Yamaha U-MAX G27E, 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 G27E OWNER S OPERATOR S MANUAL 2003 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: ... Main switch 4 1 Drive select switch 4 2 Accelerator pedal 4 3 Brake pedal 4 3 1 2 3 4 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 Accessories and loading 6 3 DRIVING YOUR VEHICLE 7 1 5 6 7 EE book Page 1 Thu...

Page 7: ... maintenance lubrication 8 3 Batteries 8 4 Battery care 8 4 Battery charging 8 7 Battery installation 8 9 Fuses 8 10 Transmission oil 8 11 Wheel removal 8 12 Wheel installation 8 13 Replacing a taillight bulb 8 18 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 June 24 2004 11 11 AM ...

Page 8: ...1 LOCATION OF THE WARNING AND SPECIFICATION LABELS EE book Page 1 Thursday June 24 2004 11 11 AM ...

Page 9: ... r o s s t h e s i d e o f a h i l l i n c r e a s e s t h e r i s k o f o v e r t u r n K e e p e n t i r e b o d y i n s i d e v e h i c l e P a s s e n g e r a n d c a r g o c a n a f f e c t v e h i c l e h a n d l i n g V e h i c l e r a t e d c a p a c i t y d r i v e r p a s s e n g e r c a r g o t r a i l e r a n d l o a d 7 0 0 l b 3 1 8 k g o n l e v e l s u r f a c e LOCATE AND READ OWN...

Page 10: ...e Top heavy loads increase the risk of overturn YAMAHA JU7 K7766 00 WARNING WARNING YAMAHA 5UG K7764 00 Keep hands body other persons away when closing bed Do not operate the vehicle with bed up 8 9 YAMAHA JU7 K7768 00 Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury Never load more than 68 kg 150 lbs tongue weight on the towing bracke...

Page 11: ...TURES 1 Steering wheel 2 Seat 3 Batteries 4 Taillight 5 Rear tire 6 Receptacle 7 Front tire 8 Front bumper 9 Headlight 10 Accelerator pedal 11 Brake pedal 12 Parking brake pedal 13 Horn button 14 Main switch 15 Drive select switch EE book Page 1 Thursday June 24 2004 11 11 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 11 11 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: ... far enough ahead of you Never go over the top of a slope at speed if you cannot see Always check for obstacles before operat ing in a new area Never operate the vehicle in fast flowing water or water deeper than 15 cm 6 in Remember that wet brakes may have re duced stopping ability Test your brakes af ter leaving water If necessary apply them several times to let friction dry out the lin ings Alw...

Page 15: ...ble and distributed evenly from side to side Be sure cargo is secured so that it cannot move around during opera tion Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking EE book Page 3 Thursday June 24 2004 11 11 AM ...

Page 16: ...ey 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 11 11 AM ...

Page 17: ... driving the utility 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 11 11 AM ...

Page 18: ...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 11 11 AM ...

Page 19: ...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 11 11 AM ...

Page 20: ...Cargo bed 1 Cargo bed Lifting and lowering the cargo bed 1 Cargo bed release lever EE book Page 5 Thursday June 24 2004 11 11 AM ...

Page 21: ...ed 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 utility vehicle and that no one is sitting...

Page 22: ...ition 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 A1 A2 F2 F1 CAUTION AVERTISSEMENT TOW RUN 1 EE book Page 7 Thursday June 24 2004 11 11 AM ...

Page 23: ...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 11 11 AM ...

Page 24: ... for proper operation condition and free play 5 3 8 14 8 16 Transmission oil Check for leakage 5 4 8 11 8 12 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 16 8 18 Wheels and tires Check tire pressure wear and damage 5 5 5 7 8 ...

Page 25: ...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 14 8 16 Batteries Charge batteries before each use See page 8 4 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 26: ...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 27: ...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 28: ...ng Corporation of America for this model Other tire combinations are not recommended 2 The tires should be set to the rec ommended pressure Recommended tire pressure Front 84 kPa 0 84 kgf cm2 12 psi Rear 84 kPa 0 84 kgf cm2 12 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Tire pressure below the minimum specified could cause the tire to di...

Page 29: ...Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst EE book Page 7 Thursday June 24 2004 11 11 AM ...

Page 30: ... 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 11 11 AM ...

Page 31: ...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 11 11 AM ...

Page 32: ...ity or suitability of them Choose 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 ...

Page 33: ...at hitch height Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo in the cargo bed as close to the center of the vehicle 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 de...

Page 34: ...g sharp turns unless at very slow speeds Avoid hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the vehicle 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...

Page 35: ...ontrols Pay particular attention to the safety information on pages 3 1 3 3 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 TH...

Page 36: ...the Maximum load limit 318 kg 700 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 pulling a t...

