Yamaha G21A, Owner'S/Operator'S Manual

Page 1: ......

Page 2: ......

Page 3: ......

Page 4: ...your new Yamaha If you have any questions about the operation or maintenance of your util ity car please consult a Yamaha deal er TECHNICAL SERVICE DEPT GOLF CAR SALES GROUP YAMAHA MOTOR MANUFACTURING CORP OF AMERICA G21A OWNER S OPERATOR S MANUAL 2000 by Yamaha Motor Manufacturing Corporation of America 1st edition All rights reserved Any reprinting or unauthorized use without the written permiss...

Page 5: ...car and should remain with the car when resold Read and understand this manual completely before operating your utility car WARNING NOTE Particularly important information is distinguished in this manual by the fol lowing notations The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING in structions could result in severe injury or death to the utility c...

Page 6: ...iii UTILITY 1 WARRANTY CONTENTS 1 IMPORTANT LABELS 2 MAINTENANCE SAFETY PROGRAM 4 MAINTENANCE 8 STORAGE SPECIFICATIONS 9 WIRING 11 OPERATION 7 PRE OPERATION CHECKS 6 CONTROLS 5 OPERATOR SAFETY 3 10 ...

Page 7: ...ents or deformation Any charges incurred in transporting a Utility Vehicle to and from an autho rized Yamaha Golf Car Dealer for service or in per forming field service is also excluded from this war ranty THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the Utility Vehicle as specified in the appropriate Owner s Operator s Manual 2 Give notice to an authorized ...

Page 8: ...y coverage if your specialty vehicle engine or a part has failed due to abuse neglect improper maintenance or unapproved modifica tions You are responsible for presenting your specialty vehicle engine to a Yamaha dealer as soon as a problem exists The warranty repairs should be completed in a reasonable time not to exceed 30 days If you have any questions regarding your warranty rights and respons...

Page 9: ...s covering the performance of regular maintenance should be retained in the event ques tions arise concerning maintenance The receipts should be transferred to each subsequent owner of this specialty vehicle engine The emission control systems of your Yamaha spe cialty vehicle engine were designed built tested and certified as being in conformity with California emission control regulations using ...

Page 10: ...LITY IMPORTANT LABELS 1 2 Y 100 6 5 9 3 4 SAFETY AND INSTRUCTION LABELS Please read the following labels carefully before operating your utility car and promptly replace any labels which become dam aged or removed WARNING 2 1 3 6 5 4 ...

Page 11: ... NUMBER The utility car serial number is stamped in the location shown The first three digits of the serial num ber are for model identification the remaining digits are the unit produc tion number Keep a record of these numbers for reference when ordering parts from a Yamaha dealer NOTE Y 851 9 Y 852 9 7 8 ...

Page 12: ...d only in designated areas Do not allow more than two people to ride in the utility car This utility car is restricted to two occupants Do not operate the utility car while under the influence of alcohol or drugs their affect on vision and judgment make operating a utility car dangerous Do not operate the utility car on pub lic streets roads or highways Such use is prohibited by law and dan gerous...

Page 13: ...of your surround ings Avoid turning the steering wheel too sharply at higher speeds Always drive slowly straight up or straight down slopes never at an angle Do not run the engine indoors Exhaust gas is poisonous Do not make any modification or addition which affects capacity or safe operation or make any changes not in accordance with the owner s operator s manual OPERATOR SAFETY Y 104 Y 103 All ...

Page 14: ...aking performance When driving on slopes reduce speed and avoid sudden starts or stops Excessive speed or sudden starts or stops could cause loss of control and could lead to vehicle overturning Abrupt starts going uphill or abrupt braking backing down a slope could cause the front wheels to lift off the ground reducing control and increasing the chance of an acci dent Do not tow with any point ex...

Page 15: ...ice manuals as well as the following safe ty procedures Properly immobilize utility car before beginning any maintenance Properly block chassis before work ing underneath utility car Before disconnecting any part of the fuel system drain the applicable part of the system to prevent fuel leaks Avoid fire hazards and have appro priate fire protection equipment available Maintain all safety devices i...

