Yamaha U-MAX G23E, Owner'S/Operator'S Manual

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Page 2: ...B6 fm Page 1 Monday June 18 2001 11 18 AM ...

Page 3: ...ions will help you to obtain maximum enjoyment from your new Yamaha If you have any questions about the operation or maintenance of your utility vehicle please con sult a Yamaha dealer TECHNICAL SERVICE DEPT YAMAHA GOLF CAR COMPANY G23E OWNER S OPERATOR S MANUAL 2004 by Yamaha Golf Car Company 2nd edition All rights reserved Any reprinting or unauthorized use without the written permission of EE b...

Page 4: ... and this manual If you have any questions concerning this manual please consult your Yamaha dealer The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the utility vehicle occupants a bystander or a person inspecting or repairing the utility vehicle CAUTION This message describes special p...

Page 5: ...ny charges incurred in transporting a Utility Vehicle to and from an authorized Yamaha Golf Car Dealer for service or in performing field service is also excluded from this warranty THE CUSTOMER S RESPONSIBILITY under this warranty shall be to Operate and maintain the Utility Vehicle as specified in the appropriate Owner s Operator s Manual Give notice to an authorized Yamaha dealer of any and all...

Page 6: ... 4 1 Main switch 4 1 Drive select switch 4 2 Accelerator pedal 4 3 Brake pedal 4 3 1 2 3 4 Trailer hitch bracket 4 9 Transmitter unit 4 10 PRE OPERATION CHECKS 5 1 Pre operation check list 5 2 Brakes 5 3 Batteries 5 3 Transmission oil 5 4 Accelerator pedal 5 4 Steering 5 5 Fittings and fasteners 5 5 Lights 5 5 Switches 5 5 Tires 5 5 OPERATION 6 1 Starting 6 1 Stopping 6 2 5 6 EE book Page 1 Thursd...

Page 7: ...brication 8 2 Seat 8 3 Cargo bed 8 3 Batteries 8 5 Battery care 8 5 Battery charging 8 7 Battery installation 8 9 Brake pedal free play adjustment 8 15 Replacing a headlight bulb 8 17 Adjusting a headlight beam 8 18 Replacing a taillight bulb 8 19 CLEANING AND STORAGE 9 1 Chassis preparation 9 1 Battery storage care 9 1 SPECIFICATIONS 10 1 MAINTENANCE RECORD 11 1 8 9 10 11 EE book Page 2 Thursday ...

Page 8: ...1 LOCATION OF THE WARNING AND SPECIFICATION LABELS EE book Page 1 Thursday June 24 2004 10 37 AM ...

Page 9: ...operators 16 and older with a valid motor vehicle license Adults must supervise use by minors Check state laws for minimum age requirements Drive slowly in turns Drive straight up and down hills driving across the side of a hill increases the risk of overturn Keep entire body inside vehicle Passenger and cargo can affect vehicle handling Vehicle rated capacity driver passenger cargo trailer and lo...

Page 10: ...ch fuel nozzle to the unopened container before removing cap Keep the fuel nozzle in contact with the container while refueling Tighten cap before putting fuel container in cargo bed WARNING JU5 K7768 00 YAMAHA WARNING WARNING Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury Do not tow more than 1000 lbs 454kg rolling weight trailer pl...

Page 11: ...URES 1 Steering wheel 2 Seat 3 Batteries 4 Taillight 5 Rear tire 6 Receptacle 7 Transmitter unit 8 Front tire 9 Headlight 10 Accelerator pedal 11 Brake pedal 12 Parking brake pedal 13 Horn button 14 Auxiliary DC jack 15 Main switch EE book Page 1 Thursday June 24 2004 10 37 AM ...

Page 12: ... the remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha dealer Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number EE book Page 2 Thursday June 24 2004 10 37 AM ...

Page 13: ...hold on to the grab rail at all times while the vehicle is in motion Never operate this vehicle on any public Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and operating conditions and your experi ence Never attempt jumps or other stunts Always inspect your vehicle each time you use it to be sure it is in safe oper...

