READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S/OPERATOR’S MANUAL
G23A
LIT-19626-01-17
JU5-F8199-10
1-
INTRODUCTION
Congratulations on your purchase of a Yamaha utility vehicle. This manual contains information you
will need for proper operation, maintenance, and care of your utility 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 utility vehicle, please consult a Yamaha dealer.
TECHNICAL SERVICE DEPT
YAMAHA GOLF-CAR COMPANY
G23A
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
Yamaha Golf-Car Company
is expressly prohibited.
Printed in U.S.A.
P/N LIT-19626-01-17
IMPORTANT MANUAL INFORMATION
WARNING
CAUTION:
NOTE:
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 utility vehicle occupants, a bystander, or a
person inspecting or repairing the utility vehicle.
This message describes special precautions that must be taken to
avoid damage to the utility vehicle.
This message provides additional key information.
NOTE:
_
●
Yamaha continually seeks advancements 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 utility 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 utility vehicle and should remain
with the car when resold.
_
WARNING
_
Read and understand this manual completely before operating your utility vehicle.
YAMAHA GOLF-CAR COMPANY
UTILITY VEHICLE LIMITED WARRANTY
Yamaha Golf-Car Company hereby warrants that any
new Utility 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 Utility Vehicle
will be one year from date of purchase for parts and
labor.
The warranty shall cover the entire vehicle 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 Golf-Car
Company.
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/Operator’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 Utility
Vehicle’s condition, operation, performance, or
durability.
f.
Damage due to improper transportation.
g.
Acts of God (i.e. lightning, 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 bed damage such as scratches, dents, or
deformation. Any 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
1.
specified in the appropriate Owner’s/Operator’s
Manual;
Give notice to an authorized Yamaha dealer of any
2.
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 GOLF-CAR COMPANY 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 GOLF-CAR COMPANY 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 GOLF-CAR COMPANY
Effective Date: 01/01/04
YAMAHA GOLF-CAR COMPANY SPECIALTY VEHICLE ENGINES
EMISSION CONTROL WARRANTY
YOUR WARRANTY RIGHTS AND OBLIGATIONS
In complance with the California Air Resources Board,
Yamaha Golf-Car Company 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/Operator’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 Depar tment at (770)
254-4164.
Yamaha Golf-Car Company 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:
Designed, built, and equipped so as to conform, at
1.
the time of sale, with all applicable regulations
adopted by the California Air Resources Board.
All warranted parts are free from defects in
2.
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:
Fuel Metering System
1.
Carburetor and internal parts (or fuel injection)
Air/fuel ratio feedback and control system
Cold start enrichment system
Air Induction System
2.
Controlled hot air intake system
Intake manifold
Ignition System
3.
Spark plugs *
Magneto or electronic ignition system
Spark advance/retard system
Exhaust Gas Recirculation (EGR) System
4.
EGR valve body, and carburetor spacer if applicable
EGR rate feedback and control system
Air Injection System
5.
Air pump or pulse valve
Valves affecting distribution of flow
Distribution manifold
Catalyst or Thermal Reactor System
6.
Catalytic converter
Thermal reactor
Exhaust manifold
Particulate Controls
7.
Traps, filters, precipitators, and any other device used
to capture particulate emissions
Miscellaneous Items Used in Above Systems
8.
Vacuum, temperature, and time sensitive valves and
switches
Electronic controls
Hoses, belts, connectors, and assemblies
Engine components damaged due to a failure under
9.
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/Operator’s Manual).
DURING THE PERIOD OF THIS WARRANTY
Yamaha Golf-Car Company 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 par ts. 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 parts 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
Golf-Car Company 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 Golf-Car Company
CONTENTS
LOCATION OF THE WARNING
1
AND SPECIFICATION LABELS....... 1-1
DESCRIPTION AND VEHICLE
2
IDENTIFICATION ............................. 2-1
Features .......................................... 2-1
Utility vehicle serial number............. 2-2
Key identification number................ 2-2
SAFETY INFORMATION.................. 3-1
3
CONTROL FUNCTIONS .................. 4-1
4
Main switch...................................... 4-1
Oil level warning light ...................... 4-2
Fuel tank cap................................... 4-2
Drive select lever............................. 4-3
Accelerator pedal ............................ 4-4
Brake pedal .....................................4-4
Parking brake pedal ........................ 4-5
Starter (choke)................................. 4-5
Horn button...................................... 4-6
Auxiliary DC jack..............................4-6
Cargo bed ........................................4-8
Trailer hitch bracket .......................4-12
PRE-OPERATION CHECKS ............5-1
5
Pre-operation check list ...................5-2
Brakes..............................................5-3
Fuel ..................................................5-4
Engine oil .........................................5-5
Transmission oil...............................5-5
Accelerator pedal.............................5-6
Steering............................................5-6
Fittings and fasteners ......................5-6
Lights................................................5-6
Switches...........................................5-6
Tires .................................................5-7
OPERATION .....................................6-1
6
Starting a cold engine ......................6-1
Starting a warm engine....................6-3
Stopping...........................................6-3
Accessories and loading..................6-4
DRIVING YOUR VEHICLE............... 7-1
7
Getting to know your vehicle........... 7-1
Learning to operate your vehicle .... 7-3
Turning your vehicle........................ 7-3
Braking ............................................ 7-3
Going uphill ..................................... 7-4
Going downhill................................. 7-5
Rough terrain .................................. 7-6
Riding in brush or wooded areas.... 7-7
PERIODIC MAINTENANCE AND
8
ADJUSTMENT ................................. 8-1
Owner’s/Operator’s Manual............ 8-1
Periodic maintenance/
lubrication...................................... 8-2
Exhaust emission control system
and components ........................... 8-4
Seat................................................. 8-5
Cargo bed ....................................... 8-5
Spark plug inspection...................... 8-7
Engine oil ........................................ 8-8
Air filter element cleaning.............. 8-11
Drive belt ....................................... 8-13
Battery ...........................................8-14
Fuse replacement.......................... 8-15
Transmission oil............................. 8-16
Wheel removal............................... 8-17
Wheel installation ..........................8-18
Brake adjustment...........................8-19
Brake pedal free play
adjustment ................................... 8-19
Replacing a headlight bulb............ 8-21
Adjusting a headlight beam........... 8-22
Replacing a taillight bulb ...............8-23
CLEANING AND STORAGE ............ 9-1
9
Draining the fuel ..............................9-1
Engine preparation .......................... 9-1
Chassis preparation ........................ 9-2
Battery preparation.......................... 9-2
SPECIFICATIONS .......................... 10-1
10
MAINTENANCE RECORD............. 11-1
11
1-
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
7
8
1-1
Read and understand all of the labels on your ve-
WARNING
hicle. They contain important information for safe
and proper operation of your vehicle.
