PISTON
PISTON RING AND PISTON PIN
" 4-19
4-20
~
CRANKSHAFT AND CONNECTING ROD 4-23 GEN
INFO
ENGINE ASSEMBL Y AND ADJUSTMENT 4-27
ENGINE BRACKET 4-27
CRANKSHAFT, CAMSHAFT AND BALANCER SHAFT 4-27
PISTON AND CONNECTING ROD 4-28 SPEC
CRANKCASE COVER 4-32
FLYWHEEL " 4-32
PRIMARY SHEAVE " 4-33
CYLINDER HEAD , 4-33
INSP
AIR SHROUD 4-35
ADJ
STARTER-GENERATOR '" . 4-37
REMOUNTING ENGINE 4-38

CHAPTER 5. ENG
CARBURET ION

CARBURETOR 5-1
SECTION ViEW 5-2
REMOVAL 5-4
CARB
DISASSEMBLY 5-4
INSPECTION 5-5
ASSEMBLY 5-6
INSTALLATION 5-7

FUEL PUMP 5-8

OVERHAULING " , 5-9

CHAS
CHAPTER 6.
POWER TRAIN (FOR G2-Al

PRIMARY SHEAVE , 6-1

REMOVAL _ 6-2
ELEC
DiSASSEMBLy 6-2
INSPECTION 6-3
ASSEMBLY _ _. _ 6-3
INSTALLATION 6-4 TRBL
SHTG
SECONDARY SHEAVE , .. 6-6
DISASSEMBLY _ 6-7
INSPECTION 6-8
ASSEMBLY , 6-8
DRIVE V-BELT 6-10
INSPECTION AND REPLACEMENT 6-10

TRANSMISSION 6-12
REMOVAL 6-12
DiSASSEMBLy 6-13
INSPECTION 6-14
ASSEMBLy 6-15
INSTALLATION , 6-16

POWER TRAIN (FOR G2-E)

TRANSMISSION 6-18
REMOVAL 6-19
DISASSEMBLY 6-19
INSPECTION 6-21
ASSEMBLY 6-21
iNSTALLATION , 6-22

CHAPTER 7.
CHASSIS

H" 7-16
REMOVAL 7-17
DISASSEMBLY 7-18
INSPECTION 7-18
ASSEMBLY 7-20
INSTALLATION 7-20
FRONT SUSPENSION AND KNUCKLE 7-23
REMOVAL 7~4
INSPECTION " " 7-26
INSTALLATION , 7-26
.t' d~
REAR SUSPENSION 7-28 I--::G::-::E""'N:-
REMOVAL 7-30
INSPECTION , ., , 7-31
INFO
INSTALLATION 7-31

CAB LES 7-32

CABLE MAINTENANCE 7-32 SPEC

CHAPTER 8.
ELECTRICAL (FOR G2-Al
INSP
G2-A CIRCUIT DIAGRAM 8-1 :=A=D=J~~~~

ELECTRICAL COMPONENTS 8-3

STARTING AND CHARGING SYSTEM 8-5 ENG

TROUBLESHOOTING 8-7
STARTER-GENERATOR .. " _ '" 8-15
SOLENOID RELAy 8-22
VOLTAGE REGULATOR 8-25
CARB
IGNITION SYSTEM _ 8-27
TROUBLESHOOTING 8-29

SIGNAL SYSTEM 8-35 1----

~
TROUBLESHOOTING 8-37
POWR
TR
ELECTRICAL (FOR G2-El

G2-E CIRCUIT DIAGRAM 8-43

CHAS
ELECTRICAL COMPONENTS 8-45

STARTING AND RECHARGING SySTEM , 8-47

TROUBLESHOOTING 8-49
G.E. TRACTION MOTOR _. 8-54
ELEC
HITACHI TRACTION MOTOR 8-61
SPEED CONTROLLER 8-67 ?
SOLENOID RELAy 8-69 I---=~_.
CHARGING RECEPTACLE ·8-71 TRBL
SHTG
SIGNAL SYSTEM 8-73
TROUBLESHOOTING 8-75
 CHAPTER 9.
TROUBLESHOOTING

TROUBLESHOOTING CHART (FOR G2-A) 9-1

ENGINE (FOR G2-A) 9-2

SUSPENSION AND STEERING 9-3

ELECTRICAL (FOR G2-A) 9-4

STARTER-GENERATOR (FOR G2-A) " 9-4

ELECTRICAL (FOR G2-E) _.' 9-5

MOTOR (FOR G2-E) _ _ 9-7

 CAR IDENTIFICATION I~EF"bI~1
GENERAL
INFORMATION
CAR IDENTIFICATION
FRAME SERIAL NUMBER
The frame serial number CD is located on the
rectangular pipe under the operator's seat.
or on the right hand side of the rectangular
D
pipe by the rear bumper.

Starting Serial Number:

G2·A J38-000101
JA2-000101
J55-000101
G2-E J41·000101
JE2-000101
J56-000101

.""'' ';:'' NOTE: _

~···';i·;',t;if,~r-~;:~,··'···,
'.,'{e;' .. ::/, 'C",
The first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.

