Yamaha G20A User Manual

MULTI­PASSENGER
OWNER’S/ OPERATOR’S MANUAL
VEHICLE
G20A
LIT-19626-20-00
JR8-F8199-00
The engine exhaust from this product
WARNING
contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
YAMAHA
LIT-CALIF-65-01
INTRODUCTION
Congratulations on your purchase of a Yamaha Multi-Passenger Vehicle. This manual contains information you will need for proper operation, main­tenance, and care of your vehicle. A thorough understanding of these sim­ple instructions will help you to obtain maximum enjoyment from your new Yamaha.
If you have any questions about the operation or maintenance of your vehicle, please consult a Yamaha dealer.
TECHNICAL SERVICE DEPT
GOLF CAR SALES GROUP
YAMAHA MOTOR
MANUFACTURING CORP.
of AMERICA
G20A
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 permission of
Yamaha Motor Manufacturing
Corporation of America is expressly prohibited.
Printed in U.S.A.
P/N LIT-19626-20-00
MULTI-PASSENGER
i
IMPORTANT MANUAL
WARNING
CAUTION
WARNING
INFORMATION
Particularly important information is distinguished in this manual by the fol­lowing notations:
The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instruc­tions could result in severe injury or death to the vehicle occupants, a bystander, or a person inspecting or repairing the utility car.
This message describes special precautions that must be taken to avoid damage to the vehicle.
Yamaha continually seeks ad-
vancements in product design and quality; therefore, while this manual contains the most current product information available at the time of printing, there may be minor dis­crepancies between your vehicle and this manual If you have any questions concerning this manual, please consult your Yamaha dealer.
This manual should be considered
a permanent part of your vehicle and should remain with the car when resold.
Read and understand this manual completely before operating your vehicle.
This message provides additional key information.
ii
MULTI-PASSENGER
CONTENTS
WARRANTY
IMPORTANT LABELS 2
OCCUPANT SAFETY 3
MAINTENANCE SAFETY PROGRAM 4
CONTROLS 5
PRE-OPERATION CHECKS 6
OPERATION 7
MAINTENANCE 8
1
1
STORAGE
SPECIFICATIONS
WIRING 11
MULTI-PASSENGER
iii
9
10
WARRANTY
1
YAMAHA MOTOR MANUFACTURING
CORPORATION OF AMERICA
G20A MULTI-PASSENGER VEHICLE
LIMITED WARRANTY
Yamaha Motor Corporation, U.S.A. hereby warrants that any new Multi-Passenger Vehicle purchased from an authorized Yamaha dealer in the United States will be free from defects in material and workmanship for the period of time stated herein, subject to the stated limitations.
THE PERIOD OF WARRANTY for any G20A will be one year from date of purchase for parts and labor.
The warranty shall cover the entire car except for batteries, tires and rims, which are warranted by their respective manufacturers.
DURING THE PERIOD OF WARRANTY any autho­rized Yamaha Golf Car Dealer will, free of charge, repair or replace, at Yamaha’s option, any part adjudged defective by Yamaha due to faulty work­manship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the machine’s warranty period. All parts replaced under warranty become property of Yamaha Motor Corporation, U.S.A.
GENERAL EXCLUSIONS from this warranty shall include any failures caused by:
a. Abnormal strain, neglect, or abuse, including
lack of proper maintenance, and use contrary
to the owner’s manual instructions. b. Accident or collision damage. c. Installation of parts or accessories that are not
original equipment. d. Fading, rust, or deterioration due to exposure
or ordinary wear and tear. e. Modification or alteration that affects the Multi-
Passenger Vehicle’s condition, operation, per-
formance, or durability. f. Damage due to improper transportation. g Acts of God (i.e. lighting, hail damage,
flooding, fire, etc.)
SPECIFIC EXCLUSIONS from this warranty shall include any parts replaced due to normal wear or routine maintenance, including oil, air filter ele­ments, brake shoes, spark plugs, starter and clutch drive belts, and other damage such as scratches, dents, or deformation. Any charges incurred in transporting a Multi-Passenger 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:
1. Operate and maintain the Multi-Passenger Vehicle as specified in the appropriate Owner’s / Operator’s Manual;
2. Give notice to an authorized Yamaha dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs by the dealer’s authorized representative.
WARRANTY TRANSFER: To transfer any remain­ing warranty from the original purchaser to any sub­sequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha Golf Car Dealer. In order for this warranty to remain in effect, this inspection and reg­istration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service.
YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WAR­RANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN­TIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA Newnan, Georgia 30265-1320
Effective Date: 8/1/99 LIT-13710-20-00
1-1
MULTI-PASSENGER
WARRANTY
YAMAHA MOTOR MANUFACTURING
CORPORATION OF AMERICA
SPECIALTY VEHICLE ENGINES
EMISSION CONTROL WARRANTY
YOUR WARRANTY RIGHTS AND OBLIGATIONS
In complance with the California Air Resources Board, Yamaha Motor Manufacturing Corporation of America is pleased to explain the emission control system warranty on your 1996 or later specialty vehicle engine. New Yamaha speciality vehicle engines must be designed, built and equipped to meet stringent anti-smog standards. Yamaha must warrant the emission control system on your spe­ciality vehicle engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your speciality vehicle engine.