1
2
Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha
3
4
5
dealer.
6
7
12
!
WARNING
ATTENTION
1-2
Improperly loading a trailer and failure to use extra care
WARNING
when pulling trailer can cause an accident or injury.
Never load more than 150 lbs (68kg) tongue weight on
the towing bracket.
Do not tow more than 1000 lbs (454kg) rolling weight
(trailer plus cargo).
Allow for increased braking distance and use extreme caution
when operating on inclines.
Read carefully the loading information and trailer hitch sections
in the owner's manual.
YAMAHA
JU5-K7768-00
YAMAHA
OFF
ON
ON
OIL
WARNING
JU5-K7761-00
Improper use can result in SEVERE INJURY or DEATH
Vehicle capacity: 1 operator and 1 passenger.
Remain seated and hold on while in motion.
This vehicle is recommended only for 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 load) 1300lb. (590kg) on level
surface.
LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
This vehicle was not manufactured for use on public streets and does not comply
with federal motor vehicle safety standards applicable to passenger cars.
8
9
10
11
12
13
14
3
WARNING
Severe INJURY or DEATH can result if you ignore the following:
Maximum Load in Cargo Bed: 800lb (363kg).
Never carry passengers or fill fuel containers in cargo bed.
Cargo can affect handling and stability.Read Owner's Manual before loading or towing.
When loading with cargo or towing a trailer: Reduce speed and allow more room to stop.
Avoid hills and rough terrain.
Be sure cargo is secured - a loose load could change handling unexpectedly.
Keep weight in the cargo bed centered, and as low and far forward as possible.
Top-heavy loads increase the risk of overturn.
YAMAHA
WARNING
4
5
WARNING
Keep hands, body, other
persons away when closing bed.
Do not operate the vehicle
YAMAHA 5UG-K7764-00
with bed up.
JU5-K7766-01
6
Do not fill portable fuel container (gas can) in cargo bed. Static electricity
sparks can ignite fuel vapor causing fire or explosion.
Set fuel container on the ground and touch 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.
YAMAHA
WARNING
JU7-K7767-00
7
8
ENGINE AIR INDEX (California only)
0 2 4 6 8 10
MOST CLEAN LEAST CLEAN
NOTE : THE LOWER THE AIR INDEX. THE LESS THE POLLUTION
THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT
FOR THE FOLLOWING USE :
MODERATE
CHECK OWNERS MANUAL FOR FURTHER DETAILS
THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY
INTERMEDIATE
EXTENDED
1-3
1-
DESCRIPTION AND VEHICLE IDENTIFICATION
FEATURES
1. Steering wheel
2. Seat
3. Battery
4. Taillight
5. Rear tire
6. Fuel tank
7. Starter (choke)
8. Drive select lever
9. Front tire
10. Headlight
11. Accelerator pedal
12. Brake pedal
13. Parking brake pedal
14. Horn button
15. Auxiliary DC jack
16. Main switch
17. Oil level warning light
1
2
3
4
5
6
7
8
9
10
11
12
13
14
2-1
Utility vehicle serial number
The utility vehicle serial number is stamped in
the location shown.
NOTE:
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.
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
2-2
SAFETY INFORMATION
1
SEVERE INJURY OR DEATH can result if
you do not follow these instructions:
●
Read this manual and all labels carefully
and follow the operating procedures described.
●
This vehicle is designed to carry the driver
and one passenger. Never carry passengers in the cargo bed.
●
Never give a ride to a passenger who is unable to put both feet firmly on the floorboard
while seated with his or her back against
the backrest. The passenger must hold on
to the grab rail at all times while the vehicle
is in motion.
●
Never operate this vehicle on any public
street, road, or highway, even a dirt or gravel one.
●
Never consume alcohol or drugs before or
while operating this vehicle.
●
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 experience.
●
Never attempt jumps or other stunts.
●
Always inspect your vehicle each time you
use it to be sure it is in safe operating condition. Always follow the inspection and
maintenance procedures and schedules
described in this manual.
●
Always keep both hands, arms, feet, and
legs inside the vehicle at all times during
operation. Keep your feet on the floorboard.
●
Always keep both hands on the steering
wheel when driving.
3-1
2
3
4
5
6
7
8
9
10
11
12
13
14
●
Always go slowly and be extra careful when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions when
driving the vehicle.
●
Never operate on rough, slippery, or loose
terrain.
●
Never turn at excessive speed. Do not attempt turns on steep slopes.
●
Never operate the vehicle on slopes that
are too steep for it or for your abilities. Go
straight up and down slopes.
●
Never operate on slopes that are slippery
or ones where you will not be able to see
far enough ahead of you. Never go over the
top of a slope at speed if you cannot see
what is on the other side.
●
Always check terrain carefully before going
down slopes. Go as slowly as possible.
Never go down a slope at high speed.
●
Always check for obstacles before operating in a new area.
●
Always be sure there are no obstacles or
people behind you when you operate in reverse. When it is safe to proceed in reverse, go slowly. Do not brake abruptly
when carrying loads in the cargo bed.
●
Always use the size and type of tires specified in this manual.
●
Always maintain proper tire pressure as described in this manual.