ENGINE SERIAL NUMBER

The engine serial number CD is located on the
1eft-hand side of crank case.

Starting Serial Number:

G2·A J38·0001 01
JA2-000101
J55·000101

NOTE: _

Designs and specifications are subject to change

without notice.

1-1
 GEN ~d~
IMPORTANT INFORMATION INFO~
IMPORTANT INFORMATION
NO FLAME SOURCES
1. Avoid any flame sources in the service shop.

WASHING AND CLEANING

1. Thoroughly clean the exterior of the car
body and engine. While cleaning, take care
to protect the electrical parts, such as relay
switches, motor, resistors, controllers, etc.,
from high pressure water splashes.

RIGHT TOOLS
1. Be sure to use the right special tool for the
right part in order to protect the part from
damage. Always use the right tool and the
right instrument.

MAKING IT NEAT
1. Keep the removed parts separately in groups
so that they will not be misplaced or
confused.

TIGHTENING TORQUE
1. Be sure to keep to tightening torque
specifications. When tightening bolts, nuts,
and screws, start with a larger-diameter one
and from an inner-positioned one to an
outer-positioned one in a criss-cross pattern.
Refer to CHAPTER 2. "TIGHTENING
TORQUE".

1-2
 GEN
IMPORTANT INFORMATION INFO ~4
ALL REPLACEMENT PARTS
1_ We recommend you use Yamaha genuine
"'- parts for all replacements. Use oil and/or
grease recommended by Yamaha for assem-
m bly and adjustment.·

-
............ c(er: ]
GASKETS, OIL SEALS, AND a-RINGS
1. All gaskets, seals, and O-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings
must be cleaned.

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/plates CD and cotter
pins must be replaced when they are re-
moved. Lock tabls) should be bent along
the bolt or nut tlatls) after the bolt or nut
has been properly tightened.

BEARINGS AND OIL SEALS

1. Install the bearing(s) CD and oil sealts) @
with their manufacturer's marks or numbers
facing outward. ! In other words, the
stamped letters must be on the side exposed
to view.) When installing oil sealls), apply a
light coating of light-weight lithium base
grease to the seal lip(sl. Oil the bearings
liberally when installing.

Do not use compressed air to spin the bearings

dry. This causes damage to the bearing surfaces,

--+t-~"
 GEN ~ dr
IMPORTANT INFORMATION INFO~
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace piston
pin clips after one use. Replace distorted
circlips. When installing a circlip CD, make
sure that the sharp-edged corner CV IS
positioned opposite to the thrust ® it
receives. See the sectional view.
3000(11
® Shaft
NOTES ON DISASSEMBLY AND ASSEMBLY
1. Parts should be cleaned and blown off with
compressed air whenever they are dis-
assembled.

2. Contact surfaces of moving parts should

be oiled when they are assembled. Apply
grease to the oil seal lips.

3. After assemb ling, make sure each of the

moving parts operates normally.

1-4
 SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool )Nill help prevent damage
caused by the use of improper tools or improvis-
ed techniques.

FOR TUNE UP
1. Inductive Tachometer
PIN YU-08036, 90890-03113
This tool is needed for detecting engine rpm.

2. Compression Gauge
PIN YU-33223, 90890-03081
This gauge is used to measure the engine com-
pression.

FOR ENGINE SERVICE

1. Heavy-Duty Universal Puller
PIN YU-33270, 90890-01362
This tool is used to remove the flywheel.

2. Valve Spring Compressor

PIN YM-04019, 90890-01253
This tool is needed to remove and install the
valve assemblies.

1-5
 GEN
SPECIAL TOOLS INFO ~
~ 3. Valve Seat Cutter Set

'6Jr:l ~ I~
piN YM-91043
This tool is used to resurface the valve seat.

i(lIJi)[]

litS
4. Valve Adjuster
PIN YM·08035, 90890-01311
This tool is used to adjust the valve clearance.

FOR POWER TRAIN

1. Primary Sheave Holder
PIN YS-01880, 90890-01701
Th is tool is used to hold the primary sheave
when removing or installing the primary sheave
securing bolt.

2. Primary Sheave Puller

PIN YG-01876, 90890-01876
This tool is used for removing the pnmary
sheave.

3. Secondary Sheave Holder

PIN YG-40103, 9089001705
This tool is used to compress the sheave spring
when removing or installing the secondary
sheave securing nut.

1-6
 5. Plastigage@ Set "Green"
PIN YU-3321 0
This gauge is needed to measure the clearance
for the connecting rod bearing and the crank
shaft bearing.

FOR CHASSIS SERVICE

1. Drift punch (6 mm) or Valv.e Guide Re-
mover
PIN YM-04064, 90890-04064
This tool is used to remove the spring pins for
steering knuckle.

2. Dial Gauge
PIN YU-03097, 90890-03097
This tool is used to measure small movement
or runout such as the rear axle deflection.