Page 37: ...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 38: ...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 39: ...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 40: ...ough water deeper than 15 cm 6 in or fast flowing water Wet brakes may have reduced effectiveness After leaving the water test your brakes If necessary apply the brakes several times to let friction dry out the linings WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Loss of control which could result in an accident including overturn HOW TO AVOID ...

Page 41: ...watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger WARNING POTENTIAL HAZARD Operating in rough terrain WHAT CAN HAPPEN The vehicle can overturn or go out of control HOW TO AVOID THE HAZARD Always be alert to changing terrain Go slow...

Page 42: ...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 43: ...anges 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 EE book Page 2 Thursday June 24 2004 11 ...

Page 44: ...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 Repair if neces...

Page 45: ...r clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physi 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 an en EE book Page 4 Thursday June 24 2004...

Page 46: ...ion to enter battery cells 2 Check the fluid level before and after charging Before charging only add distilled water if fluid is below the top of the plates and then add just enough to cover plates After charging check that the fluid level is approximately 6 4 mm 0 25 in to 12 7 mm 0 5 in above the plates and 6 4 mm 0 25 in to 9 7 mm 0 38 in below the level indicator If the fluid level is low car...

Page 47: ... against the readings on the following chart Consult a Yamaha dealer if any low readings are found or if readings vary more than one point between cells 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 EE book Page 6 Thursday June 24 2004 11 11 AM ...

Page 48: ...lated 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 The following is a summary of the charging 1 Turn the key to the OFF position 2 With the charger properly connected and grounded see charger s owner s manu al insert the DC output plug into the util ity vehicle ...

Page 49: ...nect the DC output cord from the battery receptacle when the charger is on or an arc could occur that may cause an explosion 3 The charger will turn off automatically when the batteries reach full charge 4 After the charger has turned 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 EE book Page 8 T...

Page 50: ...f the battery 1 Install the battery brackets by installing and tightening the nuts 2 Connect the wire leads as shown a Forward 1 To receptacle 2 To motor control unit 3 Between batteries 4 To relay WARNING When installing batteries Carefully place battery cables and brackets making sure that cables do a 2 1 2 3 3 4 1 a EE book Page 9 Thursday June 24 2004 11 11 AM ...

Page 51: ... the bat tery casing Fuses The fuses are located under the cargo bed but cannot be serviced easily Therefore if a fuse seems to have blown have a Yamaha dealer inspect the vehicle Specified fuses Main fuse 3A Lighting system fuse 10A EE book Page 10 Thursday June 24 2004 11 11 AM ...

Page 52: ...heck 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 1 EE book Page 11 Thursday June 24 2004 11 11 AM ...

Page 53: ... 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 12 Thursday June 24 2004 11 11 AM ...

Page 54: ... 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 13 Thursday June 24 2004 11 11 AM ...

Page 55: ...aha 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 14 Thursday June ...

Page 56: ... 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 1 2 EE book Page 15 Thursday June 24 2004 11 11 AM ...

Page 57: ...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 16 Thursday June 24 2004 11 11 AM ...

Page 58: ...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 17 Thursday June 24 2004 11 11 AM ...

Page 59: ...Replacing a taillight bulb If a taillight bulb burns out have a Yamaha dealer replace it EE book Page 18 Thursday June 24 2004 11 11 AM ...

Page 60: ...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 CAUTION Do not al...

Page 61: ...ight 1275 mm 50 2 in Height of floor 391 mm 15 4 in Wheelbase 1637 mm 64 4 in Tread Front 941 mm 37 0 in Rear 979 mm 38 5 in Ground clearance 116 mm 4 6 in Weight Dry weight without batteries 274 kg 604 lb Performance Maximum speed 24 km h 15 mph Minimum turning radius 3 0 m 118 1 in Seating capacity 2 persons EE book Page 1 Thursday June 24 2004 11 11 AM ...

Page 62: ...s 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 20 x 10 8 4 PLY Rear 20 x 10 8 4 PLY Tire pressure Front 70 84 kPa 0 70 0 84 kgf cm2 10 12 psi Rear 70 84 kPa 0 70 0 84 kgf cm2 10 12 psi Battery BCI group 24 US Battery Model G27E EE book Page 2 Thursday June 24 2004 11 11 AM ...

Page 63: ...Bulb voltage wattage quantity Headlight 12 V 30 W 30 W 2 Taillight Sealed beam 2 Specified fuses Main fuse 3 A Lighting system fuse 10 A Model G27E EE book Page 3 Thursday June 24 2004 11 11 AM ...

Page 64: ...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 book Page 1 Thursd...

Page 65: ...1 2 3 4 5 6 7 8 9 10 11 12 13 EE book Page 2 Thursday June 24 2004 11 11 AM ...

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