●
Never exceed the stated load capacity.
Cargo should be as far forward in the bed
as possible, and distributed evenly from
side to side. Be sure cargo is secured so
that it cannot move around during operation. Reduce speed and follow instructions
in this manual for carrying cargo or pulling a
trailer. Allow greater distance for braking.
3-2
CONTROL FUNCTIONS
Main switch
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.
1
2
3
4
5
6
7
8
9
The main switch positions are as follows:
OFF:
All electrical circuits are switched off. The key
can be removed in this position only.
10
11
12
13
14
4-1
Oil level warning light
This warning light comes on when the engine
oil level is low.
If the light comes on, stop
the engine, check the engine oil level, and
add oil as necessary. (See page 8-8–8-9).
1. Oil level warning light
CAUTION:
Always make sure there is enough engine
oil before starting the engine.
Fuel tank cap
Remove the fuel tank cap by turning it counterclockwise.
1. Fuel tank cap
4-2
Drive select lever
The drive select lever is used for driving the
utility vehicle either forward or in reverse.
After coming to a complete stop, shift the lever
to the desired position.
Lever position Vehicle movement
FFORWARD
R REVERSE
NOTE:
The back-up buzzer will sound when the drive
select lever is shifted to “R.”
4-3
Accelerator pedal
1
The accelerator pedal controls the utility vehicle’s speed.
Action Vehicle speed
Depress pedal Increase
Release pedal Decrease
1
1. Accelerator pedal
NOTE:
The engine does not start until the accelerator
pedal is depressed.
Brake pedal
Press the brake pedal down to slow or stop
the utility vehicle.
1. Brake pedal
NOTE:
The engine stops when the accelerator pedal
is released and the utility vehicle comes to a
complete stop.
4-4
1
Parking brake pedal
Press the parking brake pedal down whenever parking the utility vehicle.
1
1. Parking brake pedal
NOTE:
Release the parking brake by depressing the
accelerator pedal.
Starter (choke)
Pull the starter (choke) knob out and hold it
when starting a cold engine. Release it after
the engine starts.
1. Starter (choke) knob
4-5
Horn button
Step on the horn button to sound the horn.
1. Horn button
Auxiliary DC jack
The auxiliary DC jack is located in the front
panel.
The auxiliary DC jack can be used for accessories such as lights, radios, etc.
The auxiliary DC jack should only be used for
short periods if the utility vehicle is not being
operated.
1. Auxiliary DC jack cap
4-6
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)
3. Close the auxiliary DC jack cap if the jack
is not being used.
CAUTION:
Do not use accessories requiring
●
more than the maximum rated capacity for the auxiliary DC jack. This may
overload the circuit and cause the
fuse 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 and starting the
engine may become difficult.
Do not use an automotive cigarette
●
lighter or other accessories with a
plug that gets hot because the jack
can be damaged.
4-7
Cargo bed
Opening and closing the tailgate
1. Cargo bed
1. Tailgate 2. Latch (× 2)
To open:
Unhook the latches, and then lower the tailgate.
To close:
Place the tailgate in its original position, and
then hook the latches.
4-8
Lifting and lowering the cargo bed
1. Cargo bed release lever
To lift:
Pull the cargo bed release lever towards the
rear, and then slowly lift up the cargo bed until
end of the prop rod hooks onto the prop rod
guide to support the cargo bed.
To lower:
Slightly lift up the cargo bed, unhook the end
of the prop rod, and then lower the cargo bed
slowly to its original position. Make sure that
the latch for the cargo bed is properly engaged.
Maximum load limit:
363 kg (800 lb)
CAUTION:
Do not lift the cargo bed by the release lever. Damage to the lever may occur.
1. Prop rod
4-9
WARNING
WARNING
POTENTIAL HAZARD
Overloading the cargo bed.
WHAT CAN HAPPEN
Could cause changes in vehicle handling which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated maximum load
for this cargo bed.
Cargo should be properly distributed.
Reduce speed when carrying cargo. Allow greater distance for braking.
POTENTIAL HAZARD
Carrying a passenger in the cargo bed.
WHAT CAN HAPPEN
The passenger could fall, be thrown out,
or be struck by objects in the cargo bed.
HOW TO AVOID THE HAZARD
Never carry a passenger. This cargo
bed is designed to carry cargo only.
4-10
WARNING
WARNING
POTENTIAL HAZARD
Pinch point.
WHAT CAN HAPPEN
You or someone else could be pinched
between the cargo bed and the frame or
the seat backs when the bed is being
lowered.
HOW TO AVOID THE HAZARD
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 cargo bed and
seat backs.
POTENTIAL HAZARD
Fire or explosion while filling a portable
fuel container.
WHAT CAN HAPPEN
Static electricity sparks can ignite fuel
vapors. The plastic bed is not grounded,
increasing the risk of static electricity
build-up.
HOW TO AVOID THE HAZARD
Do not refill fuel containers in the plastic
bed. Set fuel container on the ground
and touch the nozzle to the container
before removing the container cap.
Keep nozzle in contact with can inlet
when filling. Tighten cap before putting
fuel container in cargo bed.
4-11
Trailer hitch bracket
This vehicle is equipped with a 5 cm (2 in) receiver bracket for a standard trailer hitch.
Trailer towing equipment can be obtained at a
Yamaha dealer. (See page 6-5 for precaution
information.)
1. Trailer hitch bracket
4-12
1-
PRE-OPERATION CHECKS
Pre-operation checks should be made each
time you use your utility vehicle. Get in the
habit of performing the following checks in the
same way so that they become second nature.
WARNING
POTENTIAL HAZARD
Failure to inspect the vehicle before operating. Failure to properly maintain the
vehicle.