3. Cable Injector
PIN ACC-llll0-43-15, 90890-70054
This tool is used to lubricate the throttle, shifter
and brake cables.

1-7
 GEN .,. dr
SPECIAL TOOLS INFO~
FOR ELECTRICAL COMPONENTS
1. Pocket Tester
PIN YS-03112. 90890-03112
This instrument IS invaluable for checking the
electrical system.

2. Hydrometer
PIN Y U-03036, 90890-03036
This gauge is used to measure the specific
gravity of battery electrolyte.

3. Low Reading Ohmmeter

PIN YU-91 026, 90890-03064
This instrument is use to measure the low range
resistance (Q - 1[1) of the electrical components.

4. Dynamic Spark Tester

PIN. YM-34487, 90890-03144
This tester is necessary for checking the ignition
system components.

1-8
 GENERAL SPECIFICATIONS

SPECIFICATIONS
GENERAL SPECIFICATIONS
FOR G2-A

Model G2-A
Model Code Number J38, JA2, J55 (For U.S.A. and Canada)

Frame Serial Number J38-000101, JA2-000101, J55-000101

Engine Serial Number J38-000101, JA2-000101, J55-000101

Dimensions:
Overall Length 2,332 mm (91.8 in)
Overall Width 1,116 mm (43.9 in)
Overall Height (Steering height) 1,175 mm (46.3 in)
Height of Floor 285 mm (10.2 in)
Height of Seat from Floor 420 mm (16.5 in)
Wheelbase 1,550 mm (61.0 in)
Tread:
Front 900 mm (35.4 in)
Rear 900 mm (35.4 in)
Min. Ground Clearance 104 mm ( 4.1 in)
Weight:
Dry Weight (Without battery) 275 kg (606 Ib)
Performance:
Maximum Loading Limit 250 kg (550 Ib)
Maximum Speed 19 km/h (12 mph)
Starter Generator Red Zone 4,000 r/min
Cranking Speed Appx. 800 r/min
Minimum Turning Radius 2,900 mm (114 in)
Braking Distance 4,500 mm (177 in)
at 19 km/h (12 mph)
Seating Capacity 2 persons
Hill Climbing Ability 26° (50% grade) on
pavement

FOR G2-E
Model G2-E
Model Code Number J41,JE2,J56
Frame Serial Number J41-000101, JE2-000101, J56-000101
Dimensions:
OveraII Length 2,332 mm (91.8 in)
Overall Width 1,116 mm (43.9 in)
Overall Height (Steering height) 1,175 mm (46.3 in)
Height of Floor 285 mm (10.2 in)
Height of Seat from Floor 420 mm (16.5 in)
Wheelbase 1,550 mm (61.0 in)
Tread:
Front 900 mm (35.4 in)
Rear 900 mm (35.4 in)
Min. Ground Clearance 104 mm ( 4.1 in)

2-'
 MAINTENANCE SPECIFICATIONS ISPECI jJ~1
Model G2-E
Weight:
Dry Weight (Without battery) 223 kg (492 Ibl
Performance:
Maximum Loading Limit 210 kg (463Ib)
Maximum Speed 19 km/h (12 mph)
Speed 6 speeds
Motor Red Zone 5,500 r/min
Minimum Turning Radius 2,900 mm (114 in)
Braking Distance 4,500 mm (177 in)
at 19 km/h (12 mph)
Seating Capacity 2 persons
Hill Climbing Ability 25° (46% grade) on
pavement

MAINTENANCE SPECIFICATIONS
ENGINE

Model G2-A
Description:
Engine Type 4-stroke, Gasoline, OHV
Number of Cylinder Single
Displacement 285 em'
Bore x Stroke 73 x 68 mm (2.84 x 2.68 in)
Compression Ratio 8.1 : 1
Cooling System Forced air cooled
Starting System Starter
Ignition System TCI
Lubrication System Wet sump
Cylinder Head:
Combustion Chamber Volume (With spark plug) 38.8 - 39.6
Head Gasket Thickness ~ * *0.2 mm (O.OOB in)

Cylinder:
Material Cast iron sleeved aluminum (crankcase)
Bore Size 73 mm (2.87 in)
Taper/Limit 0.02 mm (0.00008 inl/0.15 mm (0.006 in)
Out of Round/Limit 0.02 mm (0.00008 in)/0.15 mm (0.006 m)
Piston:
Piston-to-Cylinder Clearance 0.03 - 0.05 mm (0.0012 - 0.0020 in)
< Limit> < 0.1 mm (0.004 in) >
Oversize: 1 0.25 mm (0.01 in)
2 0.50 mm (0.02 in)
Piston Pin Outside Diameter 17.995 - 18.000 mm (0.7085 - 0.7087 in)
Piston Pin-to-Piston Clearance 0.004 - 0.020 mm (0.0002 - 0.0008 in)
< Limit> < 0.07 mm (0.003 in) >