Your emission control system may include parts such as the carburetor or fuel-injection system, the ignition system, and catalytic converter. Also includ­ed may be hoses, belts, connectors and other emis­sion-related assemblies.
Where a warrantable condition exists, Yamaha will repair your specialty vehicle engine at no cost to you including diagnosis, parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
The 1996 and later specialty vehicle engines are warranted for two years. If any emissions-related part on your engine is defective, the part will be repaired or replaced by Yamaha.
OWNER’S WARRANTY RESPONSIBILITIES
As the specialty vehicle engine owner, you are
responsible for the performance of the required maintenance listed in your owner’s manual. Yamaha recommends that you retain all receipts covering maintenance on your specialty vehicle engine, but Yamaha cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
As the specialty vehicle engine owner, you
should also be aware that Yamaha may deny you warranty coverage if your specialty vehicle engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifica­tions.
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 responsibilities, you should contact the Yamaha Customer Relations Department at (770) 254-4164.
Yamaha Motor Manufacturing Corporation of America warrants to the ultimate purchaser and each subsequent purchaser thereafter that each new 1996 and later model year specialty vehicle engine certified for sale is:
1. Designed, built, and equipped so as to conform, at the time of sale, with all applicable regula­tions adopted by the California Air Resources Board, and
2. All warranted parts are free from defects in material and workmanship for the warranty period of the specialty vehicle engine or the period prior to the first scheduled replacement point of the warranted part as required by the maintenance schedule, if applicable, whichever is less. A defect exists when a deficiency in material or workmanship is such that an emis­sion-related warranted part does not function as designed.
The warranty period begins on the date that the specialty vehicle engine is delivered to an ultimate purchaser or on the date it is first placed in service.
WARRANTED PARTS INCLUDE the following:
1. Fuel Metering System Carburetor and internal parts (or fuel injection) Air/fuel ratio feedback and control system Cold start enrichment system
2. Air Induction System Controlled hot air intake system Intake manifold
1
MULTI-PASSENGER
1-2
WARRANTY
3. Ignition System
1
Spark plugs * Magneto or electronic ignition system Spark advance/retard system
4. Exhaust Gas Recirculation (EGR) System EGR valve body, and carburetor spacer if applicable EGR rate feedback and control system
5. Air Injection System Air pump or pulse valve Valves affecting distribution of flow Distribution manifold
6. Catalyst or Thermal Reactor System Catalytic converter Thermal reactor Exhaust manifold
7. Particulate Controls Traps, filters, precipitators, and any other device used to capture particulate emissions
8. Miscellaneous Items Used in Above Systems Vacuum, temperature, and time sensitive valves and switches Electronic controls Hoses, belts, connectors, and assemblies
9. Engine components damaged due to a failure under warranty of a warranted part.
* The original spark plug(s) are warranted for the period of replacement indicated in the Owner’s/Operator’s Manual and not the useful life of the specialty vehicle engine (see your Owner’s Manual).
DURING THE PERIOD OF THIS WARRANTY
Yamaha Motor Manufacturing Corporation of America will repair or replace any warranted part deemed defective by Yamaha during the scope of the warranty without charge to the owner, including parts, labor, and diagnosis. This work must be done at an authorized Yamaha dealer. Give notice to an authorized Yamaha dealer of any apparent defect(s) within a reasonable period of time after discovery. The specialty vehicle engine must be made avail­able for inspection by an authorized Yamaha dealer.
OWNER’S RESPONSIBILITY: The owner of the
specialty vehicle engine is responsible for the per­formance of required maintenance (see your Owner’s/Operator’s Manual). Receipts and mainte­nance records covering the performance of regular maintenance should be retained in the event ques­tions arise concerning maintenance. The receipts should be transferred to each subsequent owner of this specialty vehicle engine.
The emission control systems of your Yamaha spe­cialty vehicle engine were designed, built, tested, and certified as being in conformity with California emission control regulations using genuine Yamaha parts. Accordingly, it is recommended that any replacement part(s) used for maintenance, replace­ment, or repair of emission control systems be Yamaha parts. The owner may elect to have main­tenance, replacement, or repair of the emission control devices and systems performed by any repair establishment or individual, and may elect to use parts other than Yamaha par ts for such mainte­nance, replacement, or repair without invalidating this warranty. However, the cost of such service or parts will not be covered under the warranty.
EXCLUSIONS: No warranty coverage will be allowed if the part(s) failure was caused by owner/operator abuse, neglect, tampering, improp­er adjustment unless performed by a dealer during warranty repair work, modification, misuse, alter­ation, or improper maintenance (see your Owner’s/ Operator’s Manual).
Use of parts which are not qualitatively equivalent to genuine Yamaha parts, improper service, or lack of required maintenance which causes failure of a warranted part may constitute abuse and/or improp­er service, thereby invalidating warranty liability hereunder.