WHAT CAN HAPPEN
Increases the possibility of an accident
or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your vehicle each time
you use it to make sure the vehicle is in
safe operating condition. Always follow
the inspection and maintenance procedures and schedules described in the
Owner’s/Operator’s Manual.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
5-1
Pre-operation check list
Before using this vehicle, check the following points:
ITEM ROUTINE PAGE
Brakes
Parking brake
Fuel
Engine oil
Transmission oil
Accelerator pedal
Steering
Fittings and fasteners
Lights and switches
Wheels and tires
• Check for proper operation, condition and free play. 5-3, 8-19–8-21
• Check for proper operation, condition and free play. 5-3, 8-19–8-21
• Check fuel level.
• Fill with fuel if necessary.
• Check oil level.
• Fill with oil if necessary.
• Check for leakage. 5-5, 8-16–8-17
• Check for proper accelerator pedal operation. 5-6
• Check for proper operation. 5-6
• Check all fittings and fasteners. 5-6
• Check for proper operation. 5-6, 8-21–8-23
• Check tire pressure, wear and damage. 5-7–5-9, 8-17–8-18
5-4–5-5
5-5, 8-8–8-9
5-2
Brakes
Brake pedal
Check for correct brake pedal free play. If the
brake pedal free play is incorrect, have a
Yamaha dealer adjust it. (See pages 8-19–
8-21.)
Check the operation of the brake pedal. It
should move smoothly and there should be a
firm feeling when the brakes are applied. If
not, have the vehicle inspected by a Yamaha
dealer.
Brake operation
Test the brakes at slow speed after starting
out to make sure they are working properly. If
the brakes do not provide proper braking performance, inspect the brake system. (See
pages 8-19–8-21.)
WARNING
POTENTIAL HAZARD
Driving with improperly operating
brakes.
WHAT CAN HAPPEN
You could lose braking ability, which
could lead to an accident.
HOW TO AVOID THE HAZARD
Always check the brakes at the start of
every ride. Do not operate the vehicle if
you find any problem with the brakes. If
a problem cannot be corrected by the
adjustment procedures provided in this
manual, have the vehicle inspected by a
Yamaha dealer.
5-3
Fuel
Make sure there is sufficient gasoline in the
tank.
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
30.0 L
(6.6 Imp gal, 7.9 US gal)
CAUTION:
_
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to internal engine parts, such as the valves
and piston rings, as well as to the exhaust
system.
_
Your Yamaha engine has been designed to
use regular unleaded gasoline with a pump
octane number ([R+M]/2) of 86 or higher, or
research octane number of 91 or higher. If
knocking or pinging occurs, use a different
brand of gasoline or premium unleaded fuel.
Unleaded fuel will give you longer spark plug
life and reduced maintenance cost.
Gasohol
There are two types of gasohol; gasohol containing ethanol and that containing methanol.
Gasohol containing ethanol can be used if
ethanol content does not exceed 10%. Gasohol containing methanol is not recommended
by Yamaha because it may cause fuel system
damage or vehicle performance problems.
5-4
WARNING
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire
and severe injury.
Fuel expands when it heats up. If the
fuel tank is overfilled, fuel could spill out
due to heat from the engine or the sun.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful
not to spill fuel, especially on the engine
or exhaust pipe. Wipe up any spilled fuel
immediately. Be sure the fuel tank cap is
closed securely.
Engine oil
Make sure that the engine oil is at the specified level. Add oil if necessary. (See pages
8-8–8-9 for details.)
CAUTION:
Make sure that no foreign material enters
the crankcase.
Recommended engine oil type and
quantity:
See page 10-3.
Transmission oil
Make sure the transmission oil is at the specified level. Add oil as necessary. (See pages
8-16–8-17 for details.)
Recommended oil:
SAE 90 gear oil
5-5
Accelerator pedal
Remove the key from the main switch.
Make sure that the accelerator pedal operates
properly. It must operate smoothly and fully
spring back when released. If the accelerator
pedal does not operate properly, have a
Yamaha dealer check the pedal.
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
before checking accelerator pedal operation.
Steering
Park on level ground. Turn the steering wheel
to the right and left. Check for excessive free
play, abnormal noises, or a rough feeling. If
the steering does not operate properly, have a
Yamaha dealer check the steering.
Fittings and fasteners
Always check the tightness of chassis fittings
and fasteners before a ride. Take the utility
vehicle to a Yamaha dealer or refer to the Service Manual for the correct tightening torques.
Lights
Check the headlights and taillights to make
sure they are in working condition. Repair as
necessary for proper operation.
Switches
Check the operation of all switches. Have a
Yamaha dealer repair as necessary for proper
operation.
5-6
Tires
Checking the tire pressure
Use a tire pressure gauge to measure the tire
pressure.
NOTE:
Measure the tire pressure twice and use the
second reading. Dust or dirt in the gauge
could cause the first reading to be incorrect.
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper
tires, or with improper or uneven tire
pressure.
WHAT CAN HAPPEN
Use of improper tires on this vehicle, or
operation of this vehicle with improper or
uneven tire pressure, may cause loss of
control, increasing your risk of accident.
HOW TO AVOID THE HAZARD
1. The tires listed below have been approved by Yamaha Motor Manufacturing Corporation of America for
this model. Other tire combinations
are not recommended. Use the same
brand of tires on all four wheels.
Manufacturer Size
Front Kenda or Maxxis 18 × 8.5-8 / 4 PLY
Rear Kenda or Maxxis 18 × 8.5-8 / 6 PLY
5-7
2. The tires should be set to the recommended pressure:
Recommended tire pressure
●
Front 150 kPa (1.53 kgf/cm
Rear 207 kPa (2.11 kgf/cm
2
, 21 psi)
2
, 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 kgf/cm
Rear 250 kPa (2.5 kgf/cm
2
, 36 psi)
2
, 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.
Tire wear limit
When the tire groove decreases to 1 mm
(0.04 in) due to wear, replace the tire.
a. Tire wear limit
5-8
1-
OPERATION
Starting a cold engine
1. With the parking brake applied, shift the
drive select lever to “F” for forward, or “R”
for reverse.