2-2
 MAINTENANCE SPECIFICATIONS ISPECI r~l
Model G2-A
Piston Ring:
Top Ring:
Type Keystone
Dimensions (B x T) 2.0 x 3.2 mm (0.079 x 0.126 in)
End Gap (Installedl 0.2 - 0.4 mm (0.008 - 0.016 in)
< Limit> ~JB < 1.0 mm (0.04 in) >
Size Clearance (Installed) L-----T-----J 0.03 - 0.05 mm (0.0012 - 0.0020 in)
< Limit> < 0.07 mm (0.0028 in) >
2nd Ring:
Type Plain (Taper face)
Dimensions (B x T) 2.0 x 3.2 mm (0.079 x 0.126 in)
End Gap (Installed) 0.2 - 0.4 mm (0.008 - 0.016 in)
< Limit>
Side Clearance ~~B < 1.0 mm (0.04 in) >
0.03 - 0.07 mm (0.0012 - 0.0028 in)
< Limit> (Installed) .,--- T --
< 0.09 mm (0.0035 in) >

Oil Ring: ~!'B

J! ,_
Dimensions (B x T) 2.80 x 2.95 mm (0.110 x 0.116 in)
End Gap (Installed) I - T --i 0.2 - 0.7 mm (0.008 - 0.028 in)
Small End Bearing:
Type None
Big End Bearing:
Type Plain bearing
Crankshaft:
Crankshaft Assembly Width" A" 109.65 - 110.05 mm (4.317 - 4.333 in)
Crankshaft Deflection "B" 0.05 mm (0.0020 in)
Connecting Rod Big End Side Clearance "C" 0.2 - 0.5 mm (0.008 - 0.020 in)

L
Crank Pin Outside Diameter 31.95 - 31.97 mm (1.258 - 1.259 in)
Crank Pin Type Solid crankshaft
Crank Bearing Type (Left) x O'tv # 6307 c3 x 1 pc
Crank Bearing Type (Right) x O'tv #6306 c3 x 1 pc
Crank Oil Seal Type (Left) x O'tv SO 35 50 8 x 1 pc
Crank Oil Seal Type (Right) x O:ty SO 30 45 8 x 1 pc

. 2-3
 MAINTENANCE SPECIFICATIONS ISPECll'~1
Model G2-A
Camshaft:
Drive Method Gear drive
Cam Cap Inside Diameter 16_00 - 16.05 mm (0.630 - 0.632 in)
Camshaft Outside Diameter 15.90 - 15_99 mm (0.626 - 0.630 in)
Shaft-to-cap Clearance/Limit 0.01 - 0.05 mm (0.0004 - 0_0020 in)/
0_15 mm (0.0059 in)
Cam Dimensions:
Intake "A" I 29.16 - 29.28 mm (1.148 - 1.153 in)

6~
"8"
lie" I
i
24.11 - 24.22 mm (0.949 - 0.954 in)
5.16 - 5.28 mm (0.203 - 0.208 in)
A
29.20 - 29.32 mm (1.150 - 1.154 in)

t: /1
E"haust "A"
"B" 24.15 - 24.25 mm (0.951 - 0_955 in)
"G" 5.20 - 5.32 mm (0.205 - 0.209 in)

B-J
Rocker Arm/Rocker Arm Shaft:
Arm Inside Diameter 12.00 - 12.04 mm (0.472 - 0.474 in)
Shaft Outside Diameter 11.90 - 11.99 mm (0.469 - 0.472 in)
Arm-to-shaft Clearance 0.01 - 0.07 mm (0.0004 - 0.0028 in)
Valve, Valve Seat, Valve Guide:
Valve Clearance (Cold) IN. 0.1 mm (0.004 in)
EX. 0.1 mm (0.004 in)
Valve Dimensions:

~C"
I\ !\

("~"~1
~B'
Face Width Seat Width
~"D
Margin
f---- " A " --------,
Thickness

"A" Head Dia. IN. 30 mm (1.18 in)

EX. 26 mm (1.02 in)
"B" Face Width IN. 2.26 mm (0.089 in)
EX. 2.26 mm (0.089 in)
"C" Seat Limit Width IN. 1.4 mm (0.055 in)
EX. 1.4 mm (0.055 in)
"D" Margin Thickness Limit IN. 0.8 mm (0.032 in)
EX. 0.6 mm (0.024 in)
Air Cleaner:
Element Type Wet paper with element cover
Element Assembly J38-14450-00
Element Cover Jl0-14417-00
Choke Cable:
Free Play 1 mm (0.04 in)

