LIT 19626 11 00 · 2016-07-10 · OWNER’S/ OPERATOR’S MANUAL UTILITY CAR LIT-19626-11-00 YAMAHA...

OWNER’S/OPERATOR’SMANUAL

UTILITYCAR

LIT-19626-11-00

YAMAHA MOTORMANUFACTURING CORP.

OF AMERICAJR6-F8199-00

Printed in U.S.A.

KCC

G21A

Yamaha Motor Corp., USA

Cypress, California made in

10/31/00

LIT196261100

USA

*LIT196261100*

1PC - G21A O/M

G21A O_M Cover 11/2/00, 10:22 PM1

LIT-CALIF-65-01

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birthdefects or other reproductive harm.

YAMAHA

WARNING

G21A O_M IFC 8/8/00 7:56 AM Page 1

1

2

3

4

5

6

7

8

9

10

11

iUTILITY

INTRODUCTIONCongratulations on your purchase ofa Yamaha utility car. This manual con-tains information you will need forproper operation, maintenance, andcare of your utility car. A thoroughunderstanding of these simpleinstructions will help you to obtainmaximum enjoyment from your newYamaha.

If you have any questions about theoperation or maintenance of your util-ity car, please consult a Yamaha deal-er.

TECHNICAL SERVICE DEPTGOLF CAR SALES GROUP

YAMAHA MOTORMANUFACTURING CORP OF

AMERICA

G21AOWNER’S/OPERATOR’S

MANUAL© 2000 by Yamaha Motor

Manufacturing Corporationof America1st edition

All rights reserved. Any reprintingor unauthorized use without the

written permission ofYamaha Motor Manufacturing

Corporation of Americais expressly prohibited.

Printed in U.S.A.P/N LIT-19626-11-00

LIT_19626_11_00 3/22/01 1:06 PM Page i

ii UTILITY

IMPORTANT MANUAL INFORMATION

� Yamaha continually seeks ad-vancements in product design andquality; therefore, while this manualcontains the most current productinformation available at the time ofprinting, there may be minor dis-crepancies between your utility carand this manual. If you have any questions concerning thismanual, please consult yourYamaha dealer.

� This manual should be considereda permanent part of your utility carand should remain with the carwhen resold.

Read and understand this manualcompletely before operating yourutility car.

WARNING

NOTE:Particularly important information isdistinguished in this manual by the fol-lowing notations:

The Safety Alert Symbol meansATTENTION! BE ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING in-structions could result in severeinjury or death to the utility car occupants, a bystander, or a person inspecting or repairing the utility car.

This message describes specialprecautions that must be taken toavoid damage to the utility car.

This message provides additional keyinformation.

NOTE:

CAUTION

WARNING

LIT_19626_11_00 3/22/01 1:06 PM Page ii

iiiUTILITY

1

WARRANTY

CONTENTS

1

IMPORTANT LABELS 2

MAINTENANCE SAFETY PROGRAM 4

MAINTENANCE 8

STORAGE

SPECIFICATIONS

9

WIRING 11

OPERATION 7

PRE-OPERATION CHECKS 6

CONTROLS 5

OPERATOR SAFETY 3

10

LIT_19626_11_00 3/22/01 1:06 PM Page iii

1

2

3

4

5

6

7

8

9

10

11

1-1 UTILITY

WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrantsthat any new G21A Utility Vehicle purchased froman authorized Yamaha dealer in the United States,will be free from defects in material and workman-ship for the period of time stated herein, subject tothe stated limitations.

THE PERIOD OF WARRANTY for any G21A UtilityVehicle will be one year from date of purchase forparts and labor.

The warranty shall cover the entire car except forbatteries, tires and rims, which are warranted bytheir respective manufacturers.

DURING THE PERIOD OF WARRANTY any autho-rized Yamaha Golf Car Dealer will, free of charge,repair or replace, at Yamaha’s option, any partadjudged defective by Yamaha due to faulty work-manship or material from the factory. Parts used inwarranty repairs will be warranted for the balance ofthe machine’s warranty period. All parts replacedunder warranty become property of Yamaha MotorCorporation, U.S.A.

GENERAL EXCLUSIONS from this warranty shallinclude any failures caused by:

a. Abnormal strain, neglect, or abuse, includinglack of proper maintenance, and use contraryto 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 Utility

Vehicle’s condition, operation, performance, ordurability.

f. Damage due to improper transportation.g. Acts of God (i.e. lightning, hail damage, flooding,

fire, etc.)

SPECIFIC EXCLUSIONS from this warranty shallinclude any parts replaced due to normal wear orroutine maintenance, including oil, air filter ele-ments, brake shoes, spark pugs, starter and clutchdrive belts, and bed damage such as scratches,dents, or deformation. Any charges incurred intransporting a Utility Vehicle to and from an autho-rized Yamaha Golf Car Dealer for service or in per-forming field service is also excluded from this war-ranty.

THE CUSTOMER’S RESPONSIBILITY under thiswarranty shall be to:1. Operate and maintain the Utility Vehicle as

specified in the appropriate Owner’s/Operator’s Manual;

2. Give notice to an authorized Yamaha dealer ofany and all apparent defects within ten (10)days after discovery, and make the machineavailable at that time for inspection and repairsby the dealer’s authorized representative.

WARRANTY TRANSFER: To transfer any remain-ing warranty from the original purchaser to any sub-sequent purchaser, it is imperative that the machinebe inspected and registered for warranty by anauthorized Yamaha Golf Car Dealer. In order for thiswarranty to remain in effect, this inspection and reg-istration must take place within ten (10) days aftertransfer. An inspection and registration fee will becharged for this service.

YAMAHA MOTOR CORPORATION, U.S.A. MAKESNO OTHER WARRANTY OF ANY KIND,EXPRESSED OR IMPLIED. ALL IMPLIED WAR-RANTIES OF MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE WHICH EXCEEDTHE OBLIGATIONS AND TIME LIMITS STATED INTHIS WARRANTY ARE HEREBY DISCLAIMEDBY YAMAHA MOTOR CORPORATION, U.S.A.AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG AN IMPLIED WARRANTY LASTS, SOTHE ABOVE LIMITATION MAY NOT APPLY TOYOU. ALSO EXCLUDED FROM THIS WARRANTYARE ANY INCIDENTAL OR CONSEQUENTIALDAMAGES INCLUDING LOSS OF USE. SOMESTATES DO NOT ALLOW THE EXCLUSION ORLIMITATION OF INCIDENTAL OR CONSEQUEN-TIAL DAMAGES, SO THE ABOVE EXCLUSIONMAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGALRIGHTS, AND YOU MAY ALSO HAVE OTHERRIGHTS WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA Newnan, Georgia 30265-1320

Effective Date: 10/1/00

YAMAHA MOTOR CORPORATION, U.S.A.G21A UTILITY VEHICLE

LIMITED WARRANTY

LIT_19626_11_00 3/22/01 1:06 PM Page iv

WARRANTY

1-2UTILITY

In complance with the California Air ResourcesBoard, Yamaha Motor Manufacturing Corporation ofAmerica is pleased to explain the emission controlsystem warranty on your 1996 or later specialtyvehicle engine. New Yamaha speciality vehicleengines must be designed, built and equipped tomeet stringent anti-smog standards. Yamaha mustwarrant the emission control system on your spe-ciality vehicle engine for the periods of time listedbelow provided there has been no abuse, neglect orimproper maintenance of your speciality vehicleengine.