2. Turn the main switch to “ON” or “ON ”.
1
2
3
4
5
6
7
8
CAUTION:
Do not shift from “F” forward to “R” reverse while the utility vehicle is moving.
WARNING
POTENTIAL HAZARD
Depressing accelerator pedal while
turning on the main switch.
WHAT COULD HAPPEN
The utility vehicle could start moving
unexpectedly.
HOW TO AVOID THE HAZARD
Keep foot away from accelerator pedal
while turning on the main switch.
6-1
9
10
11
12
13
14
3. Pull the starter (choke) knob out and hold
1
it while starting a cold engine. Release
the starter (choke) knob after the engine
starts.
1
1. Starter (choke) knob
NOTE:
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 engine will start and the utility vehicle
will start to move.
1. Accelerator pedal
NOTE:
The parking brake automatically releases
when the accelerator pedal is depressed.
6-2
2
1
Starting a warm engine
To start a warm engine, refer to the “Starting a
cold engine” section. The starter (choke)
should not be used.
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:
Do not hold the utility vehicle on an incline
with the accelerator – use the brake.
6-3
Accessories and loading
Accessories
Accessories can affect the handling and control of your vehicle. Keep the following in mind
when considering an accessory or operating a
vehicle which has accessories.
●
Choose only accessories designed for your
vehicle. Your Yamaha dealer has a variety
of genuine Yamaha accessories. Other accessories may also be available on the
market. However, it is not possible for
Yamaha to test all non-Yamaha accessories, nor have any control over the quality or
suitability of them. Choose a genuine
Yamaha accessory, or one that is equivalent in design and quality.
●
Accessories should be rigidly and securely
mounted. An accessory which can shift position or come off while you are operating
could affect your ability to control the vehicle.
●
Do not mount an accessory where it could
interfere with your ability to control the vehicle. Examples include (but are not limited
to) an object that limits your ability to turn
the steering wheel, one that limits your
view, or one that adversely affects the stability of the vehicle.
●
Use extra caution when driving a vehicle
with accessories. The vehicle may handle
differently than it does without accessories.
6-4
WARNING
POTENTIAL HAZARD
Operating this vehicle with improper
modifications.
WHAT CAN HAPPEN
Improper installation of accessories or
modification of this vehicle may cause
changes in handling which in some situations could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this vehicle through improper installation or use of accessories. All parts and accessories added to
this vehicle should be genuine Yamaha
or equivalent components designed for
use on this vehicle and should be installed and used according to instructions. If you have questions, consult an
authorized Yamaha Golf Car Dealer.
EBU09600
Loading
Cargo or a trailer can change the stability and
handling of a vehicle.
You must use common sense and good judgment when carrying cargo or towing a trailer.
Keep the following points in mind:
●
Never exceed the weight limits shown. An
overloaded vehicle can be unstable.
MAXIMUM LOADING LIMIT
●
Maximum cargo bed load:
363 kg (800 lb)
●
Tow hitch
Tow weight (Including driver,
passenger, vehicle cargo and trailer
and trailer cargo):
590 kg (1300 lb)
Tongue weight: 68 kg (150 lb)
6-5
●
Do not exceed the maximum tongue
weight. You can measure tongue weight
with a bathroom scale. Put the tongue of
the loaded trailer on the scale with the
tongue 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 accident.
●
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 slower you should go.
●
Allow more braking distance. A heavier vehicle takes longer to stop.
●
Avoid making sharp turns unless at very
slow speeds.
●
Avoid hills and rough terrain. Choose terrain carefully. Added weight affects the stability and handling of the vehicle.
6-6
WARNING
POTENTIAL HAZARD
Overloading this vehicle or carrying or
towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling 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.
6-7
1-
DRIVING YOUR VEHICLE
WARNING
GETTING TO KNOW YOUR VEHICLE
This off-highway utility vehicle will handle and
maneuver differently from an ordinary passenger car or other vehicle.
Before you begin to use your vehicle, be sure
you have read this Owner’s/Operator’s Manual completely and understand the operation of
the controls. Pay particular 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.
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 carry a passenger in the cargo
bed. The cargo bed is designed to carry
cargo only.
7-1
Carrying a passenger and cargo can affect
vehicle handling.
The total weight of operator, passenger, accessories, cargo, trailer tongue weight, and
the trailer must not exceed the maximum load
limit.
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 handling 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.
Remain seated and hold on when the vehicle
is in motion. Keep hands and feet inside the
vehicle at all times.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
7-2
LEARNING TO OPERATE YOUR VEHICLE
You should become familiar with the performance characteristics of the vehicle in a large,
flat area that is free of obstacles and other vehicles. Practice control of the accelerator,
brakes, steering, and forward/reverse select
lever. Drive first at slow speed and become
comfortable at that speed before gradually increasing your speed. Take the time to learn
basic operation before attempting more difficult maneuvers.
Set the parking brake. Perform the Pre-Operation Checks on pages 5-2. If the engine is
cold, pull out the choke knob. To start the engine, press the accelerator pedal slowly and
smoothly. The centrifugal clutch will engage
and you will start to accelerate. Avoid higher
speeds until you are thoroughly familiar with
the operation of your vehicle. Release the
starter (choke) knob after the engine starts.
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, reducing control and increasing the possibility of
an accident. The engine stops running when
the accelerator pedal is released.
TURNING YOUR VEHICLE
It is possible for the vehicle to roll over or go
out of control if you attempt sharp, higher
speed turns. You should also be careful making sharp turns on rough terrain. Do not attempt to turn around or make abrupt
maneuvers on slopes.
BRAKING
Braking ability is affected by the type of terrain. In most cases, gradual application of the
brakes is more effective than abrupt braking,
particularly on loose surfaces like gravel. Always allow for greater braking distance on
rough, loose, or slippery surfaces.
7-3
GOING UPHILL
Do not attempt to climb slopes until you have
mastered basic maneuvers on flat ground.
Use proper driving techniques to avoid overturns on hills and slopes. Drive straight up
slopes, and avoid crossing the side of a slope,
which increases your chance of rollover.