2-4
 MAINTENANCE SPECIFICATIONS ISPECll'~1
Model G2-A
Carburetor:
Model/Maker BV26-18/MIKUNI
P/No. J38-14101-00
I.D. Mark J3800
Venturi Diameter (Ven. T.) .p18
Main Jet (M.J.) #106.3
Main Air Jet (MAJ.) .p2.5
Pilot Jet (P.J.) #72.5
Pilot Air Jet (P.A.J.) .p 1.4
Throttle Valve (Th.V.) #120
Valve Seat (V.S.) .pl.2
By-pass (1) (B.P. 1) .p0.7
By-pass (2) (B.P.2) .p0.9
By-pass (3) (B.P.3) .p0.6
Pilot Outlet (P.O.) et.o
Pilot Screw (P.S.l 1-1/2 turn out
Float Height (F.H.) 14.5 mm (0.57 in)
Engine Idling Speed * 900 r/min
Fuel Pump:
Part No. J38-2441 0-02
Manufacturer/Type MIKUNI/DF-52 (Diaphragm)
Fuel Tank:
Fuel Grade Unleaded regular gasoline only
Fuel Tank Capacity 24.0 L (5.3 Imp gal, 6.3 US gal)
Fuel Tank Position Right side in front of rear wheel
Material/Color Polyethylene/Black
Gauge Position Side of Filler Cap
Exhaust System:
Parts No. J38-14710-01

* Firing begining point

2-5
 MAINTENANCE SPECIFICATIONSISPECI fJ~1
Tightening Torque:
Tightening torque
Part to be tightened Part name Thread size Remarks
Nm m·kg ft·lb
Spark plug M14x P1.25 20 2.0 14
Airshroud x Cylinder Head
Bolt M6 x Pl.0 8 0.8 5.8
or Crankcase
Airshroud Cylinder 1 x 2 Pan head M6 x P1.0 4 0.4 2.9
Cylinder Head: Bolt M8 x P1.25 28 2.8 20
Cylinder Head x Rocker-Arm Cover Bolt M6 x Pl.0 10 1.0 7.2
Cylinder Head x Rocker-Arm Support Bolt M6 x Pl.0 10 1.0 7.2
Valve Adjuster Locknut Nut M6 x PO.75 14 1.4 10
With Oil
Connecting Rod Cap Nut M8 x PO.75 38 3.8 27
splusher
Cylinder x Exhaust Pipe Nut M8 x Pl.25 12 1.2 8.7
Exhaust Pipe Cover Pan head M6 x P1.0 7 0.7 5.1
Clamp & Tightening
Carburetor x Joint M4 x PO.7
Pan head steady
Flywheel Nut M16xPl.0 75 7.5 54
Crankcase x Engine Bracket Bolt Ml0x Pl.25 35 3.5
Crankcase Cover Bolt M8 x Pl.25 24 2.4 17
[Cylinder Head Tightening Sequence] [Crankcase Cover Tightening Sequence]

1 ~

2-6
 MAINTENANCE SPECIFICATIONS \SPEC\ fJ~1
TRANSMISSION
For G2-A

Model G2-A
Transmission:
Type V -belt automatic centrifugal engagement
Primary Reduction Ratio 3.2 : 1 - 0.8 : 1
Shift r/min 3,400 r/min
Primary Spring: None
Secondary Spring:
Part No. 90508-45679
Outside Diameter x Wire Diameter 54.5 x 4.5 mm (2.15 x 0.177 in)
No. of Turns/Free Length 7.25/100 mm (3.94 in)
Color Code Black
Twist Angle (Preload setting) 60' (B-4)
Torque Cam Angle 50 deg
Sheave Center to Center Distance 270.5 mm
Sheave Off-Set 24.8 mm
V-belt Part No. J38-46241-00
V -belt Width and Outer Line Length 31 x 1,010 mm (1.22 x 39.76 in)
V-belt Wear Limit 27 mm (1.06 in)
Differential/Reduction Gear:
Secondary Reduction System Helical gear
Secondary Reduction Ratio:
Forward 13.65: 1
Reverse 15.25 : 1
Differential Type Bevel gear
Lubricant/Capacity SAE 90 gear oil/800 cc (0.70 Imp qt. 0.85 US qt)
Governor:
Type Oil bath flyweight
Adjustment Screw with lock nut
Factory Speed Setting 19 km/h (12 mph)

For G2-E

Model G2-E
Differential/Reduction Gear: G.E. TRACTION MOTOR
Reduction Gear Ratio/Gear Type 11.969 (60/23 x 78/17)/Helical
Differential Type Bevel gear
Oil Type/Capacity SAE 90 Gear oil/800 cc (0.70 Imp qt, 0.85 US qt)

Differential/Reduction Gear: HITACHI TRACTION MOTOR

Reduction Gear Ratio/Gear Type 13.546 (62/21 x 78/17)/Helical
Defferential Type Bevel gear
Oil Type/Capacity SAE 90 Gear oil/800 cc
(0.70 Imp qt, 0.85 US qt)

