3. EXHAUST VALVE
Fig. 1
1. Cylinder
2. Piston
3. Ring nut ass'y
4. Shaft
View in direct~on
of A 5. Butterfly exhaust valve
6. Exhaust plpe
7. Plug
8. Bear~ng
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. Rodass'y 1
20. Return spring
21. Locknut
22. Locknut
23. Torsion spring
24. Throttle wire ass'y
25. Choke wire ass'y
26. C l ~ p
27. Stopper
Fig. 2
4. 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. Settingthe governor lever
Adjust the length of the joint rod 1 so when
the accelerator pedal isfully depressed, andthe
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. (Whenthe 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 (exhaustvalve).
5. 3. Exhaust valve setting
Adjust the length of connector rod so when
the governor lever returns to the closed posi-
tion, 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' = 1 9 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 accelera-
tor pedal is fully depressed, the carburetor
throttle just reaches fuII-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 but-
terfly valve and related parts.
1. Adjusting screw 2. Governor lever
6. 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 a t 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
7. 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 con-
nector rod (2): 179 mm (7 in)
2. As illustrated, the bracket should be in-
stalled 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 sur-
face of the joint.
8. SPECIFICATIONS
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
Seatingcapacity
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 (steeringheight)
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
J24-000101
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)
9. 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)
4 1 8 x 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 . 1 6 5 2 : ~ ~ ~ ~
in)
1 00'945-0.0005
Crankpin type
Crank bearing type (Left)x Q'ty
Crank bearingtype (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-3048 8 x 1 PC
10. 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)
BV21-161MIKUNI
J24-14101-00
J2400
4 16
#97.5
41.2
2B
#42.5
4 1.o
# 100
41.0
40.8
$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.I
cm3/hat 3,250 rlmin
Approx. 5.9 cm3/h at 3,250 r/min
150 : 1 at Max. Dower
11. C. Transmission
-
4
Model
Item
Oil tank:
Oil
Oil tank capacity
Oil tank position
MaterialIColor
Jet senser:
TYpe
Pipe dia.1Material
GI-AM3
Yamalube Golf Car oil or if not available, any two
stroke oil that is B.I.A. certified for service T.C.W.
1.7 L (1.5 Imp qt, 1.8 US qt)
Top of left rear fender
Polyethylene/White
One hole (G0.85)orifice plate type with cleaner: Wire
4 6.35 mm (0.25 in)lStainless
Model
Itern
Transmission:
TYpe
Primary reduction ratio
Clutch engagement rlrnin
Shift rlrnin
Primary spring:
Parts No.
Outside dia. x Wire dia.
Set IoadISpring rate
No of turnslfree length
Color code
Secondary spring:
Part No.
Outside dia. x Wire dia.
No. of turnslfree length
Color code
Torque cam angle
Sheave center to center distance
Sheave offset
V-belt part No.
V-belt width and outer line length
V-belt wear limit
DifferentialIReduction gear:
Secondary reduction system
Secondary reduction ratio
Differential type
Lubricantlcapacity
Governor:
TYpe
Adjustment
Factory speed setting
-
GI-AM3
V-belt automatic centrifugal engagement
3.1 : 1-0.8: 1
1,500 rlrnin
3,600 rlmin
90501-32557
42.9 x 3.2 rnrn (1.69 x 0.126 in)
7.8 kg10.372 kglrnm
6.5182 rnm (2.95 in)
Cr plated (Silver)
90501-45600
54.5 x 4.5 rnrn (2.15 x 0.177 in)
6.371101 rnrn (3.98 in)
Cr plated (Gold)
Forward 50 deglReverse 45 deg
231 mrn (9.09 in)
26 mrn (1.02 in)
J17-46241-00
31 x 925 rnrn (1.22 x 36.4 in)
27 rnm (1.06 in)
-
1 Helical gear
2.952 x 4.588
SPUR gear 4 pinion
SAE 90 Gear oil1800 crn3 (27 02.)
