Yamaha U-MAX MEDIUM DUTY I ELECTRIC-G23-E User Manual
READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S/OPERATOR’S MANUAL
G23E
LIT-19626-01-18
JU6-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
G23E
OWNER’S/OPERATOR’S
MANUAL
© 2004 by Yamaha Golf-Car Company
2nd edition
All rights reserved. Any reprinting
or unauthorized use without the
written permission of
Yamaha Golf-Car Company
is expressly prohibited.
Printed in U.S.A.
P/N LIT-19626-01-18
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
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
Drive select switch........................... 4-2
Accelerator pedal ............................ 4-3
Brake pedal .....................................4-3
Parking brake pedal ........................ 4-4
Horn button...................................... 4-4
Auxiliary DC jack ............................. 4-5
Cargo bed........................................ 4-6
Tow switch....................................... 4-9
Trailer hitch bracket .........................4-9
Transmitter unit ..............................4-10
PRE-OPERATION CHECKS ............5-1
5
Pre-operation check list ...................5-2
Brakes..............................................5-3
Batteries...........................................5-3
Transmission oil...............................5-4
Accelerator pedal.............................5-4
Steering............................................5-5
Fittings and fasteners ......................5-5
Lights................................................5-5
Switches...........................................5-5
Tires .................................................5-5
OPERATION .....................................6-1
6
Starting.............................................6-1
Stopping...........................................6-2
Accessories and loading..................6-3
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.... 7-6
PERIODIC MAINTENANCE AND
8
ADJUSTMENT ................................. 8-1
Owner’s/Operator’s Manual............ 8-1
Periodic maintenance/
lubrication...................................... 8-2
Seat................................................. 8-3
Cargo bed ....................................... 8-3
Batteries .......................................... 8-5
Battery care..................................... 8-5
Battery charging.............................. 8-7
Battery installation........................... 8-9
Fuse replacement ......................... 8-11
Transmission oil ............................ 8-12
Wheel removal .............................. 8-13
Wheel installation.......................... 8-14
Brake adjustment .......................... 8-15
Brake pedal free play
adjustment ...................................8-15
Replacing a headlight bulb............ 8-17
Adjusting a headlight beam........... 8-18
Replacing a taillight bulb ...............8-19
CLEANING AND STORAGE ............ 9-1
9
Chassis preparation ........................ 9-1
Battery storage care ........................ 9-1
SPECIFICATIONS ..........................10-1
10
MAINTENANCE RECORD............. 11-1
11
1-
LOCATION OF THE WARNING AND
SPECIFICATION LABELS
1-1
Read and understand all of the labels on your
BATTERY INSTALLATION AND
WIRE LEAD CONNECTION
vehicle. 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 dealer.
1
ON
FORWARD
ON
REVERSE
JU6-K7761-00
OFF
YAMAHA
2
!
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.
WARNING
ATTENTION
1-2
3
BATTERY INSTALLATION AND
WIRE LEAD CONNECTION
TO MOTOR
CONTROL -
TO RELAY
3
4
5
6
7
8
9
10
11
12
13
14
JU6-K7765-00YAMAHA
4
WARNING
WARNING
5
WARNING
Keep hands, body, other
persons away when closing bed.
Do not operate the vehicle
YAMAHA 5UG-K7764-00
with bed up.
7
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
8
WARNING
Improperly loading a trailer and failure to use extra care
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
6
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
9
JU5-K7766-01
1-3
1-
DESCRIPTION AND VEHICLE IDENTIFICATION
FEATURES
1. Steering wheel
2. Seat
3. Batteries
4. Taillight
5. Rear tire
6. Receptacle
7. Transmitter unit
8. Front tire
9. Headlight
10. Accelerator pedal
11. Brake pedal
12. Parking brake pedal
13. Horn button
14. Auxiliary DC jack
15. Main switch
16. Drive select switch
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 affixed 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
Drive select switch
The drive select switch is used for driving the
utility vehicle either forward or in reverse.
After coming to a complete stop, push the
“FORWARD” or “REVERSE” side of the
switch.
1. Drive select switch
NOTE:
The back-up buzzer will sound when the drive
select switch is set to “REVERSE.”
4-2
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
Brake pedal
Press the brake pedal down to slow or stop
the utility vehicle.
1. Brake pedal
4-3
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.
Horn button
Step on the horn button to sound the horn.
1. Horn button
4-4
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
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.
4-5
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.
Do not use an automotive cigarette
●
lighter or other accessories with a
plug that gets hot because the jack
can be damaged.
Cargo bed
1. Cargo bed
4-6
Opening and closing the tailgate
Lifting and lowering the 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.
1. Cargo bed release lever
1. Prop rod
4-7
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