2-7
 MAINTENANCE SPECIFICATIONS ISPECI )U~I
Tightening Torque:
Tightening torque
Part to be tightened Part name Thread size Remarks
Nm m·kg tt-lb
For G2-A
Primary Sheave x Engine Bolt 1j2-UNF 75 7.5 54
Secondary Sheave x Input Shaft Castle nut M12xP1.25 60 6.0 43
Transmission Case x Rear Arm Bolt M10 x P1.25 40 4.0 29
Transmission Case x Frame Bolt M10xP1.25 40 4.0 29
Transmission Case 1 x 20 2.0 14 First
Bolt M8 x P1.25 18 Final
Transmission Case 2 25 2.5
Differential Case x Ring Gear Bolt M8 x P1 .25 38 3.8 27 ~
For G2-E
Transmission Case x Frame Bolt M10xP1.25 40 4.0 29
Transmission Case x Bolt 18
M8 x P1.25 25 2.5
Rear Axle Housing
Transmission Case 1 20 2.0 14 First
Bolt M8 x P1.25 18 Final
x Transmission Case 2 25 2.5
Differential Case x Ring Gear Bolt M8 x P1.25 34 3.4 24

2-8
 MAINTENANCE SPECIFICATIONS ISPECI fJ~1
CHASSIS

Model G2-A/G2-E
Frame:
Type Ladder type pipe structure
Materia l/Color Tubular steel (STKM)/Yamaha Black
Front Cowl: (UPR. & LWR.)
Type Injection molding
Material Polypropylene
Color Ivory white
Rear Cowl: (FR./RR.)
Type Injection molding
Material Polypropylene
Color Ivory white
Seat:
Seat Cover:
Material Vinyl chloride leather + Nylon lining
Color Ivory white
Seat Cushion:
Material Urethane foam
Bumper:
Front Steel + EVA cover
Rear Steel + EVA end
Steering System:
Type Worm and pin
Steering Angle (L.H.) 1.5 turn
(R.H.) 1.5 turn
Turning Radius 2.9 m (114 in)
Lubricant/Capacity Grease/90 cc (3.17 Imp oz, 3.04 US oz)
Front Axle:
Type Eliot kingpin type
Toe-in/Fully Loaded 10 - 20 mm (0.4 - 0.8 in)/Zero mm (Zero in)
Camber (Loaded) Zero deg
Caster 7 deg
Kingpin Inclination 3deg
Rear Axle:
Rear Wheel Axle Type Semi-floating type
Toe-in Zero mm (Zero in)
Camber Zero deg
Front Suspension:
Type Single swingarm (independent suspension)
Coil springs with hydraulic shock absorbers
(single action type)
Spring Rate 2.6 - 5.0 kg/mm (For G2-A)
3.6 kg/mm (For G2-E)
Coil Spring Free Length 170.8 mm (6.72 in) (For G2-A)
164 mm (6.46 in) (For G2-E)
Damper Type Oil damper (Single action/tension only)

2-9
 MAINTENANCE SPECIFICATIONS ISPECI fJ~1
Model G2-A/G2-E
Rear Suspension:
Type Axle type trailing arm (unit swing)
Coil springs with hydraulic shock absorbers
(double action type)
Spring Rate 2.30 - 3.07 kg/mm (For G2-A)
3.63 kg/mm (For G2-E)
Coil Spring Free Length 208 mm (8.19 in) (For G2-A)
199 mm (7.83 in) (For G2-E)
Damper Type Oil damper (Double action/Both Compo & Tens.)
Brakes:
Brakes System Mechanical brake linkage to individual drum
brakes on each rear wheel with self-adjusting
brake shoe.
Dual internal expanding shoe.
Type of Brake Leading/Trailing shoes (self-adjusting)
Lining Thickness Std/Min. 4 mm (0.16 in)/1.5 mm (0.06 in)
Brake Drum Inside Dia. 160 mm (6.30 in)
Linkage Adjustment (Brake cable end play) 0.1 - 0.5 mm (0.004 - 0.02 in)
Parking Brake:
Type Foot type; Parking brake with automatic release
Release Timing
(Bolt head round parallel to arm) 1 mm (0.04 in)
Wheel:
Tire Type (Pattern):
Front Tubeless (Rib)
Rear Tubeless (Block) (For G2-A)
Tubeless (Rib) (For G2-E)
Tire Size:
Front 18 x 8.50 - 8.00/4 PR
Rear 18 x 8.50 - 8.00/4 PR
Rim Size: 7.00 - 1 - 8.00
Tire Pressure:
Front/Rear 80 kPa (0.8 kg/em'. 12 psi) (For G2-A)
90 kPa (0.9 kg/em', 13 psi) (For G2-E)