Your emission control system may include partssuch as the carburetor or fuel-injection system, theignition system, and catalytic converter. Also includ-ed may be hoses, belts, connectors and other emis-sion-related assemblies.

Where a warrantable condition exists, Yamaha willrepair your specialty vehicle engine at no cost to youincluding diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGEThe 1996 and later specialty vehicle engines arewarranted for two years. If any emissions-relatedpart on your engine is defective, the part will berepaired or replaced by Yamaha.

OWNER’S WARRANTY RESPONSIBILITIES� As the specialty vehicle engine owner, you are

responsible for the performance of the requiredmaintenance listed in your owner’s manual.Yamaha recommends that you retain all receiptscovering maintenance on your specialty vehicleengine, but Yamaha cannot deny warranty solelyfor the lack of receipts or for your failure to ensurethe performance of all scheduled maintenance.

� As the specialty vehicle engine owner, youshould also be aware that Yamaha may deny youwarranty coverage if your specialty vehicleengine or a part has failed due to abuse, neglect,improper maintenance or unapproved modifica-tions.

� You are responsible for presenting your specialtyvehicle engine to a Yamaha dealer as soon as aproblem exists. The warranty repairs should becompleted in a reasonable time, not to exceed 30days.

If you have any questions regarding your warrantyrights and responsibilities, you should contact theYamaha Customer Relations Department at (770) 254-4164.

Yamaha Motor Manufacturing Corporation ofAmerica warrants to the ultimate purchaser andeach subsequent purchaser thereafter that eachnew 1996 and later model year specialty vehicleengine certified for sale is:

1. Designed, built, and equipped so as to conform,at the time of sale, with all applicable regula-tions adopted by the California Air ResourcesBoard, and

2. All warranted parts are free from defects inmaterial and workmanship for the warrantyperiod of the specialty vehicle engine or theperiod prior to the first scheduled replacementpoint of the warranted part as required by themaintenance schedule, if applicable, whicheveris less. A defect exists when a deficiency inmaterial or workmanship is such that an emis-sion-related warranted part does not functionas designed.

The warranty period begins on the date that thespecialty vehicle engine is delivered to an ultimatepurchaser 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 systemCold start enrichment system

2. Air Induction SystemControlled hot air intake systemIntake manifold

YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA

SPECIALTY VEHICLE ENGINESEMISSION CONTROL WARRANTY

YOUR WARRANTY RIGHTS AND OBLIGATIONS

1

2

3

4

5

6

7

8

9

10

11

LIT_19626_11_00 3/22/01 1:06 PM Page v

WARRANTY

1

2

3

4

5

6

7

8

9

10

11

1-3 UTILITY

3. Ignition SystemSpark plugs *Magneto or electronic ignition systemSpark advance/retard system

4. Exhaust Gas Recirculation (EGR) SystemEGR valve body, and carburetor spacer ifapplicableEGR rate feedback and control system

5. Air Injection SystemAir pump or pulse valveValves affecting distribution of flowDistribution manifold

6. Catalyst or Thermal Reactor SystemCatalytic converterThermal reactorExhaust manifold

7. Particulate ControlsTraps, filters, precipitators, and any otherdevice used to capture particulate emissions

8. Miscellaneous Items Used in Above SystemsVacuum, temperature, and time sensitivevalves and switchesElectronic controlsHoses, belts, connectors, and assemblies

9. Engine components damaged due to a failureunder warranty of a warranted part.

* The original spark plug(s) are warranted for theperiod of replacement indicated in theOwner’s/Operator’s Manual and not the useful life ofthe specialty vehicle engine (see your Owner’sManual).

DURING THE PERIOD OF THIS WARRANTY

Yamaha Motor Manufacturing Corporation ofAmerica will repair or replace any warranted partdeemed defective by Yamaha during the scope ofthe warranty without charge to the owner, includingparts, labor, and diagnosis. This work must be doneat an authorized Yamaha dealer. Give notice to anauthorized Yamaha dealer of any apparent defect(s)within a reasonable period of time after discovery.The specialty vehicle engine must be made avail-able for inspection by an authorized Yamaha dealer.

OWNER’S RESPONSIBILITY: The owner of thespecialty vehicle engine is responsible for the per-formance of required maintenance (see yourOwner’s/Operator’s Manual). Receipts and mainte-nance records covering the performance of regularmaintenance should be retained in the event ques-tions arise concerning maintenance. The receiptsshould be transferred to each subsequent owner ofthis specialty vehicle engine.

The emission control systems of your Yamaha spe-cialty vehicle engine were designed, built, tested,and certified as being in conformity with Californiaemission control regulations using genuine Yamahaparts. Accordingly, it is recommended that anyreplacement part(s) used for maintenance, replace-ment, or repair of emission control systems beYamaha parts. The owner may elect to have main-tenance, replacement, or repair of the emissioncontrol devices and systems performed by anyrepair establishment or individual, and may elect touse parts other than Yamaha parts for such mainte-nance, replacement, or repair without invalidatingthis warranty. However, the cost of such service orparts will not be covered under the warranty.

EXCLUSIONS: No warranty coverage will beallowed if the part(s) failure was caused byowner/operator abuse, neglect, tampering, improp-er adjustment unless performed by a dealer duringwarranty repair work, modification, misuse, alter-ation, or improper maintenance (see your Owner’s/Operator’s Manual).

Use of parts which are not qualitatively equivalent togenuine Yamaha parts, improper service, or lack ofrequired maintenance which causes failure of awarranted part may constitute abuse and/or improp-er service, thereby invalidating warranty liabilityhereunder.

This warranty does not cover damage resulting fromaccidents, acts of nature, or other events or occur-rences beyond the control of Yamaha. YamahaMotor Manufacturing Corporation of Americaexpressly disclaims responsibility for any and allconsequential damages, such as loss of time,inconvenience, loss of use of the specialty vehicle,or commercial loss.