This warranty does not cover damage resulting from accidents, acts of nature, or other events or occur­rences beyond the control of Yamaha. Yamaha Motor Manufacturing Corporation of America expressly disclaims responsibility for any and all consequential damages, such as loss of time, inconvenience, loss of use of the specialty vehicle, or commercial loss.
Yamaha Motor Manufacturing Corporation of America 1000 Hwy. 34 East Newnan, GA 30265
LIT-13710-20-01
1-3
MULTI-PASSENGER
IMPORTANT LABELS
Y-191A
1
2
3
WARNING
Y-191B
4
Y-500
11
SAFETY AND INSTRUCTION LABELS
Please read the following labels carefully before oper­ating your multi-passenger vehicle, and promptly replace any labels which become damaged or removed.
1
2
3
4
5
6
7
8
MULTI-PASSENGER
Vehicle capacity : 2 occupants per seat, 4 persons total.
2
3
Vehicle capacity : 2 occupants per seat, 4 persons total
4
9
10
11
2-1
IMPORTANT LABELS
Y-851
5
5
Y-852
1
2
3
4
5
6
7
8
9
10
11
2-2
MULTI-PASSENGER VEHICLE SERIAL
JR8
Y-102a
NUMBER
The vehicle serial number is stamped in the location shown.
The first three digits of the serial num­ber are for model identification; the remaining digits are the unit produc­tion number. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer.
MULTI-PASSENGER
OCCUPANT SAFETY
!
Y-191C
Y-8
Y-68
Yamaha vehicles are designed to be simple to operate. However, be sure to observe the following:
BEFORE OPERATING THE MULTI-PASSENGER VEHICLE
Read this Owner’s/Operator’s manu-
al and all safety and instruction labels on the vehicle before operating.
Perform the pre-operation checks
found in Section 6 of this manual.
Do not operate the vehicle while
under the influence of alcohol or drugs; their effect on vision and judgment make operating a vehicle dangerous.
Only authorized people should drive
the vehicle, from the driver’s side only, and only in designated areas. It is recommended that only people who possess a valid motor vehicle driver’s license be allowed to oper- ate the vehicle.
Do not operate the vehicle on public
streets, roads or highways. Such use is prohibited by law, and dan­gerous. Operation on public roads can result in collision with other vehicles.
Do not allow more than four people
to ride in the vehicle. This vehicle is restricted to a maximum of four occupants. A driver and passenger in the front seat and two passengers in the rear seat.
1
2
3
4
5
6
7
8
9
10
MULTI-PASSENGER
11
Y-191K
3-1
OCCUPANT SAFETY
!
1
WHILE OPERATING THE MULTI-PASSENGER VEHICLE
2
3
4
Y-104
5
6
7
8
Y-191M
9
Always drive slowly straight up or
straight down slopes – never at an angle.
Vary the speed of the vehicle to
match the terrain of the path.
Avoid turning the steering wheel too
sharply at higher speeds.
Keep your hands on the steering
wheel and your eyes on the path ahead.
Avoid starting or stopping abruptly.
All occupants should remain inside
the vehicle, remain seated, and hold on when the car is in motion.
Do not run the engine indoors.
Exhaust gas is poisonous.
Do not start the vehicle until all
occupants are seated and holding on, with their entire bodies inside the vehicle.
Use extra care in congested areas
or when backing up. Always back up slowly, and watch carefully.
10
11
3-2
Do not use rear seat for cargo or
luggage storage. Rear seat is to be used for 1 or 2 person occupancy only.
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.
Y-191D
MULTI-PASSENGER
MAINTENANCE SAFETY PROGRAM
MAINTENANCE REQUIRED FOR MULTI­PASSENGER VEHICLE SAFETY
Practice the following to help ensure the safety of vehicle operators and passengers:
Preventative Maintenance. Per-
form all scheduled maintenance in accordance with manufacturer’s rec- ommendations to provide the user with a safe, properly operating vehi­cle.
Personnel. Allow only qualified,
trained, and authorized personnel to inspect, adjust, and maintain the vehicle.
Parts and Materials. Use only
replacement parts and materials recommended by Yamaha.
Ventilation. Properly ventilate all
maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards. Ventilation is required to remove flammable vapors and fumes from gasoline powered car storage areas.
SAFETY PRECAUTIONS DURING MAINTENANCE
When performing maintenance, follow all safety instructions contained in the manufacturer’s operation and service manuals, as well as the following safe­ty procedures:
Properly immobilize vehicle before
beginning any maintenance.
Properly block chassis before work-
ing underneath vehicle.
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 including
brakes, steering mechanisms, warn­ing devices, and governors in a safe operating condition. Do not modify these safety devices as sup­plied by the manufacturer.
After each maintenance or repair,
the vehicle must be driven by a qual­ified, trained, and authorized person
in an area free of pedestrian traffic to ensure proper operation and
adjustment.
Record all maintenance performed
in a maintenance record log by date, name of person performing mainte­nance, and type of maintenance. Periodically inspect maintenance log to ensure accurate and com­plete entries.
Maintain in a legible condition all
nameplates, warnings, and instruc­tions provided by the manufacturer.