2-10
 MAINTENANCE SPECIFICATIONS ISPECll'~1
Tightening torque
Tightening torque
Part to be tightened Part name Thread size Remarks
Nm m·kg ft·lb
Front Lower Arm x Frame Bolt Ml0 x Pl.25 48 4.8 35
Rear Arm Camp. x Frame Bolt Ml0xPl.25 90 9_0 65
Tie Rod x Universal Joint Nut M12 x Pl.25 48 4.8 35
Tie Rod x Idler Arm or Knuckle Arm Nut M12xPl.25 29 2.9 21
Steering Wheel x Steering Shaft Nut Nut M12 x Pl.25 39 3_9 28
Use lock
Pitman Arm x Idler Arm Nylon nut M16xP1.5 85 8.5 61
washer
Steering Gearbox x Frame Bolt Ml0 x Pl.25 29 2.9 21
Steering Gearbox x Gearbox Cover
(For G2-Al Bolt M5 x Pl.0 7 0.7 5.1
(For G2-E) Bolt M6 x Pl.0 7 0.7 5.1
Steering Shaft Adjusting Bolt x
Nut M48 x P2.0 25 2.5 18 55 mm width
Locknut
Pitman Shaft Adjusting Bolt x
Nut M8 x Pl.25 15 1.5 11
Locknut
Front Hub x Knuckle Nylon nut M14x Pl.5 92 9.2 65
Front Wheel x Hub Nut M12xPl.25 88 8.8 64
Rear Wheel x Hub Nut M12 x Pl.25 80 8.0 58
Brake Shoe Plate Ass'y x
Bolt M8 x Pl.25 30 3.0 22
Rear Axle Housing
Shock Absorber Pivot Bolt Nylon nut M12xPl.25 29 2.9 21

2-11
 MAINTENANCE SPECIFICATIONS ISPECl r~1
ELECTRICAL
For G2-A
Model G2-A
Voltage: 12V Negative ground
Ignition System:
Type TCI
Model/Manufacturer F057T513/M ITSUBISH I
Pickup Coil Resistance (Color code) 495 - 605" at 20°C (68° F)
(White/Red - White/Black)
Output (Min.) PEAK 15V AC at Cranking speed'
Ignition Timing B.T.D.C. mm by dial indicator to crankcase
Static marks at 3,000 r/min by timing light.
Ignition Advance Curve:
,
30

, , ,
,
20
,
10

0
1 2 3 4 5
Engine speed (x 103 r/mm)
Ignition:
Model/Manufacturer F6T507/MITSUBISHI
Spark Gap 11 mm (0.43 in)/3,000 r/min
Primary Winding Resistance 3.57 - 4.83" at 20°C (68°F)
(Orange ~ Red/Wh ite)
Secondary Winding Resistance 11.2 - 15.2 k" at 20°C (68° F)
(High tension code - Red/White)
Diode (Yes or No) No
Spark Plug:
Type & Quantity NGK BR5ES or CHAMPION RN8 x 1 pc.
Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.031 in)
Thread Size M14 x P1.25
Spark Plug Gap:
Type Resistor type
Resistance 3.75 - 6.25 k" at 20°C (68° F)
TCI Unit:
Model/Manufacturer J4T01571/MITSUBISH I
Charging' Starting/System:
Type Starter generator
Model/Manufacturer HITACHI
Starting Output 0.6 kw
Charging Output 14V-15A/5,000 r/min
Armature Coil Resistance 0.010'- 0.016" at 20°C (68° F) (A 1 - A2)
Field'Coil Resistance
Shunt Coil (Battery Charging) 4.5 - 5.5" at 20°C (68°F) (Red - Green)
Series Coil (Starting) 0.005 - O.OOW at 20°C (68° F) (Fl - F2)
Brush Part Number J38-81111-1O
Brush Length Std/Min. 23 mm (0.9 in)/16 mm (0.63 in)
Spring Pressure/O'tv 300 - 500 g (10.6 -17.6 oz)/4 pes.
Commutator Outside Dia. 40.9 - 41.1 mm (1.61 - 1.62 in)
Mica Undercut/No. of Slot 0.7 mm (0.028 in)/41 pes

• Cranking speed approximately 800 r/min.

2-12
 MAINTENANCE SPECIFICATIONS ISPEcll'~1
Model G2-A
Voltage Regulator:
Type Tillil-type
Model/Manufactu rer Tl07-23/HITACHI
Regulated Voltage (No lead) 14.3- 15.3V
Voltage Regulator
Core Gap 0.6 - 1.0 mm (0.0024 - 0.04 in)
Yoke Gap 0.9 mm (0.035 in)
Point Gap 0.35 - 0,45 mm (0.014 - 0.018 in)
Voltage Coil Resistance 8.24 - 12.36n at 20°C (68°F)
Solenoid Relay:
Model (P/No.)/Manufacturer YZ29 (J38-81950-00)/ASAHI DENSO
Amperage Rating 60A
Cut in Voltage Less than 8V
Winding Resistance 6.7 -7,4n at 20°C (68°F)
Battery; For U.S.A. and Canada I For Australia and
: Others
Model/Ma nufactu rer Group 24 I N-50/FURUKAWA
Capacity (Rating minimum) 12V-48 AH : 12V-50AH
Specific Gravity 1.26 11.26
Gross Weight - : 15 kg
Electrolyte Quantity - 14.500 cc
Dimension (W x H x T) 6.3/4 x 10-1/4 x 9 in : 252 x 225 x 165 mm
Terminal Description