Yamaha Motor Manufacturing Corporation ofAmerica1000 Hwy. 34 EastNewnan, GA 30265

LIT_19626_11_00 3/22/01 1:06 PM Page vi

1

2

3

4

5

6

7

8

9

10

11

2-1UTILITY

IMPORTANT LABELS

1

2

Y-100

6

5

9

3

4 SAFETY AND INSTRUCTION LABELS

Please read the followinglabels carefully beforeoperating your utility car,and promptly replace anylabels which become dam-aged or removed.

WARNING

2

1

3

6

5

4

LIT_19626_11_00 3/22/01 1:07 PM Page 2-1

1

2

3

4

5

6

7

8

9

10

11

2-2 UTILITY

IMPORTANT LABELS

Y-1017 8

Y-102a

JR6-

0000

00

UTILITY CAR SERIALNUMBERThe utility car serial number isstamped in the location shown.

The first three digits of the serial num-ber are for model identification; theremaining digits are the unit produc-tion number. Keep a record of thesenumbers for reference when orderingparts from a Yamaha dealer.

NOTE:

Y-851

9

Y-852

9

7 8

LIT_19626_11_00 3/22/01 1:07 PM Page 2-2

1

2

3

4

5

6

7

8

9

10

11

3-1UTILITY

OPERATOR SAFETY!

Y-123

Y-68

Y-8

Yamaha utility cars are designed to besimple to operate. However, be sure toobserve the following:

BEFORE OPERATINGTHE UTILITY CAR� Read this Owner’s/Operator’s man-

ual and all safety and instructionlabels on the utility car before oper-ating.

� Perform the pre-operation checksfound in Section 6 of this manual.

� Only authorized people should drivethe utility car, from the driver’s sideonly, and only in designated areas.

� Do not allow more than two peopleto ride in the utility car.This utility caris restricted to two occupants.

� Do not operate the utility car whileunder the influence of alcohol ordrugs; their affect on vision andjudgment make operating a utilitycar dangerous.

� Do not operate the utility car on pub-lic streets, roads or highways. Suchuse is prohibited by law, and dan-gerous. Operation on public roadscan result in collision with othervehicles.

WHILE OPERATING THEUTILITY CAR� Keep your entire body inside the util-

ity car, remain seated, and hold onwhen the car is in motion.

� Do not start the utility car until alloccupants are seated.

LIT_19626_11_00 3/22/01 1:07 PM Page 3-1

1

2

3

4

5

6

7

8

9

10

11

3-2 UTILITY

� Keep your hands on the steeringwheel and your eyes on the pathahead.

� Use extra care in congested areasor when backing up. Always back upslowly, and watch carefully.

� Avoid starting or stopping abruptly.

� Vary the speed of the utility car tomatch the terrain of your surround-ings.

� Avoid turning the steering wheel toosharply at higher speeds.

� Always drive slowly straight up orstraight down slopes – never at anangle.

� Do not run the engine indoors.Exhaust gas is poisonous.

� Do not make any modification oraddition which affects capacity orsafe operation, or make anychanges not in accordance with theowner’s/operator’s manual.

OPERATOR SAFETY!

Y-104

Y-103

� All occupants should remain insidethe vehicle. Remain seated, andhold on when the car is in motion.

LIT_19626_11_00 3/22/01 1:07 PM Page 3-2

1

2

3

4

5

6

7

8

9

10

11

3-3UTILITY

LOADING/TOWING� Do not drive across the face of slope.� Avoid poor driving conditions such

as wet lawns and rough surfaces.Vehicle handling and stability may bereduced.

� Stop the engine, remove ignition keyand make sure trailer is correctlyinstalled before towing trailer.

� Do not allow people to ride in cargobed or trailer.

� Reduce speed and exercise extremecaution when carrying cargo or tow-ing a trailer, which could affect han-dling, control, stability, and brakingperformance.

� When driving on slopes, reducespeed and avoid sudden starts orstops.Excessive speed or sudden starts orstops could cause loss of control andcould lead to vehicle overturning.Abrupt starts going uphill or abruptbraking backing down a slope couldcause the front wheels to lift off theground, reducing control andincreasing the chance of an acci-dent.

� Do not tow with any point exceptspecified hitch point and neverexceed maximum specified weighton hitch point.

� Do not operate on steep hills whenfully loaded.

� Do not exceed the maximum loadlimit.

Be sure to check “LOADING/ TRAIL-ER TOWING” carefully before load-ing or towing (See page 7-2).

WARNING

OPERATOR SAFETY!

Y-105

Y-106

LIT_19626_11_00 3/22/01 1:07 PM Page 3-3

1

2

3

4

5

6

7

8

9

10

11

4-1 UTILITY

MAINTENANCE SAFETY PROGRAM

MAINTENANCE REQUIRED FOR UTILITYCAR SAFETYPractice the following to help ensurethe safety of utility car operators:

� Preventative Maintenance. Per-form all scheduled maintenance inaccordance with manufacturer’s rec-ommendations to provide the userwith a safe, properly operating utilitycar.

� Personnel. Allow only qualified,trained, and authorized personnel toinspect, adjust, and maintain utilitycars.

� Parts and Materials. Use onlyreplacement parts and materialsrecommended by Yamaha.

� Ventilation. Properly ventilate allmaintenance and storage areas inaccordance with applicable firecodes and ordinances to avoid firehazards. Ventilation is required toremove flammable vapors andfumes from gasoline powered carstorage areas.

SAFETY PRECAUTIONSDURING MAINTENANCE

When performing maintenance, followall safety instructions contained in themanufacturer’s operation and servicemanuals, as well as the following safe-ty procedures:

� Properly immobilize utility car beforebeginning any maintenance.

� Properly block chassis before work-ing underneath utility car.

� Before disconnecting any part of thefuel system, drain the applicablepart of the system to prevent fuelleaks.

� Avoid fire hazards, and have appro-priate fire protection equipmentavailable.

� Maintain all safety devices includingbrakes, steering mechanisms, warn-ing devices, and governors, in a safeoperating condition. Do not modifythese safety devices as supplied bythe manufacturer.

� After each maintenance or repair,the car must be driven by a quali-fied, trained, and authorized person– in an area free of pedestrian traffic– to ensure proper operation andadjustment.

� Record all maintenance performedin a maintenance record log by date,name of person performing mainte-nance, and type of maintenance.Periodically inspect maintenancelog to ensure accurate and com-plete entries.

� Maintain in a legible condition allnameplates, warnings, and instruc-tions provided by the manufacturer.

� If new nameplates, warnings, orinstructions are needed, contactyour Yamaha dealer.