If new nameplates, warnings, or
instructions are needed, contact your Yamaha dealer.
1
2
3
4
5
6
7
8
9
10
11
MULTI-PASSENGER
4-1
MAINTENANCE SAFETY PROGRAM
FUEL HANDLING/
1
STORAGE AND BATTERY CHARGING
2
Take the following precautions to ensure maintenance worker safety:
Supervise the storage and handling
3
4
5
6
7
of liquid fuels in accordance with applicable fire and safety require­ments.
Only use battery changing and
charging facilities and procedures that are in accordance with applica­ble ordinances and regulations.
Periodically inspect fueling and
charging facilities and procedures to be certain that applicable safety codes, regulations, and procedures are being followed.
8
9
10
11
4-2
MULTI-PASSENGER
CONTROLS
1
7
6
5
9
10
Y-12
FEATURES
1 Steering wheel 2 Front seat 3 Rear seat 4 Battery 5 Brake pedal 6 Parking brake pedal 7 Accelerator pedal 8 Drive selector lever 9 Main switch a Oil warning light b Choke knob c Front cowl d Front tire e Front bumper f Rear cowl g Rear tire h Fuel cap
17
2
1
2
3
4
5
6
3
7
8
14
12
13
MULTI-PASSENGER
15
9
16
10
4
11
8
Y-191E
11
5-1
CONTROLS
1
2
OFF
3
ON
MAIN SWITCH
The main switch controls the following items:
OFF Ignition circuit is switched off. The key can be removed only in this position.
4
Y-15
5
ON
OFF
6
ON
Electrical circuits are switched on. The vehicle can be driven.
7
Y-16
8
OIL WARNING LIGHT
9
10
11
5-2
OIL
WARNING
OFF
A
ON
Y-17
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 6-3).
å Oil warning light
MULTI-PASSENGER
CONTROLS
Y-18
Y-191F
DRIVE SELECT LEVER
The drive select lever is used to shift the vehicle into forward or reverse. After coming to a complete stop, move the lever to the desired position.
Lever Position Car Movement
F FORWARD
R REVERSE
The back-up buzzer will beep when the drive select lever is turned to “R.
ACCELERATOR PEDAL
The accelerator pedal controls the vehicle’s speed.
1
2
3
4
5
6
7
8
B
MULTI-PASSENGER
Action Car Speed
Depress pedal Increase
Release pedal Decrease
å Accelerator pedal
BRAKE PEDAL
Press down on the brake pedal to stop the vehicle.
Brake pedal
Y-21
9
10
11
5-3
CONTROLS
1
A
2
3
Y-22
4
5
A
6
CHOKE
Y-23
PARKING BRAKE PEDAL
Press down on the parking brake pedal whenever parking the vehicle.
å Parking brake pedal
Release the parking brake by de­pressing the accelerator pedal.
CHOKE KNOB
Pull and hold out choke knob when starting a cold engine. Release the knob after the engine starts.
å Choke knob
7
8
9
10
11
5-4
.
MULTI-PASSENGER
PRE-OPERATION CHECKS
WARNING
Pre-operation checks should be made each time you use your vehicle. Get in the habit of performing the following checks in the same way so that they become second nature.
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.
PRE-OPERATION CHECKLIST
Before each use check the following:
Fuel systemEngine oil levelAir cooling ductBatteryTire conditionSteering systemBack-up buzzerPedal operationBody and chassis
1
2
3
4
5
6
7
8
9
MULTI-PASSENGER
Y-191G
SEAT
Open the rear seat for checking and servicing.
6-1
10
11
CAUTION
WARNING
PRE-OPERATION CHECKS
1
2
3
4
5
6
7
8
9
10
FUEL SYSTEM
Make sure there is sufficient fuel in the tank, and check fuel line and connec-
B
A
Y-191I
tions for leakage.
å Fuel tankFuel cap
Gasoline and its vapors are highly flammable and explosive.
Do not smoke when refueling and
keep away from sparks, flames, or other sources of ignition.
Stop engine and allow it to cool
for several minutes before refuel­ing.
Refuel in a well-ventilated area.
Take care not to spill gasoline. If
gasoline spills, wipe it up imme­diately with dry rags. Always dis­pose of gasoline-soaked rags properly.
Tighten the filler cap securely
after refueling.
If you swallow gasoline, inhale a
lot of gasoline vapor, or get gaso­line in your eyes, get immediate medical attention.
If any gasoline gets on your skin,
immediately wash with soap and water. Change clothing if gaso­line spills on it.
11
6-2
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
6.3 US gal (24.0 L, 5.3 Imp gal)
Avoid using gasoline blended with methyl alcohol which can damage fuel system parts.
MULTI-PASSENGER
CAUTION
PRE-OPERATION CHECKS
ENGINE OIL
With the vehicle parked on level ground, remove the dipstick and make sure the engine oil is between the MIN and MAX marks (the crosshatched area on the end of the dipstick).