Page 14: ...terrain carefully before going down slopes Go as slowly as possible Always check for obstacles before operat ing in a new area Always be sure there are no obstacles or people behind you when you operate in re verse When it is safe to proceed in re verse go slowly Do not brake abruptly when carrying loads in the cargo bed Always use the size and type of tires spec ified in this manual Always mainta...

Page 15: ...tched off The key can be removed in this position only ON All electrical circuits except for the headlights and taillights are switched on The utility vehicle can be operated ON All electrical circuits are switched on The headlights and taillights come on The utility vehicle can be operated EE book Page 1 Thursday June 24 2004 10 37 AM ...

Page 16: ...ility vehicle either forward or in reverse After coming to a complete stop push the FORWARD or REVERSE side of the switch 1 Drive select switch NOTE The back up buzzer will sound when the drive select switch is set to REVERSE EE book Page 2 Thursday June 24 2004 10 37 AM ...

Page 17: ...e utility vehi cle s speed 1 Accelerator pedal Brake pedal Press the brake pedal down to slow or stop the utility vehicle 1 Brake pedal Action Vehicle speed Depress pedal Increase Release pedal Decrease 1 1 EE book Page 3 Thursday June 24 2004 10 37 AM ...

Page 18: ...l down whenev er parking the utility vehicle 1 Parking brake pedal NOTE Release the parking brake by depressing the accelerator pedal Horn button Step on the horn button to sound the horn 1 Horn button 1 EE book Page 4 Thursday June 24 2004 10 37 AM ...

Page 19: ...C jack should only be used for short periods if the utility vehicle is not being operated 1 Auxiliary DC jack cap 1 Set the main switch to ON 2 Open the auxiliary DC jack cap and then insert the accessory power plug into the jack 1 Auxiliary DC jack Maximum rated capacity for the auxiliary DC jack DC 12 V 120 W 10 A EE book Page 5 Thursday June 24 2004 10 37 AM ...

Page 20: ...to blow If accessories are used for extended periods when the utility vehicle is not being operated or with the main switch set to ON the battery will lose its charge Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged Cargo bed 1 Cargo bed EE book Page 6 Thursday June 24 2004 10 37 AM ...

Page 21: ...atch 2 To open Unhook the latches and then lower the tail gate To close Place the tailgate in its original position and then hook the latches Lifting and lowering the cargo bed 1 Cargo bed release lever EE book Page 7 Thursday June 24 2004 10 37 AM ...

Page 22: ... release le ver Damage to the lever may occur WARNING Apply the parking brake and remove the key from the main switch before lifting the cargo bed Otherwise the utility vehicle could move unexpect edly Never operate the utility vehicle with the cargo bed in the up position Inju ry could occur if the cargo bed falls accidentally Before closing the cargo bed be sure others are standing away from the...

Page 23: ...sition to the TOW position and im mediately moved back to RUN there is a Trailer hitch bracket This vehicle is equipped with a 5 cm 2 in re ceiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at a Yamaha dealer See page 6 4 for precaution information 1 Trailer hitch bracket 1 EE book Page 9 Thursday June 24 2004 10 37 AM ...

Page 24: ... unit MCU by way of a personal digital assistant PDA The unit allows information from the MCU of a utility vehicle to be trans ferred by way of infrared technology to and from the PDA Please refer to the G23A E Service Manual for operation details and in structions EE book Page 10 Thursday June 24 2004 10 37 AM ...

Page 25: ...e Get in the habit of performing the following checks in the same way so that they become second na ture WARNING Be sure the main switch key is removed before performing the pre operation checks to prevent accidental starting and apply the parking brake to keep the car from moving EE book Page 1 Thursday June 24 2004 10 37 AM ...

Page 26: ... for proper operation condition and free play 5 3 8 15 8 17 Transmission oil Check for leakage 5 4 8 12 8 13 Accelerator pedal Check for proper accelerator pedal operation 5 4 Steering Check for proper operation 5 5 Fittings and fasteners Check all fittings and fasteners 5 5 Lights and switches Check for proper operation 5 5 8 17 8 19 Wheels and tires Check tire pressure wear and damage 5 5 5 7 8 ...

Page 27: ...he brakes at slow speed after starting out to make sure they are working properly If the brakes do not provide proper braking per formance inspect the brake system See pages 8 15 8 17 Batteries Charge batteries before each use See page 8 5 8 10 Check that the batteries are held securely in place to prevent the batteries from being dam aged from vibration or jarring Also check that no battery caps ...