LIT_19626_11_00 3/22/01 1:07 PM Page 3-4

1

2

3

4

5

6

7

8

9

10

11

4-2UTILITY

MAINTENANCE SAFETY PROGRAM

FUEL HANDLING/STORAGE AND BATTERY CHARGINGTake the following precautions toensure maintenance worker safety:

� Supervise the storage and handlingof liquid fuels in accordance withapplicable fire and safety require-ments.

� Only use battery changing andcharging facilities and proceduresthat are in accordance with applica-ble ordinances and regulations.

� Periodically inspect fueling andcharging facilities and procedures tobe certain that applicable safetycodes, regulations, and proceduresare being followed.

LIT_19626_11_00 3/22/01 1:07 PM Page 3-5

1

2

3

4

5

6

7

8

9

10

11

5-1 UTILITY

CONTROLS

Y-12

4

5

6

1

9 8

Y-107

2

14

15

16107

12

11

13

3

FEATURES1 Steering wheel2 Seat3 Battery4 Brake pedal5 Parking brake pedal6 Accelerator pedal7 Drive selector lever8 Main switch9 Oil warning lighta Choke knobb Front cowlc Front tired Front bumpere Rear cowlf Rear tireg Fuel cap

LIT_19626_11_00 3/22/01 1:07 PM Page 3-6

1

2

3

4

5

6

7

8

9

10

11

5-2UTILITY

CONTROLS

Y-15

OFF

ON

Y-16

OFF

ON

OFFOILWARNING

ON

Y-17

A

MAIN SWITCHThe main switch controls the followingitems:

OFFIgnition circuit is switched off.The key can be removed only in thisposition.

ONElectrical circuits are switched on.The utility car can be driven.

OIL WARNING LIGHT When the engine oil level falls belowan acceptable level, this light comeson. If the light comes on, stop theengine, check the engine oil level,and add oil as necessary. (See page6-4).

å Oil warning light

LIT_19626_11_00 3/22/01 1:07 PM Page 3-7

1

2

3

4

5

6

7

8

9

10

11

5-3 UTILITY

DRIVE SELECT LEVERThe drive select lever is used to shiftthe utility car into forward or reverse.After coming to a complete stop, move the lever to the desired posi-tion.

Lever Position Car Movement

F FORWARDR REVERSE

The back-up buzzer will sound whenthe drive select lever is turned to “R.”

ACCELERATOR PEDALThe accelerator pedal controls the util-ity car’s speed.

Action Car Speed

Depress pedal Increase

Release pedal Decrease

å Accelerator pedal

BRAKE PEDALPress down on the brake pedal to stopthe utility car.

å Brake pedal

NOTE:

CONTROLS

Y-109

Y-20

A

Y-18

Y-21

A

LIT_19626_11_00 3/22/01 1:07 PM Page 3-8

1

2

3

4

5

6

7

8

9

10

11

5-4UTILITY

PARKING BRAKE PEDALPress down on the parking brake pedalwhenever parking the utility car.

å Parking brake pedal

Release the parking brake by de-pressing the accelerator pedal.

CHOKE KNOBPull and hold out choke knob whenstarting a cold engine. Release theknob after the engine starts.

å Choke knob

TOW HITCHUse the tow point within the specifiedweight limits.

1 Tow point

* Tow weight 590 kg (1300 lb)

Tongue weight 68 kg (150 lb)

Do not drive the machine over awalking speed of 5 km/h (3 mph)while towing. Otherwise, an acci-dent could result.

* Including driver, passenger, vehiclecargo and trailer cargo, on levelground.

WARNING

NOTE:

CONTROLS

Y-110

Y-22

A

Y-23

ACHOKE

LIT_19626_11_00 3/22/01 1:07 PM Page 3-9

1

2

3

4

5

6

7

8

9

10

11

6-1 UTILITY

PRE-OPERATION CHECKS

Y-115

BA

Pre-operation checks should be madeeach time you use your utility car. Getin the habit of performing the followingchecks in the same way so that theybecome second nature.

� Be sure the main switch key isremoved before performing thepre-operation checks to preventaccidental starting, and apply theparking brake to keep the carfrom moving.

� During the pre-operation checks,avoid touching engine parts orthe muffler while they are still hot.

PRE-OPERATIONCHECKLISTBefore each use check the following:

✔ Fuel system✔ Engine oil level✔ Battery✔ Tire condition✔ Steering system✔ Back-up buzzer✔ Pedal operation✔ Body and chassis

SEATOpen the seat and lift the cargo bedfor checking and servicing.

å Seat∫ Prop rod

WARNING

LIT_19626_11_00 3/22/01 1:07 PM Page 3-10

1

2

3

4

5

6

7

8

9

10

11

6-2UTILITY


Y-112

Y-113

Y-114

A

CARGO BEDLift the cargo bed for engine servicing.1. Pull the bed latch towards the rear

with right hand.2. Lift the cargo bed with left hand.3. Lift the cargo bed up until the prop

rod latches in place.

� Remove the main switch key andapply the parking brake beforelifting the cargo bed. Otherwisethe vehicle could unexpectedlymove.

� Never drive the car with the bed inthe up position. Injury couldoccur if the bed fell accidentally.

� Before closing the bed, be sureothers are standing away from thecar and that no one is sitting onthe seat. Keep hands and fingersaway from the pinch pointbetween the bed and seat back.

å Prop rod

WARNING

LIT_19626_11_00 3/22/01 1:07 PM Page 3-11

1

2

3

4

5

6

7

8

9

10

11

6-3 UTILITY

FUEL SYSTEM

Make sure there is sufficient fuel in thetank, and check fuel line and connec-tions for leakage.

å Fuel level gauge∫ “F” Fullç “E” Empty

Gasoline and its vapors are highlyflammable and explosive.� Do not smoke when refueling and

keep away from sparks, flames,or other sources of ignition.

� Stop engine and allow it to coolfor several minutes before refuel-ing.

� Refuel in a well-ventilated area.� Take care not to spill gasoline. If

gasoline spills, wipe it up imme-diately with dry rags. Always dis-pose of gasoline-soaked ragsproperly.

� Tighten the filler cap securelyafter refueling.

� If you swallow gasoline, inhale alot of gasoline vapor, or get gaso-line in your eyes, get immediatemedical attention.

� If any gasoline gets on your skin,immediately wash with soap andwater. Change clothing if gaso-line spills on it.

Avoid using gasoline blended withmethyl alcohol which can damagefuel system parts.