Practice first on gentle inclines before attempting slopes. Always check the terrain
carefully before attempting any slope. Use
common sense and remember that some
slopes are too steep for you to climb.
Choose carefully which slopes 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.
WARNING
POTENTIAL HAZARD
Operating on steep slopes.
WHAT CAN HAPPEN
The utility vehicle can overturn more
easily on steep slopes than on level surfaces or gentle inclines.
HOW TO AVOID THE HAZARD
Never operate your vehicle on slopes
too steep for it or your abilities.
Do not drive across the face of a slope.
Go straight up the slope.
Practice on smaller slopes before attempting large slopes.
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 obstacle, or a sharp drop off.
7-4
If you start to lose traction or momentum
when going up a slope, and you decide you
will be unable to continue, use the brakes to
come to a stop. Do not attempt to turn the vehicle around. Instead, back down the hill as
slowly as possible, gently applying the brakes
when necessary.
GOING DOWNHILL
Check the terrain carefully before going down
a slope. When possible, choose a path that
lets you drive your vehicle straight downhill.
Carefully choose your path and drive no faster
than you will be able to react to obstacles that
may appear. If you must turn to avoid an obstacle, do not turn at a sharp angle that could
allow the vehicle to pitch or roll over.
WARNING
POTENTIAL HAZARD
Going down a slope improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the
vehicle to overturn.
HOW TO AVOID THE HAZARD
Always check the terrain carefully before you start down any slope. Never go
down a slope at high speed. Avoid going down a slope at an angle that would
cause the vehicle to lean sharply to one
side. Go straight down the slope where
possible.
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
cause the vehicle to start sliding.
If you start to slide or skid, try to steer in the direction the vehicle is sliding to help you regain
control.
7-5
If you must turn on the slope to avoid an obstacle, do so slowly and carefully. If the vehicle starts to tip, gradually steer in the downhill
direction if there are no obstacles in your path.
As you regain proper balance, gradually steer
again in the direction you want to go.
ROUGH TERRAIN
Avoid operating over rough terrain. Look for
obstacles that could cause damage to the vehicle or could lead to a rollover or accident.
Avoid jumping the vehicle as injury, loss of
control, and damage to the vehicle could occur.
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
slowly and be extra careful on unfamiliar terrain, so you will have enough time
to react to hidden rocks, bumps, or
holes in your path.
7-6
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
the vehicle might hit, causing an accident, or
for brush that might enter the vehicle as you
pass and strike the driver or passenger.
7-7
EBU05150
1-
PERIODIC MAINTENANCE AND
ADJUSTMENT
Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and
most efficient condition possible. Safety is an
obligation of the vehicle owner. The most important points of vehicle inspection, adjustment and lubrication are explained on the
following pages.
WARNING
POTENTIAL HAZARD
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts
of the body, causing injury.
Electrical components can cause
shocks or can start fires.
HOW TO AVOID THE HAZARD
Turn off the engine and remove the main
switch key when performing maintenance unless otherwise specified.
Have a Yamaha dealer perform service if
you are not familiar with vehicle service.
EBU05620
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 manual is intended to provide you, the owner, with
the necessary information for completing your
own preventive maintenance and minor repairs.
NOTE:
_
If you do not have a torque wrench available
during a service operation requiring one, take
your vehicle to a Yamaha dealer to check the
torque settings and adjust them as necessary.
_
8-1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PERIODIC MAINTENANCE/LUBRICATION
NOTE:
● For vehicles not equipped with an odometer or an hour meter, follow the month maintenance intervals.
● For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in
mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed.
ITEM ROUTINE
Valves*
Spark plug
Air filter element and pre-air filter
element
Carburetor*
Exhaust system*
Fuel line*
Engine oil
Transmission oil
Brakes*
Accelerator pedal*
V-belt*
Whichever
comes first
• Check valve clearance.
• Adjust if necessary.
• Check condition.
• Adjust gap and clean.
• Replace if necessary.
• Clean.
• Replace if necessary.
• Check starter operation.
• Adjust if necessary.
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
• Check fuel hose for cracks or damage.
• Replace if necessary.
• Replace (warm engine before draining).
• Check oil level/oil leakage.
• Replace. Every 4 years
• Check operation/brake shoe wear.
• Correct if necessary. Replace shoes if worn to the limit.
• Check operation and free play.
• Check operation.
• Check for wear, cracks, or damage.
month 1 6 6 12
km
(mi)
hours 20 125 125 250
INITIAL EVERY
160
(100)
1,000
(600)
Every 20–40 hours
(More often in wet or dusty areas.)
1,000
(600)
8-2
2,000
(1,200)
ITEM ROUTINE
Wheels*
Wheel bearings*
Front and rear suspension*
Steering system*
Engine mounts*
Fittings and fasteners*
* Since these items require special tools, data and technical skills have a Yamaha dealer perform the service.
• Check balance/damage/runout.
• Repair if necessary.
• Check bearing assemblies for looseness/damage.
• Replace if damaged.
• Check operation and for leakage.
• Correct if necessary.
• Check operation and for looseness/Replace if damaged.
• Check toe-in/Adjust if necessary.
• Check for cracks or damage.
• Check bolt tightness.
• Check all chassis fittings and fasteners.
• Correct if necessary.
Whichever
comes first
month 1 6 6 12
km
(mi)
hours 20 125 125 250
INITIAL EVERY
160
(100)
1,000
(600)
1,000
(600)
2,000
(1,200)
8-3
EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS
Item Acronym
●
CARB. ASSY., LH., JT., CARBURETOR
CARB (Carburetor)
2 & JT., CARBURETOR 1
●
T.C.I. MAGNETO ASSY. & PLUG, SPARK El (Electronic Ignition)
●
CRANKCASE 1 & HEAD, CYLINDER 1 PCV (Positive Crankcase 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.
8-4
Seat
Lift the seat to check the fuel level and add fuel.
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. Seat 2. Prop rod
Cargo bed
Lift the cargo bed to service the engine.