/ o., -\?@,\
,o,¢O¢OO

/
Battery Charger:
A.C. Input (Hose hold use) At your requirement 50/60 Hz, 410 VA
D.C. Out Put 6- 12V20A, 18- 24V lOA
Battery Charge Rating 5% of AH rating
Back Buzzer:
Type Continuous beep
Model/Manufacturer S-12/NIKKO
Frequency 500 - 700 Hz
Current Less than 0.08A
Fuse;
Amperage x Q'ty
Plus Fuse lOA x 1
Minus Fuse lOA xl
Spare Fuse lOA x 2

2-13
 MAINTENANCE SPECIFICATIONS ISPECI fJ~1
For G2-E

Model G2-E
Voltage: 36V DC, 6V Battery x 6 pes series
G.E. Traction Motor:
Model/Manufacturer 5BC48JB845/G.E.
Rated Vo Itage 36V DC
Power/Horsepower 2.2 kw/2.97 ph at 2,450 r/min
Current 77A
Voltage 36V
Torque 6.8 - 8.3 Nm (0.68 - 0.83 kg' rn, 4.9 - 6.0 ft·lb)
Revolution 2,300 - 2,900 r/min
Allowable Maximum Revolution 5,500 r/min
Direction of Rotation Clockwise and counterclockwise
8rush Length-Std/Min. 34.3 mm (1.35 in)/14.5 mm (0.57 in)
Brush Spring Pressure-Max.lMin. 720 - 1,080 g (24.3 - 36.5 oz)/450 g (15.2 oz)
Mica Undercut-Std/Min. 0.79 mm (0.031 inl/0.25 mm (0.010 in)
Armature Coil Resistance 0.018 - 0.022~ at 20°C (68° F)
Field Coil Resistance 0.012 - 0.014~ at 20°C (68°F)
Insulation Resistance (All measurements) lM~

HITACHI Traction Motor:

Model/Manufacturer MT320-06/H ITACH I
Rated Voltage 36V DC
Power/Horsepower 2.0 kw/2.7 ph at 2,600 r/min
Current 70A
Voltage 36V
Torque 7.5 Nm (0.75 kq-rn, 5.4 ft-Ib l ± 10%
Revolution 2,600 r/min ± 10%
Allowable Maximum Revolution 5,500 r/min
Direction of Rotation Clockwise or counterclockwise
Shaft Dia. 20 mm (0.787 inl
Shaft Bearing 6204
Brush Part Number J14-81811-10
Brush Length-Std/Min. 29 mm (1.14 in)/15 mm (0.59 in)
Brush Spring Pressure-Max.lMin. 1,000 ± 160 g (33.8 ± 5.4 ozl/400 g (13.5 oz.)
Mica Undercut-Std/Min. 1.0 mm (0.039 in )/0.3 mm (0.012 in l
Armature Coil Resistance 0.02~ ± 10% at 20°C (68°F)
Field Coil Resistance 0.016~ ± 10% at 20°C (68°F)
Insulation Resistance (All measurements) 1,000,000~
Controller:
Voltage/Maximum Current Capacity 36V DC/400A
Contact Pressure-Nominal/Min. 1.0 - 1.4 kg (2.2 - 3.1 Ib)/1.0 kg (2.2 lb)
at Max. adjustment
Movable Contact
Material Copper alloy (Copper - Graphite impregnated)
Thickness-Std/Min. 7 mm (0.28 in)/4 mm (0.16 in)
Stationary Contact
Material Copper
Thickness-Std/Min. 6 mm (0.24 in)/4 mm (0.16 in)
Resistor:
Coil Diameter 100 mm (3.94 in)
Wire Diameter 4.5 mm (0.177 in)
Winding 21 turns
Resistance 0.485 - 0.535~ at 20°C (68°F)

2-14
 MAINTENANCE SPECIFICATIONS ISPECI p~1
Model G2-E
Shift Switch:
Voltage/Maximum Current Capacity 36V DC/300A
Movable Contact
Material Copper
Thickness-Std/Min. 3 mm (0.12 in)/2.5 mm (0.10 in)
Stationary Contact
Material Copper
Thickness-Std/Min. 6 mm (0.24 in)/5.5 mm (0.22 in)

To motor F1 t t To solenoid relay

Fl S TERMINAL
.~)->: -1/ )l
SWITCH
POSITION
5 F2 Fl R
e-L .1\ .J FORWARD
10 {
2'-t.- K
/n l:::; ~ REVERSE
( -
R" ~2 0- G
To controller t 'V To motor F2

Battery:
Type 6V Electric vehicle deep cycle
Quantity/Connection 6 pes/Series
Minimum Recommended Output 90 minutes at 75A or 185 AH
Specific Gravity As specified by manufacturer at 80° F
Maximum Difference (at 1.200 corrected rnin.) 0.050

[Battery Arrangement and

Terminal Connections]
FORWARD

)D lr 0 r
O~ O~I' Om- O~
0 0 0 0
lo ~O 3
~O
;:='
r= ~~ I(D
W
'8o 0
~9
15 o EB1B
0 Q

~ To solenoid 0 ~-TomotorA2 e

2-15
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