CAUTION

WARNING


Recommended fuel:Unleaded gasoline

Fuel tank capacity:6.3 US gal(24.0 L, 5.3 Imp gal)

Y-850

AC

BE F

LIT_19626_11_00 3/22/01 1:07 PM Page 3-12

1

2

3

4

5

6

7

8

9

10

11

6-4UTILITY

ENGINE OILWith the utility car parked on levelground, remove the dipstick and makesure the engine oil is between the MINand MAX marks (the crosshatchedarea on the end of the dipstick).

å Oil level dipstick∫ Maximum oil levelç Safe operating range

If the oil level is below the MIN markon the dipstick, add oil through the oilfiller hole until the oil level is betweenthe MIN and MAX marks.

å Oil filler hole

� Use care not to fill past the MAXdipstick mark, and be sure no for-eign material enters the crank-case.

� Use care not to get oil on thestarter belt.

The distance between the dipstickmarks represents approx. 1/2 US qt(1/2 L) of oil.

Recommended engine oil classifica-tion: API Service SE, SF, or SG.Engine oils labeled “Energy Con-serv-ing II” are recommended.

NOTE:

NOTE:

CAUTION


Recommended oil:YAMALUBE 4-cycle oil orSAE 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)

Y-514

MIN MAX

Y-28

A

B

C

Y-515

A

LIT_19626_11_00 3/22/01 1:07 PM Page 3-13

1

2

3

4

5

6

7

8

9

10

11

6-5 UTILITY


Y-30

A

Y-31

BATTERYCheck that the battery is held secure-ly in place to prevent the battery frombeing damaged from vibration or jar-ring. Also check that no battery capsare missing to prevent battery acidfrom spilling from the battery. Checkthe battery terminals for corrosion.

TIRE CONDITION

Tire Air PressureCheck the tire air pressure beforeoperating the utility car.

Tire pressure:For G21-A:

Front Tires20 - 23 psi(140 - 160 kPa, 1.4 - 1.6 kgf/cm2)

Rear Tires29 - 31 psi(197 - 217 kPa, 2.0 - 2.2 kgf/cm2)

Tire Wear LimitCheck the tire surface for damage,cracks or embedded objects. Whentire tread wears down to 0.04 in. (1mm), replace the tire.

åWear limit

LIT_19626_11_00 3/22/01 1:07 PM Page 3-14

1

2

3

4

5

6

7

8

9

10

11

6-6UTILITY


Y-116

Y-33

Y-21

A

STEERING SYSTEMCheck the steering system for exces-sive freeplay by:

� moving the steering wheel up anddown, and back and forth.

� turning the steering wheel slightly tothe right and left.

If you feel excessive freeplay, or hearrattling sounds which may indicateloose steering components, consult aYamaha dealer.

BACK-UP BUZZERCheck the back up buzzer by movingthe drive select lever to “R” for reverse.The buzzer should sound.

PEDAL OPERATIONCheck the following pedal controls forproper operation. If a pedal does notwork properly, consult a Yamaha deal-er.

Brake PedalMake sure the brake pedal feels firmwhen pressed and returns to its origi-nal position when released.

å Brake pedal

LIT_19626_11_00 3/22/01 1:07 PM Page 3-15

1

2

3

4

5

6

7

8

9

10

11

6-7 UTILITY


Y-22

A

Y-20

A

Parking Brake PedalMake sure the parking brake pedallocks in place with a positive click, andreleases when the accelerator pedal ispressed.

å Parking brake pedal

Release the parking brake bydepressing the accelerator pedal.

Accelerator Pedal

Before checking operation of theaccelerator pedal, be sure the mainswitch is in the “OFF” position.

Make sure the accelerator pedal oper-ates smoothly.


BODY AND CHASSISBefore each use, visually inspect theutility car body and chassis for dam-age and/or missing parts.

WARNING

NOTE:

LIT_19626_11_00 3/22/01 1:07 PM Page 3-16

1

2

3

4

5

6

7

8

9

10

11

7-1UTILITY

OPERATION

Y-16

OFF

ON

Y-18

Y-23

ACHOKE

Y-20

A

STARTING1. With the parking brake applied,

turn the drive select lever to “F” forforward, or “R” for reverse.

Do not shift from “F” forward to “R”reverse while the utility car is mov-ing.

2. Turn the main switch to “ON.”

Do not depress the acceleratorpedal when turning on the mainswitch or the utility car may sud-denly start moving.

3. Pull the choke knob out and hold itwhile starting. Release the chokeknob after the engine starts.

å Choke knob

The choke is not required when theengine is warm.

4. Check that your path is clear in thedirection you plan to go, and slow-ly depress the accelerator pedal.The utility car will start to move.


The parking brake automaticallyreleases when the accelerator pedal isdepressed.

NOTE:

NOTE:

WARNING

CAUTION

LIT_19626_11_00 3/22/01 1:07 PM Page 7-1

1

2

3

4

5

6

7

8

9

10

11

7-2 UTILITY

OPERATION

MAXIMUM LOADING LIMIT

� Maximum cargo bed load:363 kg (800 lb)

� Tow hitchTow weight (Including driver,passenger, vehicle cargoand trailer and trailer cargo):

590 kg (1300 lb)Tongue weight:

68 kg (150 lb)

Y-65

B

A

Y-117

Y-119

STOPPINGTo stop the utility car, gradually pressdown on the brake pedal.

å Brake pedal

When the car has come to a stop,apply the parking brake pedal and turnthe main switch to “OFF.”

∫ Parking brake pedal

Do not hold the utility car on anincline with the accelerator – usethe brake.

LOADING/TRAILERTOWING

Be sure to check “SAFETY INFOR-MATION” carefully before loadingor towing. (See page 3-3)

� Do not exceed the maximumloading limits. An overloadedvehicle can be unstable.

� Keep load as low as possible.Drive slowly when cargo isloaded. No top heavy loads.

� Secure loads to prevent shifting.� Cargo should be evenly spread in

cargo bed as far forward as pos-sible the center of gravity mayaffect the handling, steering, andbraking performance.

� Make sure cargo in the trailercannot move around. A shiftingload can cause an accident.

WARNING

WARNING

CAUTION

LIT_19626_11_00 3/22/01 1:07 PM Page 7-2

PERIODIC MAINTENANCE CHARTSRegular maintenance is required for the best performance and safe operation ofyour utility car.

Be sure to turn off the main switch and apply the parking brake when you perform maintenance unlessotherwise specified. If the owner is not familiar with machine servicing, this work should be done by aYamaha dealer or other qualified mechanic.