Page 16: ...e storage and handling of liquid fuels in accordance with applicable fire and safety require ments Only use battery changing and charging facilities and procedures that are in accordance with applica ble ordinances and regulations Periodically inspect fueling and charging facilities and procedures to be certain that applicable safety codes regulations and procedures are being followed ...

Page 17: ... 14 15 16 10 7 12 11 13 3 FEATURES 1 Steering wheel 2 Seat 3 Battery 4 Brake pedal 5 Parking brake pedal 6 Accelerator pedal 7 Drive selector lever 8 Main switch 9 Oil warning light a Choke knob b Front cowl c Front tire d Front bumper e Rear cowl f Rear tire g Fuel cap ...

Page 18: ...nition circuit is switched off The key can be removed only in this position ON Electrical circuits are switched on The utility car can be driven OIL WARNING LIGHT When the engine oil level falls below an acceptable level this light comes on If the light comes on stop the engine check the engine oil level and add oil as necessary See page 6 4 å Oil warning light ...

Page 19: ... tion Lever Position Car Movement F FORWARD R REVERSE The back up buzzer will sound when the drive select lever is turned to R ACCELERATOR PEDAL The accelerator pedal controls the util ity car s speed Action Car Speed Depress pedal Increase Release pedal Decrease å Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the utility car å Brake pedal NOTE CONTROLS Y 109 Y 20 A Y 18 Y 21...

Page 20: ...knob when starting a cold engine Release the knob after the engine starts å Choke knob TOW HITCH Use the tow point within the specified weight limits 1 Tow point Tow weight 590 kg 1300 lb Tongue weight 68 kg 150 lb Do not drive the machine over a walking speed of 5 km h 3 mph while towing Otherwise an acci dent could result Including driver passenger vehicle cargo and trailer cargo on level ground...

Page 21: ...rforming the pre operation checks to prevent accidental starting and apply the parking brake to keep the car from moving During the pre operation checks avoid touching engine parts or the muffler while they are still hot PRE OPERATION CHECKLIST Before each use check the following Fuel system Engine oil level Battery Tire condition Steering system Back up buzzer Pedal operation Body and chassis SEA...

Page 22: ... rod latches in place Remove the main switch key and apply the parking brake before lifting the cargo bed Otherwise the vehicle could unexpectedly move Never drive the car with the bed in the up position Injury could occur if the bed fell accidentally Before closing the bed be sure others are standing away from the car and that no one is sitting on the seat Keep hands and fingers away from the pin...

Page 23: ...ake care not to spill gasoline If gasoline spills wipe it up imme diately with dry rags Always dis pose of gasoline soaked rags properly Tighten the filler cap securely after refueling If you swallow gasoline inhale a lot of gasoline vapor or get gaso line in your eyes get immediate medical attention If any gasoline gets on your skin immediately wash with soap and water Change clothing if gaso lin...

Page 24: ...e MIN and MAX marks å Oil filler hole Use care not to fill past the MAX dipstick mark and be sure no for eign material enters the crank case Use care not to get oil on the starter belt The distance between the dipstick marks represents approx 1 2 US qt 1 2 L of oil Recommended engine oil classifica tion API Service SE SF or SG Engine oils labeled Energy Con serv ing II are recommended NOTE NOTE CA...

Page 25: ...battery acid from spilling from the battery Check the battery terminals for corrosion TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the utility car Tire pressure For G21 A Front Tires 20 23 psi 140 160 kPa 1 4 1 6 kgf cm2 Rear Tires 29 31 psi 197 217 kPa 2 0 2 2 kgf cm2 Tire Wear Limit Check the tire surface for damage cracks or embedded objects When tire tread wear...

Page 26: ...ive freeplay or hear rattling sounds which may indicate loose steering components consult a Yamaha dealer BACK UP BUZZER Check the back up buzzer by moving the drive select lever to R for reverse The buzzer should sound PEDAL OPERATION Check the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha deal er Brake Pedal Make sure the brake pedal feels firm ...

Page 27: ...pressed å Parking brake pedal Release the parking brake by depressing the accelerator pedal Accelerator Pedal Before checking operation of the accelerator pedal be sure the main switch is in the OFF position Make sure the accelerator pedal oper ates smoothly å Accelerator pedal BODY AND CHASSIS Before each use visually inspect the utility car body and chassis for dam age and or missing parts WARNI...