Y-514
å Oil level dipstick
B
Maximum oil level ç Safe operating range
MIN
C
A
Recommended oil:
YAMALUBE 4-cycle oil or
SAE 10W-30
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)
MAX
A
Y-28
Y-515
If the oil level is below the MIN mark on the dipstick, add oil through the oil filler hole until the oil level is between the MIN and MAX marks. Do not add oil if the level is above the MIN mark.
6
å Oil filler hole
Use care not to fill past the MAX
dipstick mark, and be sure no for­eign material enters the crank­case.
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 classifica­tion: API Service SE, SF, or SG. Engine oils labeled Energy Conserv­ing IIare recommended.
MULTI-PASSENGER
6-3
PRE-OPERATION CHECK
1
A
2
3
Y-191L
4
5
Engine Cooling Inlet Duct
Check the engine cooling inlet duct for debris. Remove any debris present.
å Engine cooling inlet duct
BATTERY
Check that the battery is held secure­ly in place to prevent the battery from being damaged from vibration or jar­ring. Also check that no battery caps are missing to prevent battery acid from spilling from the battery. Check the battery terminals for corrosion.
TIRE CONDITION
6
Tire Air Pressure
Check the tire air pressure before
7
8
operating the vehicle.
Tire pressure:
Y-30
For G20-A:
20 - 23 psi (140 - 160 kPa, 1.4 - 1.6 kgf/cm2)
9
A
Tire Wear Limit
10
11
6-4
Check the tire surface for damage, cracks or embedded objects. When tire tread wears down to 0.04 in. (1 mm), replace the tire.
Y-31
å Wear limit
MULTI-PASSENGER
PRE-OPERATION CHECKS
STEERING SYSTEM
Check the steering system for exces­sive freeplay by:
moving the steering wheel up and
down, and back and forth.
turning the steering wheel slightly to
the right and left.
Y-191H
If you feel excessive 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.
Y-33
6
A
MULTI-PASSENGER
PEDAL OPERATION
Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha deal­er.
Brake Pedal
Make sure the brake pedal feels firm when pressed and returns to its origi­nal position when released.
å Brake pedal
Y-21A
6-5
PRE-OPERATION CHECKS
WARNING
WARNING
1
A
2
3
Y-22
4
Parking Brake Pedal
Before checking operation of the parking brake, be sure the main switch is in the “OFF” position.
Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed.
å Parking brake pedal
5
Release the parking brake by depressing the accelerator pedal.
6
Accelerator Pedal
7
8
B
Before checking operation of the accelerator pedal, be sure the main switch is in the “OFF” position.
9
10
11
6-6
Y-20
Make sure the accelerator pedal oper­ates smoothly.
Accelerator pedal
BODY AND CHASSIS
Before each use, visually inspect the vehicle body and chassis for damage and/or missing parts.
MULTI-PASSENGER
OPERATION
WARNING
CAUTION
STARTING
1. With the parking brake applied, turn the drive select lever to “Ffor forward, or “R” for reverse.
1
2
Y-18
Do not shift from “F” forward to “R” reverse while the vehicle is moving.
2. Turn the main switch to “ON.
3
4
OFF
ON
Y-16
Do not depress the accelerator pedal when turning on the main switch or the vehicle may suddenly start moving.
3. Pull the choke knob out and hold it while starting. Release the choke knob after the engine starts.
5
6
7
å Choke knob
A
CHOKE
Y-23
B
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 slow­ly depress the accelerator pedal. The vehicle will start to move.
Accelerator pedal
8
9
10
MULTI-PASSENGER
Y-20
11
The parking brake automatically releases when the accelerator pedal is depressed.
7-1
OPERATION
CAUTION
1
B
2
A
3
Y-65
STOPPING
To stop the vehicle, gradually press down on the brake pedal.
å Brake pedal
When the car has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.
Parking brake pedal
4
Do not hold the vehicle on an incline with the accelerator – use
5
the brake.
6
7
8
9
10
11
7-2
MULTI-PASSENGER
MAINTENANCE
PERIODIC MAINTENANCE CHARTS
Regular maintenance is required for the best performance and safe operation of your vehicle.
WARNING
Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic.
FOR G20A
C - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
20 Rounds 125 rds 250 rds 500 rds 1000 rds
Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mls Page
PRE- Check engine oil CC C 6-3 OPER- Check air cooling duct CC C CCC6-4 ATION Check fuel lines for leakage CC C CCC6-2 CHECKS Check fuel level CC C CCC6-2
EVERY Check fuel filter for clogging C C CCC* MONTH
EVERY 6 Wash pre-filter, check air S SSS8-6 MONTHS
EVERY Replace engine oil RRR8-5 YEAR Adjust throttle cables,** CA CA CA *
* Items with out a page number reference should be serviced by a Yamaha dealer or other qualified
**Related to emission control system.
MULTI-PASSENGER
Check for looseness CC C CCC6-4 and corrosion of battery terminals and hold downs
Check brake pedal freeplay CCA CA CACACA8-12 and adjust if necessary
Check steering operation CC C C C 6-5 Check tire pressure, tread CCA CACACACA6-5
depth, tire surface for damage Check body and chassis for CC C CCC6-6
damage Check tightness of all bolts, CC C CCC*
nuts, and screws Check reverse buzzer CC C CCC6-5
operation
Check wear of drive belt C C CCC8-8 Check operation of C C CCC6-5
Forward / Reverse shifting Clean / Lube pedal control area CL
cleaner element Check spark plug and plug cap C CCC8-4/*
condition** / Check compression Check shock absorbers for oil C CCC*
leaks and damaged springs
choke cable, check carburetor throttle shaft for wear**
Check starter V-belt for CCC* damage and tension
mechanic. This manual does not contain these procedures. They are contained in the Service Manual.