FOR G21A

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 rdsPre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs

Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mlstion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms

(Every (Every 6 (Every (Every (Everymonth) months) year) 2 years) 4 years) Page

PRE- Check engine oil C C C 6-4

OPER- Check air cooling duct C C C C C C *

ATION Check fuel lines for leakage C C C C C C 6-3

CHECKS Check fuel level C C C C C C 6-3

Check for loosenessand corrosion of battery C C C C C C 6-5terminals and hold downs

Check brake pedal freeplayC CA CA CA CA CA 8-12and adjust if necessary

Check steering operation C C C C C 6-6

Check tire pressure, treadC CA CA CA CA CA 6-5depth, tire surface for damage

Check body and chassis forC C C C C C

6-7damage

Check tightness of all bolts,C C C C C C *nuts, and screws

Check reverse buzzerC C C C C C 6-6operation

EVERY Check fuel filter for clogging C C C C C *

MONTH Check wear of drive belt C C C C C 8-8

Check operation ofC C C C C –Forward / Reverse shifting

Clean / Lube pedal control area CL –

EVERY 6 Wash pre-filter, check airS S S S 8-6MONTHS cleaner element

Check spark plug and plug capC C C C 8-4/*condition** / Check compression

Check shock absorbers for oilC C C *leaks and damaged springs

* Items with out a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does not contain these procedures. They are contained in the Service Manual.

**Related to emission control system.

WARNING

8-1UTILITY

MAINTENANCE

1

2

3

4

5

6

7

8

9

10

11

LIT_19626_11_00 3/22/01 1:07 PM Page 8-1

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 rdsPre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs

Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mlstion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms

(Every (Every 6 (Every (Every (Everymonth) months) year) 2 years) 4 years) Page

EVERY Replace engine oil R R R 8-5

YEAR Adjust throttle cables,**choke cable, check carburetor CA CA CA *throttle shaft for wear**

Check starter V-belt forC C C *damage and tension

Check drive belt for slippage,C C C 8-8wear or scratches

Check sliding sheave andCL CL CL *ramp shoes; Grease secondary

sheave bearing.

Grease primary sheave L L L *

Check operation of speed limiter C C C *

Apply battery terminal protectant S S S –

Check wiring connectionsC C C –and insulation

Check shoe lining thicknessC C C *and rear axle bearing play

Check kingpin play, seal, andCA CA CA *cap / Adjust wheel alignment

Check wheel nut tightness,C C C *front wheel bearing play

Check gear box oil levelC C C 8-10and leakage

Check operation and adjustCA CA CA *pedal stop if necessary

EVERY Check brushes for wear andC S *2 YEARS commutator for dirt

EVERY Replace fuel filter andR *4 YEARS fuel hoses

Check tightness of cylinder CA *head / Adjust valves

Replace gear box oil R 8-10

Check for grease leakage;CA *adjust gearbox if necessary

* Items with out a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does not contain these procedures. They are contained in the Service Manual.

**Related to emission control system.

1

2

3

4

5

6

7

8

9

10

11

8-2 UTILITY

MAINTENANCE

LIT_19626_11_00 3/22/01 1:07 PM Page 8-2

8-3UTILITY

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 correspond-ing acronyms are provided in accor-dance with U.S. EPA REGULATIONSFOR SMALL NONROAD ENGINESand the CALIFORNIA REGULA-TIONS FOR NEW 1995 AND LATEROFF-HIGHWAY RECREATIONALVEHICLES AND ENGINES.

The acronyms conform to the latestversion of the SAE’s recommendedpractice document J1930, “DiagnosticAcronyms, Terms, and Definitions ForElectrical/Electronic System”.

It is recommended that these itemsbe serviced by a Yamaha dealer orother qualified mechanic.

1

2

3

4

5

6

7

8

9

10

11

LIT_19626_11_00 3/22/01 1:07 PM Page 8-3

1

2

3

4

5

6

7

8

9

10

11

8-4 UTILITY

MAINTENANCE

Spark Plug InspectionYou should periodically remove andinspect the spark plug. Dirty or wornspark plugs can cause poor perfor-mance.

å Spark plug∫ Spark plug cap

1. Check for discoloration and heavycarbon deposits. The normalelectrode color will be tan. If it isnot, replace it.

2. Check the spark plug type, andcheck the spark plug gap with afeeler gauge.

Standard spark plug:BPR2ES or BPR4ES

Spark plug gap:0.028 ˜ 0.031 in (0.7 ˜ 0.8 mm)

å Gap

3. Clean the gasket and plug sur-faces and install the spark plug fin-ger tight before tightening to thefollowing torque:

Spark plug torque:14.5 ft.lb(20 Nm, 2.0 m.kg)

When removing or installing thespark plug, be careful not to dam-age the insulator. A damaged insu-lator could allow external sparks,which could lead to explosion orfire.

WARNING

Y-516A

B

A

Y-37

LIT_19626_11_00 3/22/01 1:07 PM Page 8-4

1

2

3

4

5

6

7

8

9

10

11

8-5UTILITY

MAINTENANCE

Engine Oil Replacement

1. Warm up the engine for severalminutes, place the utility car on alevel surface, then stop theengine.

Use caution not to touch hot engineoil or hot engine parts, during thefollowing procedure.

2. Place an oil pan under the enginedrain plug.

3. Remove the oil drain plug and letthe oil drain completely.

Dispose of used oil in an environmen-tally safe way, such as taking oil to anoil collection station.

4. Install the drain plug, along with anew drain plug gasket, finger tightbefore tightening to the followingtorque:

Drain plug torque:23 ft.lb(31 Nm, 3.1 m.kg)

5. Add the correct quantity of oilthrough the oil filler hole.

Recommended engine oil classifica-tion: API Service SE, SF, or SG.Engine oils labeled “Energy Conserv-ing II” are recommended.

NOTE:

NOTE:

WARNING

Recommended oil:YAMALUBE 4-cycle oil orSAE 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)

Y-624

LIT_19626_11_00 3/22/01 1:07 PM Page 8-5

8-6 UTILITY

MAINTENANCE

Y-515

A

Y-518

A

A

A

B

Y-519

A

B

å Oil filler hole

Use care not to fill past the MAXdipstick mark, and be sure no for-eign material enters the crank-case. After replacing engine oil,check for oil leaks around the drainplug. If oil leaks are found, consulta Yamaha dealer.

Air FilterTo remove the air filter elements:

1. Unlatch the air filter cover clipsand remove cover.

å Air filter cover clips∫ Air filter cover

2. Lift the air filter and pre-filter outof the air filter case.

å Air filter∫ Pre-filter

Be careful not to drop anythinginto the air inlet.

CAUTION

CAUTION

1

2

3

4

5

6

7

8

9

10

11

LIT_19626_11_00 3/22/01 1:07 PM Page 8-6

1

2

3

4

5

6

7

8

9

10

11

8-7UTILITY

MAINTENANCE

BA

Y-508

Inspection and cleaning:

3. Wash the foam pre-filter in soapand water. Allow it to dry.

å Soap and water∫ Foam element

4. Check the filter element. If dam-aged or dirty, replace it.

Do not wring out the foam pre-fil-ter, this could cause it to tear.