1. Pull the cargo bed release lever towards
the rear.
2. Lift the cargo bed.
1. Cargo bed release lever
CAUTION:
Do not lift the cargo bed by the release lever. Damage to the lever may occur.
8-5
1. Prop rod
WARNING
Remove the key from the main switch
●
and apply the parking brake before
lifting the cargo bed. Otherwise, the
utility vehicle could move unexpectedly.
Never operate the utility vehicle with
●
the cargo bed in the up position. Injury 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 cargo bed and seat backs.
8-6
a
Spark plug inspection
Periodically remove and inspect the spark
plug. Dirty or worn spark plugs can cause
poor engine performance.
2
1
1. Spark plug 2. Spark 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.
Specified spark plug:
BPR2ES (NGK)
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
a. Spark plug gap
8-7
3. Clean the gasket and plug surfaces and
install the spark plug, and then tighten it
to the specified torque.
Spark plug torque:
20 Nm (2.0 m·kgf, 14.5 ft·lbf)
WARNING
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.
Engine oil
Checking the engine oil level
1. Place the utility vehicle on a level surface.
2. Lift the cargo bed. (See page 8-5–8-6 for
lifting and lowering procedures.)
3. Remove the dipstick, wipe it off with a
clean rag, and then insert the dipstick
back into the dipstick hole.
1
1. Dipstick
8-8
NOTE:
Insert the dipstick into the crankcase until it
firmly seats in place.
4. Remove the dipstick and check the oil
level.
3
MIN
2
MAX
1
1. Dipstick
2. Maximum level mark 3. Minimum level mark
5. The oil level should be between the maximum and minimum marks. If the level is
low, add oil to raise it to the specified level.
CAUTION:
Be sure no foreign material enters the
crankcase.
Replacing the engine oil
1. Place the utility vehicle on a level surface.
2. Place a container under the engine.
3. Remove the engine oil filler cap and engine oil drain bolt to drain the oil.
1
1. Engine oil filler cap
8-9
1. Engine oil drain bolt
NOTE:
●
The engine oil can be drained quickly if
the utility vehicle has been operated for
several minutes to warm up the engine
before changing the oil.
●
Dispose of used oil in an environmentally
safe manner, such as taking oil to an oil
collection station.
4. Install the drain bolt along with a new
drain bolt gasket, and then tighten it to
the specified torque.
Tightening torque:
Drain bolt:
30 Nm (3.0 m·kgf, 22 ft·lbf)
5. Add the specified amount of engine oil,
and then install the oil filler cap.
Recommended oil:
See page 10-3.
Oil change quantity:
0.9 L (0.79 Imp qt, 0.95 US qt)
CAUTION:
Be sure no foreign material enters the
crankcase.
8-10
6. Operate the utility vehicle for several minutes to warm up the engine, and then
check for oil leakage.
CAUTION:
If oil leakage is found, check for the cause.
Air filter element cleaning
To remove the air filter elements:
1. Unlatch the air filter cover holders and remove cover.
1
2
1
1
2. Lift the air filter element and pre-air filter
element out of the air filter case.
1
2
1. Air filter element
2. Pre-air filter element
CAUTION:
Be careful not to drop anything into the air
inlet.
1. Air filter cover holders 2. Air filter cover
8-11
Inspection and cleaning:
3. Wash the pre-air filter element in soap
and water. Allow it to dry.
1
1. Soap and water 2. Pre-air filter element
2
CAUTION:
Do not wring out the pre-air filter element,
this could cause it to tear.
4. Check the air filter element. If damaged
or dirty, replace it.
CAUTION:
Do not attempt to clean the air filter element with compressed air. It could be
damaged.
5. To replace the elements, reverse the
above steps.
CAUTION:
The “UP” mark on the pre-air filter element
should face up.
8-12
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.
Y-60
Inspection:
To inspect the drive belt, check for frayed edges
or tears, and measure the drive belt as shown.
If the belt shows excessive wear or damage or
if it reaches the wear limit of 27.9 mm (1.10 in),
replace the belt with a new one.
a
a. Wear limit
5. To install the drive belt, reverse the
above steps.
4. Remove the drive belt from the primary
sheave.
NOTE:
Roll the drive belt over the secondary sheave
when installing.
8-13
Battery
WARNING
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 battery doesn’t require the addition of water. If the battery loses its charge, have an experienced mechanic charge it.
8-14
Fuse replacement
The fuses are located under the passenger’s
side of the seat. (See page 8-5 for seat opening and closing procedures.)
If a fuse is blown, replace it.
WARNING
Be sure to use the specified fuse. Using a
wrong fuse can cause electrical system
damage and create a fire hazard.
1
2
3
CAUTION:
When replacing a fuse be sure the main
switch is turned off to prevent accidental
short-circuiting.
1. Main fuse 2. Auxiliary DC jack fuse
3. Headlight/signaling system fuse
Replacement Fuse:
Main fuse: 20 A
Headlight/signaling system fuse: 10 A
Auxiliary DC jack fuse: 10 A
8-15
Transmission oil
Transmission oil measurement
1. Place the vehicle on a level surface.
2. Remove the transmission oil filler plug
and 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 recommended type to raise it to the specified level.
1
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
Oil quantity:
0.42 L (0.37 Imp qt, 0.44 US qt)
8-16
4. Check for oil leakage. If oil leakage is
found, check for the cause.
NOTE:
For transmission oil replacement, consult a
Yamaha dealer.
Wheel removal
To remove and install a wheel on your utility
vehicle:
1
1
1. Nut (× 4)
1. With the wheels blocked to prevent the
utility vehicle from moving, loosen the
wheel nuts.
2. Elevate the utility vehicle with a jack and
remove the wheel nuts.
3. Remove the wheel.
8-17
Wheel installation
1. Install the wheel and the nuts.
NOTE:
_
Tapered nuts are used for both 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:
Front: 88 Nm (8.8 m·kgf, 64 ft·lbf)
Rear: 88 Nm (8.8 m·kgf, 64 ft·lbf)
8-18
Brake adjustment
The brakes on your utility vehicle are selfadjusting.