Pre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs
tion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms
(Every (Every 6 (Every (Every (Every
month) months) year) 2 years) 4 years)
8-1
1
2
3
4
5
6
7
8
9
10
11
MAINTENANCE
1
2
3
4
5
6
7
8
9
C - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
20 Rounds 125 rds 250 rds 500 rds 1000 rds
Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mls Page
EVERY Check drive belt for slippage, CCC8-8 YEAR wear or scratches
EVERY Check brushes for wear and CS* 2 YEARS commutator for dirt
EVERY Replace fuel filter and R * 4 YEARS fuel hoses
* Items without a page number reference should be serviced by a Yamaha dealer or other qualified
**Related to emission control system.
Check sliding sheave and CL CL CL * ramp shoes; Grease secondary sheave bearing.
Grease primary sheave LLL* Check operation of speed limiter CCC* Apply battery terminal protectant SSS Check wiring connections CCC
and insulation Check shoe lining thickness CCC*
and rear axle bearing play Check kingpin play, seal, and CA CA CA *
cap / Adjust wheel alignment Check wheel nut tightness, CCC*
front wheel bearing play Check gear box oil level CCC8-10
and leakage Check operation and adjust CA CA CA *
pedal stop if necessary
Check tightness of cylinder CA * head / Adjust valves
Replace gear box oil R 8-10 Check for grease leakage; CA *
adjust gearbox if necessary
mechanic. This manual does not contain these procedures. They are contained in the Service Manual.
Pre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs
tion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms
(Every (Every 6 (Every (Every (Every
month) months) year) 2 years) 4 years)
10
11
8-2
MULTI-PASSENGER
MAINTENANCE
EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS
Item Acronym
CARB. ASSY., LH., JT., CARB (Carburetor) CARBURETOR 2 & JT., CARBURETOR 1
T.C.I. MAGNETO ASSY. & El (Electronic Ignition) PLUG, SPARK
CRANKCASE 1 & HEAD, PCV (Positive Crankcase CYLINDER 1 Ventilation)
AIR FILTER ASSY. ACL (Air Cleaner)
MUFF., 2
The above items and the correspond­ing acronyms are provided in accor­dance with U.S. EPA REGULATIONS FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULA­TIONS 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 recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
1
2
3
4
5
6
7
8
9
10
MULTI-PASSENGER
11
8-3
WARNING
MAINTENANCE
1
2
B
3
A
Y-516
4
5
A
6
Y-37
Spark Plug Inspection
You should periodically remove and inspect the spark plug. Dirty or worn spark plugs can cause poor perfor­mance.
å Spark plugSpark plug cap
1. Check for discoloration and heavy carbon deposits. The normal electrode color will be tan. If it is not, replace it.
2. Check the spark plug type, and check the spark plug gap with a feeler gauge.
Standard spark plug:
BPR2ES
Spark plug gap:
0.028 ˜0.031 in (0.7 ˜ 0.8 mm)
7
å Gap
8
9
3. Clean the gasket and plug sur-
faces and install the spark plug fin­ger tight before tightening to the following torque:
10
11
8-4
Spark plug torque:
14.5 ft.lb (20 Nm, 2.0 m.kg)
When removing or installing the spark plug, be careful not to dam­age the insulator. A damaged insu­lator could allow external sparks, which could lead to explosion or fire.
MULTI-PASSENGER
WARNING
MAINTENANCE
Y-624
Engine Oil Replacement
1. Warm up the engine for several minutes, place the vehicle on a level surface, then stop the engine.
Use caution not to touch hot engine oil or hot engine parts during the following procedure.
2. Place an oil pan under the engine drain plug.
3. Remove the oil drain plug and let the oil drain completely.
Dispose of used oil in an environmen­tally 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:
1
2
3
4
5
6
7
8
Recommended oil:
YAMALUBE 4-cycle oil or
SAE 10W-30
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)
MULTI-PASSENGER
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 classifica­tion: API Service SE, SF, or SG. Engine oils labeled Energy Conserv­ing IIare recommended.
8-5
9
10
11
CAUTION
CAUTION
MAINTENANCE
1
A
2
3
Y-515
4
5
B
A
A
6
7
Y-518
8
å Oil filler hole
Use care not to fill past the MAX dipstick mark, and be sure no for­eign material enters the crank­case. After replacing engine oil, check 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 clipsAir filter cover
A
2. Lift the air filter and pre-filter out of the air filter case.
A
9
10
11
8-6
å Air filterPre-filter
B
Y-519
Be careful not to drop anything into the air inlet.