5. To replace the elements, reversethe above steps.

The pre-filter has a notch on oneside. It will only fit in the case oneway.

CAUTION

CAUTION

LIT_19626_11_00 3/22/01 1:07 PM Page 8-7

1

2

3

4

5

6

7

8

9

10

11

8-8 UTILITY

MAINTENANCE

Y-60

B

A

Y-44

Drive BeltTo remove the drive belt:

1. Set the drive select lever halfwaybetween forward and reverse.

2. Pull up on the drive belt and pushit outward over the edge of thesecondary sheave.

3. Turn the secondary sheave clock-wise and the drive belt will roll offthe sheave.

4. Remove the drive belt from the pri-mary sheave.

Inspection:

To inspect the drive belt, check forfrayed edges or tears, and measuredrive belt against the following specifi-cation. If the belt shows excessivewear or damage, replace the belt witha new one.

å New: 1.22 in. (31.0 mm)∫ Replace when belt reaches:

1.06 in. (27 mm)

5. To install the drive belt, reverse theabove steps, rolling the belt backover the secondary sheave.

LIT_19626_11_00 3/22/01 1:07 PM Page 8-8

1

2

3

4

5

6

7

8

9

10

11

8-9UTILITY

MAINTENANCE

Y-45

++

––

Battery

Battery electrolyte is poisonous anddangerous, causing severe burns,etc. It contains sulfuric acid. Avoidcontact with skin, eyes, or clothing.Antidote:EXTERNAL: Flush with water.INTERNAL: Drink large quantities ofwater or milk. Follow with milk ofmagnesia, beaten egg, or vegetableoil. 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 inenclosed space. Always shield eyeswhen working near batteries.KEEP OUT OF REACH OF CHIL-DREN.

The 12-volt battery that provides start-ing power to your gas car normallydoesn’t require the addition of waterduring the one year warranty periodprovided by the battery manufacturer.If the battery loses its charge, have anexperienced mechanic charge it.

WARNING

LIT_19626_11_00 3/22/01 1:07 PM Page 8-9

1

2

3

4

5

6

7

8

9

10

11

8-10 UTILITY

MAINTENANCE

Fuse Replacement

Be sure to use the specified fuse.Using a wrong fuse can cause elec-trical system damage and create afire hazard.

When replacing a fuse be sure themain switch is turned off to preventaccidental short-circuiting.

å Fuse case∫ Fuseç Replacement fuse

Gear Box OilTo check gear box oil level:

1. Place the utility car on a level sur-face.

2. Lift the seat and cargo bed.

3. Remove the oil plug (A).

Recommended oil:SAE 90 gear oil

Gearcase capacity:0.44 US qt(0.42 L, 0.09 Imp gal)

CAUTION

WARNING

Replacement Fuse:10 Amp, Blade Style

Y-35

BA

C

Y-111

Y-520

A

B

LIT_19626_11_00 3/22/01 1:07 PM Page 8-10

1

2

3

4

5

6

7

8

9

10

11

8-11UTILITY

MAINTENANCE

Wheel nut tightening torque:58 ft.lb (80 Nm, 8.0 m.kg)

Consult your Yamaha dealer beforeusing your utility car if you suspectbrake problems. Brake failure couldresult in a serious accident.

WARNING

Y-57

� Add gear oil little by little until oilflows from the plug hole (B).

4. Allow excess gear oil to flow outuntil it stops.

Do not allow foreign material toenter the gear box.

5. Reinstall the oil plug.

For gear oil replacement, consult aYamaha dealer or other qualifiedmechanic.

Wheel ReplacementTo remove and install a wheel on yourutility car:

1. With the wheels blocked to preventthe utility car from moving, loosenthe wheel nuts.

2. Elevate the utility car with a jackand remove the wheel nuts andthe wheel.

3. Reverse the removal steps wheninstalling the wheel.

Brake AdjustmentThe brakes on your utility car are self-adjusting.

Before you operate the car, pressdown on the brake pedal several timesto make sure the brakes are function-ing properly.

NOTE:

CAUTION

LIT_19626_11_00 3/22/01 1:07 PM Page 8-11

1

2

3

4

5

6

7

8

9

10

11

8-12 UTILITY

MAINTENANCE

Brake Pedal Free PlayAdjustment

Before adjusting brake pedal freeplay, pump the brake pedal severaltimes to self-adjust the brakes.

To adjust the brake pedal free play:

1. Remove the service lid from thefloor of the utility car.

2. Check the brake pedal free play bypressing against the pedal withtwo fingers (using light force) andmeasuring the distance the pedaltravels before resistance is felt.

Brake pedal free play:25-30 mm (0.98-1.18 in.)

3. If the free play distance needsadjusting, loosen the lock nut andturn the adjusting nut in or out (in180° increments only, due to thecam shape of adjuster), until thefree play specification is met.Thentighten the lock nut in place.

Do not overtighten the brakecables. The self adjusters may notoperate properly, reducing brakingperformance.

WARNING

CAUTION

Y-61

7

1817

1615

1413

1211

109

8

Y-62

25-30 mm

Y-63A

LIT_19626_11_00 3/22/01 1:07 PM Page 8-12

1

2

3

4

5

6

7

8

9

10

11

9-1UTILITY

STORAGE

Perform the following preparationswhen storing your utility car for extend-ed periods of time:

Turn main switch key to “OFF” position,remove key, and store key in a safeplace.

DRAINING FUEL

Gasoline and its vapors are highlyflammable and explosive.

� Do not smoke when refueling andkeep away from sparks, flames, orother sources of ignition.

� Stop engine and allow it to coolfor several minutes before refuel-ing.

� Refuel in a well-ventilated area.� Take care not to spill gasoline. If

gasoline spills, wipe it up immedi-ately with dry rags. Always dis-pose of gasoline-soaked ragsproperly.

� Tighten the filler cap securelyafter refueling.

� If you swallow gasoline, inhale alot of gasoline vapor, or get gaso-line in your eyes, get immediatemedical attention.

� If any gasoline gets on your skin,immediately wash with soap andwater. Change clothing if gasolinespills on it.

1. Fill the fuel tank.

å Float bowl drain screw

2. Drain the carburetor float bowl intoa suitable container by turning thescrew located on the bottom of thecarburetor.

WARNING

NOTE:

Y-521

A

LIT_19626_11_00 3/22/01 1:07 PM Page 9-1

1

2

3

4

5

6

7

8

9

10

11

9-2 UTILITY

STORAGE

ENGINE PREPARATION With the key removed and the sparkplug lead disconnected, turn theclutch by hand until compression isfelt. This puts the valves in the closedposition.