Before you operate the vehicle, press down
on the brake pedal several times to make sure
the brakes are functioning properly.
WARNING
Consult your Yamaha 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
8-19
2. Check the brake pedal free play by
pressing against the pedal with two fingers (using light force) and measuring
the distance the pedal travels before resistance is felt.
Brake pedal free play:
20–25 mm (0.79–0.98 in)
8
1
7
1
6
1
5
a
1
4
1
3
1
2
1
11
10
9
8
7
3. 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.
2
1
a. Brake pedal free play
1. Locknut 2. Adjusting nut
Tightening torque:
17 N·m (1.7 m·kgf, 12 ft·lbf)
8-20
WARNING
Do not overtighten the locknut. The self
adjusters may not operate properly, reducing braking performance.
Replacing a headlight bulb
If a headlight bulb burns out, replace it as follows.
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 tabs.
8-21
1. Headlight bulb holder tab (× 2)
3. Insert a new headlight bulb into the bulb
holder, and then hook the headlight bulb
holder tabs.
4. Install the headlight bulb holder by turning 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.
1. Headlight beam adjusting screw
8-22
Replacing a taillight bulb
If a taillight bulb burns out, have a Yamaha
dealer replace it.
8-23
1-
CLEANING AND STORAGE
Perform the following preparations when storing your utility vehicle for extended periods of
time:
NOTE:
Turn main switch key to “OFF” position, remove key, and store key in a safe place.
Draining the fuel
1. Fill the fuel tank with fresh fuel and add
the specified amount of Yamaha Fuel
Stabilizer and Conditioner or equivalent
product. Operate the utility vehicle for at
least 5 minutes to distribute treated fuel
through the fuel system.
2. Drain the carburetor float chamber into a
clean container by loosening the drain
bolt; this will help prevent fuel deposits
from building up. Pour the drained fuel
into the fuel tank.
Specified amount:
1 oz of stabilizer for each gallon of fuel
(7.5 cc of stabilizer for each liter of fuel)
NOTE:
Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system. Consult a Yamaha dealer if the fuel system needs
to be drained instead.
Engine preparation
1. With the key removed and the spark plug
lead disconnected, turn the clutch by
hand until compression is felt. This puts
the valves in the closed position.
2. Remove the spark plug, pour about one
tablespoon of SAE 10W30 or 20W40
motor oil in the spark plug hole and reinstall the spark plug. Ground the spark
plug wire and turn the engine over several times to coat the cylinder wall with oil.
3. Lubricate all control cables.
9-1
Chassis preparation
1. Block up the frame to raise 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.
NOTE:
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.
1
2
3
4
5
6
Battery preparation
1. Remove the battery from the utility vehicle and store it in a cool, dry place that
stays between 0 °C (32 °F) and 30 °C
(90 °F).
2. Have the battery recharged every 60–90
days to keep it fully charged. The battery
must be kept fully charged to avoid damage.
7
8
9
10
11
12
13
14
9-2
1-
SPECIFICATIONS
Model G23A
Dimensions:
Overall length 2915 mm (114.7 in)
Overall width 1243 mm (48.9 in)
Overall height (steering height) 1155 mm (45.5 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)
10-1
Model G23A
Weight:
Dry weight (without battery) 386 kg (851 lb)
Performance:
Maximum speed 19 km/h (12 mph)
Minimum turning radius 3.3 m (130 in)
Seating capacity 2 persons
Engine:
Engine type Air-cooled 4-stroke, OHV
Cylinder arrangement Forward-inclined single cylinder
Displacement 357 cm
3
Bore x stroke 85 x 63 mm (3.30 x 2.48 in)
Compression ratio 8.0:1
Starting system Electric starter
Ignition system TCI Magneto
Spark plug type/manufacturer BPR2ES/NGK
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
Lubrication system Splash
1
2
3
4
5
6
7
8
9
10
11
12
13
14
10-2
Model G23A
Engine oil:
Type YAMALUBE 4 (10W30) or SAE 10W30
Recommended engine oil classification API Service SE type or higher
Quantity:
Oil change 0.9 L (0.79 Imp qt, 0.95 US qt)
Transmission:
Type V-belt automatic centrifugal
V-belt width and outer line length 31 x 1010 mm (1.22 x 39.76 in)
V-belt wear limit 27.9 mm (1.10 in)
Transmission oil:
Type SAE 90 gear oil
Quantity 0.42 L (0.37 Imp qt, 0.44 US qt)
Steering system:
Type Worm and pin
10-3
Model G23A
Brakes:
Brake system Mechanical drum brake on front and rear wheels with
self-adjusters
Type of brake Dual internal expanding shoe
Leading/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:
2
Front 140–160 kPa (1.4–1.6 kgf/cm
Rear 197–217 kPa (2.0–2.2 kgf/cm
, 20–23 psi)
2
, 29–31 psi)
Battery: BCI group 24 (52 AH, 20 hr rate)
RC: minimum 75 min
CCA: minimum 400A
10-4
Model G23A
Bulb voltage, wattage × quantity:
Headlight 12 V, 30 W / 30 W × 2
Taillight Sealed beam × 2
Indicator light:
Engine oil level warning light 12 V, 3.4 W × 1
Specified fuses:
Main fuse 20 A
Headlight/signaling system fuse 10 A
Auxiliary DC jack fuse 10 A
10-5
1-
MAINTENANCE RECORD
Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the maintenance work is required. It is not acceptable proof of maintenance
work.
1
2
3
4
MAINTENANCE
INTERVAL
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
60 10,000 (6,000) 1,250
DATE OF
SERVICE
MILEAGE
SERVICING DEALER
NAME AND ADDRESS
11-1
REMARKS
5
6
7
8
9
10
11
12
13
14
PRINTED IN USA
2004.06-0.3×2 CR
(E)
Loading...