MULTI-PASSENGER
CAUTION
CAUTION
MAINTENANCE
A
B
Y-508
Inspection and cleaning:
3. Wash the foam pre-filter in soap and water. Allow it to dry.
å Soap and waterFoam element
4. Check the filter element. If dam­aged or dirty, replace it.
1
2
3
4
Do not wring out the foam pre-fil­ter, this could cause it to tear.
5. To replace the elements, reverse the above steps.
5
6
The pre-filter has a notch on one side. It will only fit in the case one way.
7
8
MULTI-PASSENGER
9
10
11
8-7
MAINTENANCE
1
2
3
4
5
Y-60
6
A
7
B
8
Y-44
Drive Belt
To remove the drive belt:
1. Set the drive select lever halfway between forward and reverse.
2. Pull up on the drive belt and push it outward over the edge of the secondary sheave.
3. Turn the secondary sheave clock­wise and the drive belt will roll off the sheave.
4. Remove the drive belt from the pri­mary sheave.
Inspection:
To inspect the drive belt, check for frayed edges or tears, and measure drive belt against the following specifi­cation. 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)
9
10
11
8-8
5. To install the drive belt, reverse the above steps, rolling the belt back over the secondary sheave.
MULTI-PASSENGER
WARNING
MAINTENANCE
Battery
Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or 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 physician 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 CHIL­DREN.
The 12-volt battery that provides start­ing power to your vehicle normally
+
+
doesnt require the addition of water during the one year warranty period provided by the battery manufacturer. If the battery loses its charge, have an experienced mechanic charge it.
1
2
3
4
5
6
7
8
9
10
MULTI-PASSENGER
11
Y-45
8-9
CAUTION
WARNING
MAINTENANCE
1
A
2
3
4
Replacement Fuse:
10 Amp, Blade Style
5
6
7
8
9
Fuse Replacement
B
Be sure to use the specified fuse. Using a wrong fuse can cause elec­trical system damage and create a fire hazard.
C
Y-35
When replacing a fuse be sure the main switch is turned off to prevent accidental short-circuiting.
å Fuse caseFuse ç Replacement fuse
Gear Box Oil
To check gear box oil level:
1. Place the vehicle on a level sur-
face.
2. Remove the access panel by
removing the screws in the two lower corners of the panel and pulling the panel from the car.
10
11
8-10
Y-191J
3. Remove the oil plug (A).
Recommended oil:
SAE 90 gear oil
Gearcase capacity:
0.44 US qt
A
B
Y-520
(0.42 L, 0.09 Imp gal)
MULTI-PASSENGER
WARNING
CAUTION
MAINTENANCE
Add gear oil little by little until oil
flows from the plug hole (B).
4. Allow excess gear oil to flow out until it stops.
Do not allow foreign material to enter 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 vehicle:
1. With the wheels blocked to prevent the vehicle from moving, loosen the wheel nuts.
1
2
3
4
5
6
7
8
Wheel nut tightening torque:
58 ft.lb (80 Nm, 8.0 m.kg)
Consult your Yamaha dealer before using your vehicle if you suspect brake problems. Brake failure could result in a serious accident.
MULTI-PASSENGER
Y-57
2. Elevate the vehicle with a jack and remove the wheel nuts and the wheel.
3. Reverse the removal steps when installing the wheel.
Brake Adjustment
The brakes on your vehicle are self­adjusting.
Before you operate the vehicle, press down on the brake pedal several times to make sure the brakes are function­ing properly.
8-11
9
10
11
WARNING
CAUTION
MAINTENANCE
1
2
3
4
5
6
7
8
9
10
11
25-30 mm
Brake Pedal Free Play Adjustment
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 vehicle.
Y-61
2. Check the brake pedal free play by pressing against the pedal with two fingers (using light force) and
18
17
16
15
14
13
12
11
10
9
8
7
Y-62
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.
8-12
Y-63
Do not overtighten the brake cables. The self adjusters may not operate properly, reducing braking performance.
MULTI-PASSENGER
WARNING
Y-521
A
STORAGE
Perform the following preparations when storing your vehicle for extend­ed periods of time:
Turn main switch key to “OFF” position, remove key, and store key in a safe place.
DRAINING FUEL
Gasoline and its vapors are highly flammable and explosive.
Do not smoke when draining fuel
and keep away from sparks, flames, or other sources of ignition.
Stop engine and allow it to cool
for several minutes before drain­ing fuel.
Drain fuel in a well-ventilated area.
Take care not to spill gasoline. If
gasoline spills, wipe it up immedi­ately with dry rags. Always dis­pose of gasoline-soaked rags properly.
Tighten the filler cap securely
after checking fuel level.
If you inhale a lot of gasoline
vapor, or get gasoline in your eyes, get immediate medical attention.
If any gasoline gets on your skin,
immediately wash with soap and water. Change clothing if gasoline spills on it.
1. Fill the fuel tank.
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2
3
4
5
6
7
8
9
10
11
MULTI-PASSENGER
å Float bowl drain screw
2. Drain the carburetor float bowl into a suitable container by turning the screw located on the bottom of the carburetor.