CHASSIS PREPARATION1. Increase the front tire pressure to

23 psi (160 kPa, 1.6 kgf/cm2) andincrease the rear tire pressure to31 psi (217 kPa, 2.2 kgf/cm2).

2. Clean exterior of the utility car andapply a rust inhibitor.

3. Cover the utility car with a breath-able cover and store it in a dry,well-ventilated area.

BATTERY PREPARATION1. Remove the battery from the utility

car and store it in a cool, dry placethat stays between 32˚F (0˚C) and90˚F (30˚C).

2. Have the battery recharged every60-90 days to keep it fullycharged. The battery must be keptfully charged to avoid damage.

Batteries like the one supplied withyour car normally do not require you tocheck the water level inside the bat-tery for the one year warrantyperiod provided by the manufacturer.

NOTE:

LIT_19626_11_00 3/22/01 1:07 PM Page 9-2

1

2

3

4

5

6

7

8

9

10

11

10-1UTILITY

SPECIFICATIONS

GENERAL SPECIFICATIONS

Items G21A

Dimensions:Overall length 120.0 in. (3050 mm)Overall width 51.5 in. (1308 mm)Overall height (steering height) 47.2 in. (1200 mm)Height of floor 11.8 in. (300 mm)Wheelbase 74.8 in. (1900 mm)Tread:

Front 38.6 in. (980 mm)Rear 38.6 in. (980 mm)

Min. ground clearance 4.5 in. (115 mm)

Weight:

Dry weight (without battery) 851 lb (386 kg)

Performance:

Maximum speed 12 mph

(19 km/h)

Minimum turning radius 129.92 in. (3.3 m)

Seating capacity 2 persons

Hill climbing ability 22˚ (40% grade)on pavement

LIT_19626_11_00 3/22/01 1:07 PM Page 10-1

1

2

3

4

5

6

7

8

9

10

11

10-2 UTILITY

SPECIFICATIONS

ENGINEItems G21A

Description:Engine type 4-stroke, Gasoline, OHVNumber of cylinders SingleDisplacement 357 cm3

Bore x stroke 3.30 x 2.48 in. (85 x 63 mm)Compression ratio 8.1:1Rated output 11.4 hp (8.5 kw)/3500 rpmCooling system Forced air cooledStarting system StarterIgnition system TCI MagnetoSpark plug type BPR2ESSpark plug gap 0.028-0.031 in. (0.7-0.8 mm)Lubrication system SplashEngine oil type YAMALUBE 4 cycle oil or SAE 10W30Engine 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)

TRANSMISSIONItems G21A

Transmission:Type V-belt automatic centrifugal engagementV-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 flyweightFactory speed setting 12 mph (19 km/h)

Differential/reduction gear: G21ADifferential type Bevel gearLubricant/capacity SAE 90 gear oil/0.44 US qt

(0.42 L, 0.09 Imp gal)

BATTERIESItems G21A

Battery: BCI group 24,RC: minimum 75 minCCA: minimum 400A

LIT_19626_11_00 3/22/01 1:07 PM Page 10-2

1

2

3

4

5

6

7

8

9

10

11

10-3UTILITY

SPECIFICATIONS

CHASSIS

Items G21A

Steering system:Type Worm and pinSteering angle (L.H.) 1.5 turnSteering angle (R.H.) 1.5 turnLubricant/capacity Grease/3.0 US oz (0.09 L, 3.17 Imp oz)

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 linkageadjustment 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 PRRear 18 x 8.50–8.00/TURF

Rim size: 7.00–I–8.00Tire pressure: For G21A:

Front 20 - 23 psi (140 - 160 kPa, 1.4 - 1.6 kgf/cm2)Rear 29 - 31 psi (197 - 217 kPa, 2.0 - 2.2 kgf/cm2)

LIT_19626_11_00 3/22/01 1:07 PM Page 10-3

RB

RB

P

B RR

EV

FW

DR P

BB

PP

B P

Br

R/W

Br

R/W

Br

A1

F2

BB

RW

RW

R R

RR

R/W

R/W

GB

RW

G G G

G

G

B

Br

B B

R/W

Br

R/W

OF

FO

N

Br

R/Y

LBB L

G Br

PB

R/W R

/W

L L

L

BB

B

B

B

—+

Y-5

09

GG Br

Br

BR

W

R Br

RR

Y

Br

Br

161

2

3

4

5

67

8

910

1415 13 12 11 17 18RR P

1E

ngin

e st

op r

elay

aB

atte

ry2

Eng

ine

grou

ndb

Pilo

t la

mp

(12V

, 3.

4W)

3P

icku

pc

Mai

n sw

itch

4R

otor

dA

ccel

erat

or s

top

switc

h5

Oil

leve

l gau

gee

Bac

k sw

itch

6B

lade

fus

e (1

0A)

fB

uzze

r7

Vol

tage

reg

ulat

org

Bod

y gr

ound

8S

tart

er g

ener

ator

hH

orn

9R

elay

iH

orn

sw.

CO

LO

R C

OD

EB

......

......

......

......

.Bla

ckL.

......

......

......

......

..Blu

eG

......

......

......

.....G

reen

Y...

......

......

......

..Yel

low

R...

......

......

......

......

Red

P...

......

......

......

.....P

ink

Br.

......

......

......

...B

row

nW

......

......

......

.....W

hite

B/R

......

......

.Bla

ck/R

edY

/B...

......

.Yel

low

/Bla

ckR

/Y...

......

...R

ed/Y

ello

wR

/W...

......

...R

ed/W

hite

11-1

G21A WIRING DIAGRAMWIRING

1

2

3

4

5

6

7

8

9

10

11

UTILITY

LIT_19626_11_00 3/22/01 1:08 PM Page 10-4

OWNER’S/OPERATOR’SMANUAL

UTILITYCAR

LIT-19626-11-00

YAMAHA MOTORMANUFACTURING CORP.

OF AMERICAJR6-F8199-00

Printed in U.S.A.

KCC

G21A

Yamaha Motor Corp., USA

Cypress, California made in

10/31/00

LIT196261100

USA

*LIT196261100*

1PC - G21A O/M

G21A O_M Cover 11/2/00, 10:22 PM1

LIT 19626 11 00 · 2016-07-10 · OWNER’S/ OPERATOR’S MANUAL UTILITY CAR LIT-19626-11-00 YAMAHA...

Documents

Transcript of LIT 19626 11 00 · 2016-07-10 · OWNER’S/ OPERATOR’S MANUAL UTILITY CAR LIT-19626-11-00 YAMAHA...