Oil bath flyweight
Screw with locknut
19 krnlh (12 rnph)
12. D. Chassis
G1-AM3
Ladder type pipe structure
Tubular steel (STKM)
Yamaha Black
(RIM)
Urethane
lvory white
Match metal die shell type fiber galss (SMC)
Fiber reinforced plastic (FRP)
Ivory white
Vinyl chloride leather + Nylon lining
Ivory white
Urethanefoam
Steel + EVA end
Steel + EVA end
Worm and pin
1.4 turn
1.4 turn
3.0 m
SAE 90 Gear oil
150 cc (5.1 oz)
Single wish bone
10 ? 5 mm (0.394 f 0.197 in)
0 deg
7 deg
3 deg
Semi-floatingsplit
0 mm (0 in)
0 deg
Single swingarm (independent suspension)
Coil springs with hydraulic shock absorbers
(Singleaction type)
3.6 kgfmm
185 mm (7.28 in)
Oil damper (Single actionftension only)
Axle type trailing arm (Unit swing)
Coil springs with hydraulic shock absorbers
(double action type)
2.1 kgfmm
240 mm (9.45 in)
Oil damper (Double actionfBoth Comp & Tens)
- Model
Item
Frame:
Type
Material
Color
Front cowl:
Type
Material
Color
Rear cowl:
Type
Material
Color
Seat:
Seat cover Material
Color
Seat cushion Material
Bumper:
Front
Rear
Steeringsystem:
Type
Steering angle (L, HI
(R, H)
Turning radius
Lubricant Type
Capacity
Front axle:
Type
Toe-in
Camber
Caster
Kingpin inclination
Rear axle:
Rear wheel axle type
Toe-in
Camber
Front suspension:
Type
Spring rate
Coil spring free length
Damper type
Rear suspension:
Type
Spring rate
Coil spring free length
Damper type
13. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
14. E. Electrical
Model
Item
Brakes:
Brake system
Method of operation
Lining thickness StdIMin.
Brake drum inside dia.
Linkage adjustment (Brake wire free play)
Parking brake Type
Release timing
(Freeplay of throttle wire end)
Wheel:
Tire type Front
(pattern) Rear
Tire size Front
Rear
Tire pressure FrontIRear
Rim size FrontIRear
GI-AM3
Mechanical brake linkage to individual drum brakes
on each rear wheel with self-adjustingbrake shoe.
Dual internal expanding shoe
LeadingITrailing shoes (self-adjusting)
4 mm (0.157 in)/1.5 mm (0.06 in)
160 mm (6.30 in)
0.1 -0.5 mm (0.004 -0.020 in)
Foot type; Parking brake with automatic release
0 -0.5 mm (0 -0.02 in)
Lightly depress the accelerator pedal with your hand
(The parking brake is not released.)
Tubeless (Rib)
Tubeless (Block)
18 x 8.50 - 8.0014 ply rating
18 x 8.50 - 8.0014 ply rating
0.8 kg/cm2 (12 psi)
7.00 - I - 8.00
= Cranking speed approximately 800 rlmin
- 11 -
Flywheel magneto (C.D.I. type)
ModelIManufacturer F3T35671lMITSUBISHI
Pulser coil resistance (Color code) 1 4 ~ + 1 0 % a t 2 0 ~ ~ ( 6 8 ~ ~ )
(WhiteIRed-Black)
4.5V AC @ Cranking speed*
Chargingcoil resistance (Color code) 350a + 10%a t 20' ( 6 8 ' ~ ) (Brown - Black)
Output (Min.) 40V AC @ Cranking speed*
Ignition timimg Static B.T.D.C. 1.3 mm (0.051 in) by dial indicator
9 mm (0.35 in)/300 rlmin.
11 mm (0.43 in)/3.000 rlmin
Primary winding resistance 1.0a + 15%a t 2 0 ' ~(68"F) (Orange- Black)
Secondary winding resistance 5.9ka ? 15 % at 2 0 " ~
(68' F)
Diode (Yes or No)
-
(High tension code - Black)
No
15. = Cranking speed approximately 800 rlmin
- 12 -
Spark plug:
Type & Quantity
Spark plug gap
Thread size
Spark plug cap:
TYpe
Noise suppressor resistance
C.D.I. unit:
ModelIManufacturer
Minimum C.D.I. output
Charging StartingISystern:
TYpe
ModelIManufacturer
Starting output
Charging output
Armature coil resistance
Field coil resistance
Shunt coil (Battery charging)
Series coil (Starting)
Brush port number
Bursh length StdIMin.
Spring pressure/Qrty
Commutator outside dia.
Mica undercutINo. of slot
Voltage regulator:
Type
Model/Manufacturer
Regulatedvoltage (No load)
Voltage regulator
Core gap
Yoke gap
Point gap
Voltage coil resistance
Soleniod relay:
GI-AM3
NGK BP-6HSx 1 pc
0.6 -0.7 rnrn (0.024 -0.028 in)
M14x P1.25
Noise supGessor
5kQ 2 15%at 2 0 " ~
(68"F)
F8T 02171/MITSUBISHI
4.OV @ Cranking speed*
Starter generator
GSBI07-02lHITACHI
0.6 kw
14V-15A15,OOOrlmin
0.013Q * 20%at 2 0 " ~
(68"F) (A1 - A2)
5Q + 10%at 2 0 " ~
(68°F) (Red - Green)
0.006Q ? 20%at 20" C (68" F) (F1 - F2)
J10-81111-10
23 rnrn (0.9 in)/16 rnrn (0.63 in)
700 - 900 g (24.7 -31.7 oz)/4 pcs.