Page 28: ...ator pedal when turning on the main switch or the utility car may sud denly start moving 3 Pull the choke knob out and hold it while starting Release the choke knob after the engine starts å Choke knob The choke is not required when the engine is warm 4 Check that your path is clear in the direction you plan to go and slow ly depress the accelerator pedal The utility car will start to move å Accel...

Page 29: ...rake pedal Do not hold the utility car on an incline with the accelerator use the brake LOADING TRAILER TOWING Be sure to check SAFETY INFOR MATION carefully before loading or towing See page 3 3 Do not exceed the maximum loading limits An overloaded vehicle can be unstable Keep load as low as possible Drive slowly when cargo is loaded No top heavy loads Secure loads to prevent shifting Cargo shou...

Page 30: ...Check for looseness and corrosion of battery C C C C C C 6 5 terminals and hold downs Check brake pedal freeplay C CA CA CA CA CA 8 12 and adjust if necessary Check steering operation C C C C C 6 6 Check tire pressure tread C CA CA CA CA CA 6 5 depth tire surface for damage Check body and chassis for C C C C C C 6 7 damage Check tightness of all bolts C C C C C C nuts and screws Check reverse buzz...

Page 31: ...limiter C C C Apply battery terminal protectant S S S Check wiring connections C C C and insulation Check shoe lining thickness C C C and rear axle bearing play Check kingpin play seal and CA CA CA cap Adjust wheel alignment Check wheel nut tightness C C C front wheel bearing play Check gear box oil level C C C 8 10 and leakage Check operation and adjust CA CA CA pedal stop if necessary EVERY Chec...

Page 32: ...bove items and the correspond ing acronyms are provided in accor dance with U S EPA REGULATIONS FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULA TIONS FOR NEW 1995 AND LATER OFF HIGHWAY RECREATIONAL VEHICLES AND ENGINES The acronyms conform to the latest version of the SAE s recommended practice document J1930 Diagnostic Acronyms Terms and Definitions For Electrical Electronic System It is reco...

Page 33: ...it 2 Check the spark plug type and check the spark plug gap with a feeler gauge Standard spark plug BPR2ES or BPR4ES Spark plug gap 0 028 0 031 in 0 7 0 8 mm å Gap 3 Clean the gasket and plug sur faces and install the spark plug fin ger tight before tightening to the following torque Spark plug torque 14 5 ft lb 20 Nm 2 0 m kg When removing or installing the spark plug be careful not to dam age th...

Page 34: ... in an environmen tally safe way such as taking oil to an oil collection station 4 Install the drain plug along with a new drain plug gasket finger tight before tightening to the following torque Drain plug torque 23 ft lb 31 Nm 3 1 m kg 5 Add the correct quantity of oil through the oil filler hole Recommended engine oil classifica tion API Service SE SF or SG Engine oils labeled Energy Conserv in...

Page 35: ...heck for oil leaks around the drain plug If oil leaks are found consult a Yamaha dealer Air Filter To remove the air filter elements 1 Unlatch the air filter cover clips and remove cover å Air filter cover clips Air filter cover 2 Lift the air filter and pre filter out of the air filter case å Air filter Pre filter Be careful not to drop anything into the air inlet CAUTION CAUTION 1 2 3 4 5 6 7 8 ...

Page 36: ...d water Allow it to dry å Soap and water Foam element 4 Check the filter element If dam aged or dirty replace it Do not wring out the foam pre fil ter this could cause it to tear 5 To replace the elements reverse the above steps The pre filter has a notch on one side It will only fit in the case one way CAUTION CAUTION ...

Page 37: ...eave clock wise and the drive belt will roll off the sheave 4 Remove the drive belt from the pri mary sheave Inspection To inspect the drive belt check for frayed edges or tears and measure drive belt against the following specifi cation If the belt shows excessive wear or damage replace the belt with a new one å New 1 22 in 31 0 mm Replace when belt reaches 1 06 in 27 mm 5 To install the drive be...