Page 28: ...released If the accelerator pedal does not operate properly have a Yamaha dealer check the pedal Recommended oil SAE 90 gear oil WARNING POTENTIAL HAZARD Checking operation of the accelerator pedal with the key in the main switch WHAT CAN HAPPEN The engine can start and the vehicle can start moving when the accelerator pedal is depressed HOW TO AVOID THE HAZARD Remove the key from the main switch ...

Page 29: ...nd fasteners before a ride Take the utility vehicle to a Yamaha dealer or refer to the Ser vice Manual for the correct tightening torques Lights Check the headlights and taillights to make sure they are working properly Replace or have a Yamaha dealer replace if necessary Tires Checking the tire pressure Use a tire pressure gauge to measure the tire pressure NOTE Measure the tire pressure twice an...

Page 30: ...odel Other tire combinations are not recommended Use the same 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 150 kPa 1 53 kgf cm2 21 psi Rear 207 kPa 2 11 kgf cm2 30 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kg...

Page 31: ...Tire wear limit When the tire groove decreases to 1 mm 0 04 in due to wear replace the tire a Tire wear limit EE book Page 7 Thursday June 24 2004 10 37 AM ...

Page 32: ... Starting 1 With the parking brake applied push the FORWARD or REVERSE side of the drive select switch 1 Drive select switch CAUTION 2 Turn the main switch to ON or ON EE book Page 1 Thursday June 24 2004 10 37 AM ...

Page 33: ...celerator pedal NOTE The parking brake automatically releases when the accelerator pedal is depressed Stopping To stop the utility vehicle gradually press down on the brake pedal When the utility vehicle has come to a stop apply the parking brake pedal and turn the main switch to OFF 1 Brake pedal 2 Parking brake pedal CAUTION 1 2 1 EE book Page 2 Thursday June 24 2004 10 37 AM ...

Page 34: ...oose a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are operating could affect your ability to control the vehi cle Do not mount an accessory where it could interfere with your ability to control the vehi cle Examples include but are not limited to an object ...

Page 35: ... of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through im proper installation or use of accesso ries All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this vehicle and should be in stalled and used according to instruc MAXIMUM LOA...

Page 36: ...e as possible Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where you are going Drive more slowly than you would without a load The more weight you carry the slow er you should go Allow more braking distance A heavier ve hicle takes longer to ...

Page 37: ... in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking EE book Page 6 Thursday June 24 2004 10 37 AM ...

Page 38: ...ticular attention to the safety information on pages 3 1 3 2 Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger Never carry passengers in the cargo bed WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never ...

Page 39: ...et inside the Maximum load limit 590 kg 1300 lb WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or ...

Page 40: ...ly The motor will operate and you will start to accelerate Avoid higher speeds until you are thoroughly familiar with the operation of your vehicle When slowing down or stopping take your foot off the accelerator pedal and smoothly press the brake pedal Improper use of the brakes can cause the tires to lose traction re ducing control and increasing the possibility of an accident The motor stops op...

Page 41: ...pes you attempt to drive on Avoid slopes with slippery surfaces or ones where you will not be able to see far enough ahead of you Slow down when you reach the crest of the hill if you cannot clearly see what is on the other side there could be another person an ob WARNING POTENTIAL HAZARD Operating on steep slopes WHAT CAN HAPPEN The utility vehicle can overturn more easily on steep slopes than on...

Page 42: ...es that may appear If you must turn to avoid an ob stacle do not turn at a sharp angle that could allow the vehicle to pitch or roll over Go as slowly as possible If you are starting to go too fast apply the brakes gently Avoid sudden application of the brakes which could WARNING POTENTIAL HAZARD Going down a slope improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to over...

Page 43: ...ident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could oc cur RIDING IN BRUSH OR WOODED AREAS When operating in areas with brush or trees watch carefully on both sides and above the vehicle for obstacles such as branches that WARNING POTENTIAL HAZARD Operating in rough terrain WHAT CAN HAPPEN The vehicle can overturn or go out of control HOW TO AVOID THE HAZARD A...