9-1
STORAGE
ENGINE PREPARATION
1
With the key removed and the spark plug lead disconnected, turn the clutch by hand until compression is
2
felt. This puts the valves in the closed position.
3
CHASSIS PREPARATION
1. Increase the tire pressure to 23 psi
4
5
6
(160 kPa, 1.6 kgf/cm2).
2. Clean exterior of the vehicle and apply a rust inhibitor.
3. Cover the vehicle with a breath­able cover and store it in a dry, well-ventilated area.
7
8
BATTERY PREPARATION
1. Remove the battery from the vehi­cle 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.
Batteries like the one supplied with your vehicle normally do not require you to check the water level inside the battery for the one year warranty period provided by the manufacturer.
9
10
11
9-2
MULTI-PASSENGER
SPECIFICATIONS
GENERAL SPECIFICATIONS
Items G20A
Dimensions:
Overall length 128.0 in. (3250 mm) Overall width 47.2 in. (1200 mm) Overall height (steering height) 46.8 in. (1190 mm) Height of floor 11.8 in. (300 mm) Wheelbase 97.8 in. (2483 mm) Tread:
Front 34.3 in. (870 mm) Rear 38.6 in. (980 mm)
Min. ground clearance 3.8 in. (97 mm)
Weight:
Dry weight (without battery) 855 lb (388 kg)
Performance:
Maximum speed 12 mph
(19 km/h)
Minimum turning radius 167.0 in. (4.24 m)
Seating capacity 4 persons
1
2
3
4
5
6
7
8
MULTI-PASSENGER
9
10
11
10-1
SPECIFICATIONS
ENGINE
1
Description:
2
3
4
5
6
7
8
9
10
11
Engine type 4-stroke, Gasoline, OHV Number of cylinders Single Displacement 301 cm Bore x stroke 3.07 x 2.48 in. (78 x 63 mm) Compression ratio 8.1:1 Rated output 9.5 hp (7.1 kw)/4000 rpm Cooling system Forced air cooled Starting system Starter Ignition system TCI Magneto Spark plug type BPR2ES Spark plug gap 0.028-0.031 in. (0.7-0.8 mm) Lubrication 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
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 setting 12 mph (19 km/h)
Differential/reduction gear: G20A
Differential type Bevel gear Lubricant/capacity SAE 90 gear oil/0.44 US qt
Items G20A
3
Items G20A
(0.42 L, 0.09 Imp gal)
BATTERIES
Items G20A
Battery: BCI group 24,
10-2
RC: minimum 75 min CCA: minimum 400A
MULTI-PASSENGER
SPECIFICATIONS
CHASSIS
Items G20A
Steering system:
Type Worm and pin Steering angle (L.H.) 1.5 turn Steering angle (R.H.) 1.5 turn Lubricant/capacity Grease/3.0 US oz (0.09 L, 3.17 Imp oz)
Brakes:
Brake system Mechanical drum brake on each rear wheel
with self-adjusters.
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 pressure: For G20A:
20 - 23 psi (140 - 160 kPa, 1.4 - 1.6 kgf/cm2)
1
2
3
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5
6
7
8
9
MULTI-PASSENGER
10
11
10-3
R
B
R
B
P
B
R
REV
FWD
R
P
BBP
P
B
P
Br
R/W
Br
R/W
Br
A1
F2
B
B
RW
RW
R
R
R
R
R
Y
BL
BrBrRR
BYRB
BBBB
B
B
B
BY
YBR
R
R
R/W
R/W
G
B
RW
G
G
G
G
G
B
Br
B
B
R/W
Br
R/W
OFF ON
Br
R/Y
BL
BB
BL
G
Br
B
R/W
R/W
BL
BL
BL
BB
B
B
B
+
Y-191N
GG
BrBr
B
RW
R
Br
R
RY
BrBr
16
1
2
3
4
5
6
7
8
9
10
14
15
13
12
11
BR
GRBBB
BrWRB
RGBB
R.R.
L.R.
L.R.
R.F.
17
18
19 20
21
22
23
24
WIRING
G20A WIRING DIAGRAM
1
2
3
4
5
6
7
8
9
10
11
11-1
MULTI-PASSENGER
1 Engine stop relay 2 Engine ground 3 Pickup 4 Rotor 5 Oil level gauge 6 Blade fuse (10A) 7 Voltage regulator 8 Starter generator 9 Relay a Battery b Pilot lamp (12V, 3.4W) c Main switch d Accelerator stop switch e Back switch f Buzzer g Body ground h Signal lights i Turn signal lever j Head lights k Tail lights l Head light switch m Flasher unit n Brake light switch o Brake light sensor
WIRING
1
2
3
4
5
6
7
MULTI-PASSENGER
COLOR CODE
B.........................Black
BL ........................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
8
9
10
11
11-2
10/31/00
1PC - G20A O/M
LIT196262000
*LIT196262000*
Yamaha Motor Corp., USA
Cypress, California
made in
YAMAHA MOTOR
OF AMERICA
USA
Printed in U.S.A.
KCC
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