Page 38: ...cian immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHIL DREN The 12 volt battery that provides start ing power to your gas car normally doesn t require the addition of water...

Page 39: ...ure the main switch is turned off to prevent accidental short circuiting å Fuse case Fuse ç Replacement fuse Gear Box Oil To check gear box oil level 1 Place the utility car on a level sur face 2 Lift the seat and cargo bed 3 Remove the oil plug A Recommended oil SAE 90 gear oil Gearcase capacity 0 44 US qt 0 42 L 0 09 Imp gal CAUTION WARNING Replacement Fuse 10 Amp Blade Style Y 35 B A C Y 111 Y ...

Page 40: ...er the gear box 5 Reinstall the oil plug For gear oil replacement consult a Yamaha dealer or other qualified mechanic Wheel Replacement To remove and install a wheel on your utility car 1 With the wheels blocked to prevent the utility car from moving loosen the wheel nuts 2 Elevate the utility car with a jack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the w...

Page 41: ...ngers using light force and measuring the distance the pedal travels before resistance is felt Brake pedal free play 25 30 mm 0 98 1 18 in 3 If the free play distance needs adjusting loosen the lock nut and turn the adjusting nut in or out in 180 increments only due to the cam shape of adjuster until the free play specification is met Then tighten the lock nut in place Do not overtighten the brake...

Page 42: ...fuel ing Refuel in a well ventilated area Take care not to spill gasoline If gasoline spills wipe it up immedi ately with dry rags Always dis pose of gasoline soaked rags properly Tighten the filler cap securely after refueling If you swallow gasoline inhale a lot of gasoline vapor or get gaso line in your eyes get immediate medical attention If any gasoline gets on your skin immediately wash with...

Page 43: ...f the utility car and apply a rust inhibitor 3 Cover the utility car with a breath able cover and store it in a dry well ventilated area BATTERY PREPARATION 1 Remove the battery from the utility car and store it in a cool dry place that stays between 32 F 0 C and 90 F 30 C 2 Have the battery recharged every 60 90 days to keep it fully charged The battery must be kept fully charged to avoid damage ...

Page 44: ...t steering height 47 2 in 1200 mm Height of floor 11 8 in 300 mm Wheelbase 74 8 in 1900 mm Tread Front 38 6 in 980 mm Rear 38 6 in 980 mm Min ground clearance 4 5 in 115 mm Weight Dry weight without battery 851 lb 386 kg Performance Maximum speed 12 mph 19 km h Minimum turning radius 129 92 in 3 3 m Seating capacity 2 persons Hill climbing ability 22 40 grade on pavement ...

Page 45: ...ation system Splash Engine oil type YAMALUBE 4 cycle oil or SAE 10W30 Engine oil capacity 1 16 US qt 1 1 L 0 24 Imp gal Oil change quantity 1 0 US qt 0 9 L 0 19 Imp gal TRANSMISSION Items G21A Transmission Type V belt automatic centrifugal engagement V belt width and outer line length 1 22 x 39 76 in 31 x 1010 mm V belt wear limit 1 06 in 27 mm Governor Type Oil bath flyweight Factory speed settin...

Page 46: ...s Type of brake Dual internal expanding shoe Leading trailing shoes self adjusting Brake pedal freeplay linkage adjustment 25 30 mm Brake cable end play 0 004 0 02 in 0 1 0 5 mm Parking brake Type Foot type parking brake with automatic release Release timing Bolt heads round parallel to arm 0 04 in 1 mm Wheel Tire size Front 18 x 8 50 8 00 4 PR Rear 18 x 8 50 8 00 TURF Rim size 7 00 I 8 00 Tire pr...

Page 47: ... R P 1 Engine stop relay a Battery 2 Engine ground b Pilot lamp 12V 3 4W 3 Pickup c Main switch 4 Rotor d Accelerator stop switch 5 Oil level gauge e Back switch 6 Blade fuse 10A f Buzzer 7 Voltage regulator g Body ground 8 Starter generator h Horn 9 Relay i Horn sw COLOR CODE B Black L Blue G Green Y Yellow R Red P Pink Br Brown W White B R Black Red Y B Yellow Black R Y Red Yellow R W Red White ...

Page 48: ......