Page 44: ...r is not familiar with vehicle ser vicing this work should be done by a Yamaha dealer or other qualified mechan ic Owner s Operator s Manual You are recommended to put this Owner s Operator s Manual in the vinyl bag and always keep it with the vehicle The service information included in this man ual is intended to provide you the owner with the necessary information for completing your own prevent...

Page 45: ...00 600 2 000 1 200 hours 20 125 125 250 Batteries Check electrolyte level Check for loose or broken connections Battery condition Perform a discharge test Transmission oil Check oil level oil leakage Replace Every 4 years Brakes Check operation brake shoe wear Correct if necessary Replace shoes if worn to the limit Accelerator pedal Check operation and free play Wheels Check balance damage runout ...

Page 46: ...cargo bed release lever towards the rear 2 Lift the cargo bed 3 Lift the cargo bed up until the end of the prop rod hooks onto the prop rod guide to support the cargo bed 1 Cargo bed release lever CAUTION Do not lift the cargo bed by the release le ver Damage to the lever may occur EE book Page 3 Thursday June 24 2004 10 37 AM ...

Page 47: ...operate the utility vehicle with the cargo bed in the up position Inju ry could occur if the cargo bed falls accidentally Before closing the cargo bed be sure others are standing away from the utility vehicle and that no one is sitting on the seat Keep hands and fingers away from the space between the car go bed and seat backs EE book Page 4 Thursday June 24 2004 10 37 AM ...

Page 48: ...utes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Eight 6 volt deep cycle batteries provide pow er for your electric utility vehicle and must be properly maintained and recharged for maxi mum performance and service life To maintain your batteries 1 Clean the tops of the batteries with a so lution of baking soda and water as nec essary to...

Page 49: ...level is low carefully add distilled water Adding distilled water after charging helps prevent boil over CAUTION Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water 3 Using a hydrometer check the specific gravity of the battery fluid in each cell against the readings on the following chart Consult a Yamaha dealer if any low readings are foun...

Page 50: ... well ventilated areas a mini mum of 5 air changes per hour is recom mended To charge the batteries in your utility vehicle follow the instructions contained in your bat tery charger s owner s manual Temperature Satisfactory Uncorrected Hydrometer Reading F C 120 48 9 1 244 110 43 3 1 248 100 37 8 1 252 90 32 2 1 256 80 26 7 1 260 70 21 1 1 264 60 15 6 1 268 50 10 0 1 272 40 4 4 1 276 30 1 1 1 280...

Page 51: ... s manual provided with your charger 1 Turn the key to the OFF position 2 With the charger properly connected and 1 DC output plug 2 Receptacle CAUTION Use only battery chargers that are rated for use with 48 volt Yamaha Utility Vehi cles Thoroughly read and understand the user manual supplied with your 48 volt charger EE book Page 8 Thursday June 24 2004 10 37 AM ...

Page 52: ...rned off discon nect the DC output plug from the utility vehicle receptacle by grasping the plug body and pulling the plug straight out of the receptacle Battery installation WARNING When working with batteries do not put wrenches or other metal objects across the battery terminals An arc can occur causing explosion of the battery 1 Install the battery brackets by installing and tightening the nut...

Page 53: ... relay 4 Between batteries WARNING When installing batteries Carefully place battery cables and brackets making sure that cables do CAUTION Do not overtighten the battery bracket nuts Excessive force will damage the bat tery casing a 1 3 4 4 2 EE book Page 10 Thursday June 24 2004 10 37 AM ...

Page 54: ...place it WARNING Be sure to use the specified fuse Using a wrong fuse can cause electrical system damage and create a fire hazard CAUTION When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting 1 Main fuse Replacement Fuse Main fuse 10 A EE book Page 11 Thursday June 24 2004 10 37 AM ...

Page 55: ...check the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommend 1 Transmission oil plug CAUTION Be sure no foreign material enters the transmission case 3 Install the transmission oil filler plug Recommended oil SAE 90 gear oil EE book Page 12 Thursday June 24 2004 10 37 AM ...