41 + 0.1 rnrn (1.61 + 0.004 in)
0.7 rnrn (0.028 in)/41 pcs
Tillil type
T107-23lHITACHI
14.8 + 0.5V
0.6 -1.0 rnrn (0.0024 -- 0.04 in)
0.9 rnrn (0.035 in)
0.35 -0.45 rnrn (0.014 -0.018 in)
10.3!2 * 20%at 20°C (68°F)
Model (P/No.)/Manufacturer
Amperage rating
Cut in voltage
Winding resistance
Battery:
ModelIManufacturer
Capacity (Rating minimum)
Specific gravity
Gross weight
Electrolyte quantity
Dimension (W x H x T)
Terminal description
YZ18 (J17-81950-00)/ASAHI DENS0
60A
Less than 8V
11.8Q + 5%at 2 0 " ~
(68" F)
I
I
For U.S.A. and Canada I For Australia and Japan
I
Group 24 I N-50lFURUKAWA
12V-48 AH I 12V-50AH
1.26
I
1 1.26
- 1 15kg
- I 4,500 cc
I
6-314x10-114x9in 1 2 5 2 ~ 2 2 5 x l 6 5 m m
OQQQOO
16. G1-AM3
ltern
Battery charger:
A.C. Input (Household use)
D.C. Out put
Battery charge rating
Back buzzer:
TYpe
ModelIManufacturer
Frequency
Current
Fuse:
Plus fuse: ArnperagelQ'ty
Minum fuse: Amperage/Q1ty
At your requirement 50160 Hz, 410 VA
6 -12V 20A, 18 -24V 10A
5%of AH rating
Continuous beep
S-121NIKKO
600 2 100 Hz.
Less than 0.08A
10Al1pc plus one spare
10A/lpc plus one spare
17. 10-3. TIGHTENING TORQUE
Part to be tightened
[Engine]
Spark plug
Airshroud x Cylinder head crankcase
Airshroud cylinder 1 x 2
Cylinder head: First
Final
Cylinder x Exhaust pipe ring nut
Carburetor x Joint
Oil pump ass'y x Gear unit ass'y
Fan x CDI magneto
Flywheel magneto
Crankcase x Engine bracket
Crankcase left x Right
Part name
Bolt
Pan head
Nut
Bolt
Clamp &
Pan head
Pan head
Bolt
Nut
Bolt
Pan head
[Crankcase righrening sequence]
-
Thread size Remarks
Use LoctiteB
Use LoctiteB
Tightening
steady
Use loctitea
[Drive]
Primary sheave cap x Engine
Secondary sheave x Input shaft
Transmission case x Rear arm
Transmissioncase x Rear arm housing
Transmissioncase 1
x Transmissioncase 2
Differential case x Ring gear
Governor fork x Governor shaft
[Chassis]
Tension rod x Front lower arm
Tension rod x Frame
Front lower arm x Frame
Rear arm comp. x Frame
Tie rod x Ball joint
King pin x Steering knuckle
Pitman arm x Idler arm
Steering gear housing x Steering cover
Steering adjusting bolt x Nut
Wheel x Hub or drum
Back plate ass'y x Rear axle housing
Back lower support x Hinge
[Electrical]
Battery hold down x Battery
Traction motor terminal x Wire
Relay terminal x Wire
Bolt
Castle nut
Bolt
Bolt
Nut
Bolt
Pan head
Bolt
Bolt
Bolt
Bolt
Nut
Nylon nut
Nylon nut
Bolt
Nut
Nut
Bolt
Nut
Nylon nut
Nut
Nut
18. GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fas-
teners with standard I.S.O. pitch threads.
Torque specifications for special components
or assemblies are included in the applicable
sections of this book. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross fashion, in progressive stages, until full
torque is reached. Unless otherwise specified,
torque specifications call for clean, dry
threads. Components should be a t room
temperature.
General torque
specifications
(Nut) ("It) Nm 1 m-kg I ft-lb
CONVERSION TABLES
9.807 Nrn
7.233 ft-Ib
METRIC TO INCH SYSTEM
Known
L (liter) -1
INCH TO METRIC SYSTEM
Multiplier Known
Nm
ft-lb
N
Ib
1 33.3 pa
0.03937 inHg
Result
1 0.8802
L (liter)
1 1.057
Multiplier
0.10197
0.13826
0.10197
0.4535
Imp qt
v
Result
mekg
kg
-
Imp oz 28.35
129.57
ICentigrade ('c) 915 roc)t32 ( Fahrenheit (OF) (
Imp gal
US gal
Imp qt
US qt
N/mm
Ib/in
kP
a
psi
pa
inHg
4.545
3.785
1.136
3.785
0.10197
0.0178
0.0102
0.0703
0.0075
25.4
Fahrenheit (OF)
L (liter)
L (liter)
kg/mm
kg/cm2
mmHg
5
1
9 (OF) - 32 1 Centigrade (OC)