Page 56: ... NOTE For transmission oil replacement consult a Yamaha dealer Wheel removal 1 Loosen the wheel nuts 2 Elevate the vehicle and place a suitable stand under the frame 3 Remove the nuts from the wheel 4 Remove the wheel Y 57 EE book Page 13 Thursday June 24 2004 10 37 AM ...

Page 57: ... the front and rear wheels Install the nut with its tapered side towards the wheel 1 Tapered nut 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque 88 Nm 8 8 m kgf 64 ft lbf EE book Page 14 Thursday June 24 2004 10 37 AM ...

Page 58: ...amaha dealer before using your utility vehicle if you suspect brake problems Brake failure could result in a serious accident Brake pedal free play adjustment CAUTION Before adjusting brake pedal free play pump the brake pedal several times to self adjust the brakes To adjust the brake pedal free play 1 Remove the service lid from the floor of the utility vehicle Y 61a EE book Page 15 Thursday Jun...

Page 59: ... If the free play distance needs adjusting loosen the locknut 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 locknut to the specified torque Brake pedal free play 20 25 mm 0 79 0 98 in 7 18 17 16 15 14 13 12 11 10 9 8 a 2 1 EE book Page 16 Thursday June 24 2004 10 37 AM ...

Page 60: ...rformance Replacing a headlight bulb If a headlight bulb burns out replace it as fol lows 1 Remove the headlight bulb holder by turning it counterclockwise 1 Headlight bulb holder 2 Remove the defective bulb by unhooking the headlight bulb holder projections EE book Page 17 Thursday June 24 2004 10 37 AM ...

Page 61: ...nto the headlight bulb 4 Install the headlight bulb holder by turn ing it clockwise Adjusting a headlight beam CAUTION It is advisable to have a Yamaha dealer make this adjustment To raise the beam turn the adjusting screw in direction a To lower the beam turn the adjusting screw in direction b EE book Page 18 Thursday June 24 2004 10 37 AM ...

Page 62: ...Replacing a taillight bulb If a taillight bulb burns out have a Yamaha dealer replace it EE book Page 19 Thursday June 24 2004 10 37 AM ...

Page 63: ...ise all wheels off the ground 2 Clean exterior of the utility vehicle and apply a rust inhibitor 3 Cover the utility vehicle with a breathable cover and store it in a dry well ventilated area Battery storage care 1 Recharge the batteries and check the flu id levels at least once a month 2 Clean the tops of the batteries with a so lution of baking soda and water as nec essary to remove corrosion CA...

Page 64: ...5 5 in Height of floor 300 mm 11 8 in Wheelbase 1900 mm 74 8 in Tread Front 980 mm 38 6 in Rear 980 mm 38 6 in Ground clearance 115 mm 4 5 in Weight Dry weight without batteries 315 kg 694 lb Performance Maximum speed 24 km h 14 9 mph Minimum turning radius 3 3 m 130 in Seating capacity 2 persons EE book Page 1 Thursday June 24 2004 10 37 AM ...

Page 65: ...ding trailing shoes self adjusting Brake pedal freeplay linkage adjustment 20 25 mm 0 79 0 98 in Parking brake Type Foot type with automatic release Wheel Tire size Front 18 x 8 5 8 4 PLY Rear 18 x 8 5 8 6 PLY Tire pressure Front 140 160 kPa 1 4 1 6 kgf cm2 20 23 psi Rear 197 217 kPa 2 0 2 2 kgf cm2 29 31 psi Battery BCI group 24 US Battery Model G23E EE book Page 2 Thursday June 24 2004 10 37 AM ...

Page 66: ...Bulb voltage wattage quantity Headlight 12 V 30 W 30 W 2 Taillight Sealed beam 2 Specified fuses Main fuse 10 A Model G23E EE book Page 3 Thursday June 24 2004 10 37 AM ...

Page 67: ...a re minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 160 100 20 6 1 000 600 125 12 2 000 1 200 250 18 3 000 1 800 375 24 4 000 2 400 500 30 5 000 3 000 625 36 6 000 3 600 750 42 7 000 4 200 875 48 8 000 4 800 1 000 54 9 000 5 400 1 125 EE boo...

Page 68: ...B6 fm Page 1 Monday June 18 2001 11 18 AM ...

Page 69: ...B6 fm Page 1 Monday June 18 2001 11 18 AM ...

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