User manual | Yamaha G11A Operator`s manual

OWNER’S/

OPERATORS

MANUAL

UTILITY

CAR

01/10/01

1PC - G11A O/M

LIT196261197

*LIT196261197*

USA Yamaha Motor Corp., USA

Cypress, California made in

YAMAHA MOTOR

MANUFACTURING CORP.

OF AMERICA

Printed in U.S.A.

KCC

LIT-19626-11-97

G11A

JR3-F8199-10

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UTILITY

INTRODUCTION

Congratulations on your purchase of a Yamaha utility car. This manual contains information you will need for proper operation, maintenance, and care of your utility car. 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 car, please consult a Yamaha dealer.

TECHNICAL SERVICE DEPT

GOLF CAR SALES GROUP

YAMAHA MOTOR

MANUFACTURING CORP OF

AMERICA

G11A

OWNER’S/OPERATOR’S

MANUAL

© 1996 by Yamaha Motor

Manufacturing Corporation of America

1st edition

All rights reserved. Any reprinting or unauthorized use without the written permission of

Yamaha Motor Manufacturing

Corporation of America is expressly prohibited.


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IMPORTANT MANUAL

INFORMATION

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means

ATTENTION! BE ALERT! YOUR

SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the utility car occupants, a bystander, or a person inspecting or repairing the utility car.

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 car 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 car and should remain with the car when resold.

CAUTION

This message describes special precautions that must be taken to avoid damage to the utility car.

WARNING

Read and understand this manual completely before operating your utility car.

NOTE :

This message provides additional key information.

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WARRANTY

IMPORTANT LABELS

OPERATOR SAFETY

MAINTENANCE SAFETY PROGRAM

CONTROLS

PRE-OPERATION CHECKS

OPERATION

MAINTENANCE

CONTENTS

STORAGE

SPECIFICATIONS

WIRING

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WARRANTY

YAMAHA MOTOR

CORPORATION, U.S.A.

G11A UTILITY VEHICLE

LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that any new G11A Utility Vehicle Yamaha Golf Car 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 G11A Utility

Vehicle will be one year from date of purchase for parts and labor.

warranty 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 of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs by the dealer’s authorized representative.

The warranty shall cover the entire car except for batteries, tires and rims, which are warranted by their respective manufacturers.

DURING THE PERIOD OF WARRANTY any authorized Yamaha Golf Car Dealer will, free of charge, repair or replace, at Yamaha’s option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the machine’s warranty period. All parts replaced under warranty become property of Yamaha Motor

Corporation, U.S.A.

GENERAL EXCLUSIONS from this warranty shall include any failures caused by:

WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha Golf Car Dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES

NO OTHER WARRANTY OF ANY KIND,

EXPRESSED OR IMPLIED. ALL IMPLIED WAR-

RANTIES OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE WHICH EXCEED

THE OBLIGATIONS AND TIME LIMITS STATED IN

THIS WARRANTY ARE HEREBY DISCLAIMED

BY YAMAHA MOTOR CORPORATION, U.S.A.

AND EXCLUDED FROM THIS WARRANTY.

a.

Abnormal strain, neglect, or abuse, including lack of proper maintenance, and use contrary to the owner’s manual instructions.

b.

Accident or collision damage.

c.

Installation of parts or accessories that are not original equipment.

d.

Fading, rust, or deterioration due to exposure or ordinary wear and tear.

e.

Modification or alteration that affects the Utility

Vehicle’s condition, operation, performance, or durability.

f.

Damage due to improper transportation.

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 CONSEQUEN-

TIAL DAMAGES, SO THE ABOVE EXCLUSION

MAY NOT APPLY TO YOU.

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 pugs, 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.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL

RIGHTS, AND YOU MAY ALSO HAVE OTHER

RIGHTS WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA

Newnan, Georgia 30265-1320

Effective Date: 4/1/92

LIT-13710-05-92

THE CUSTOMER’S RESPONSIBILITY under this

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WARRANTY

YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA

SPECIALTY VEHICLE ENGINES

CALIFORNIA EMISSION CONTROL WARRANTY

1

2

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Yamaha

Motor Manufacturing Corporation of America are pleased to explain the emission control system warranty on your 1996 or later specialty vehicle engine.

In California, new specialty vehicle engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. Yamaha must warrant the emission control system on your specialty vehicle engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your specialty vehicle engine.

Your emission control system may include parts such as the carburetor or fuel-injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Yamaha will repair your specialty vehicle engine at no cost to you including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE

The 1996 and later specialty vehicle engines are warranted for two years. If any emissions-related part on your engine is defective, the part will be repaired or replaced by Yamaha.

OWNER’S WARRANTY RESPONSIBILITIES

● As the specialty vehicle engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.

Yamaha recommends that you retain all receipts covering maintenance on your specialty vehicle engine, but Yamaha cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

● As the specialty vehicle engine owner, you should also be aware that Yamaha may deny you warranty coverage if your specialty vehicle engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

3

● You are responsible for presenting your specialty vehicle engine to a Yamaha dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact the

Yamaha Customer Relations Department at (770)

254-4161.

Yamaha Motor Manufacturing Corporation of

America warrants to the ultimate purchaser and each subsequent purchaser thereafter that each new 1996 and later model year specialty vehicle engine certified for sale and sold in California is:

1.

Designed, built, and equipped so as to conform, at the time of sale, with all applicable regulations adopted by the California Air Resources

Board, and

2.

All warranted parts are free from defects in material and workmanship for the warranty period of the specialty vehicle engine or the period prior to the first scheduled replacement point of the warranted part as required by the maintenance schedule, if applicable, whichever is less. A defect exists when a deficiency in material or workmanship is such that an emission-related warranted part does not function as designed.

The warranty period begins on the date that the specialty vehicle engine is delivered to an ultimate purchaser or on the date it is first placed in service.

WARRANTED PARTS INCLUDE the following:

1.

Fuel Metering System

Carburetor and internal parts (or fuel injection)

Air/fuel ratio feedback and control system

Cold start enrichment system

2.

Air Induction System

Controlled hot air intake system

Intake manifold

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WARRANTY

3.

Ignition System

Spark plugs *

Magneto or electronic ignition system

Spark advance/retard system

4.

Exhaust Gas Recirculation (EGR) System

EGR valve body, and carburetor spacer if applicable

EGR rate feedback and control system

5.

Air Injection System

Air pump or pulse valve

Valves affecting distribution of flow

Distribution manifold

6.

Catalyst or Thermal Reactor System

Catalytic converter

Thermal reactor

Exhaust manifold

7.

Particulate Controls

Traps, filters, precipitators, and any other device used to capture particulate emissions

8.

Miscellaneous Items Used in Above Systems

Vacuum, temperature, and time sensitive valves and switches

Electronic controls

Hoses, belts, connectors, and assemblies

9.

Engine components damaged due to a failure under warranty of a warranted part.

* The original spark plug(s) are warranted for the period of replacement indicated in the

Owner’s/Operator’s Manual and not the useful life of the specialty vehicle engine (see your Owner’s

Manual).

DURING THE PERIOD OF THIS WARRANTY


America will repair or replace any warranted part deemed defective by Yamaha during the scope of the warranty without charge to the owner, including parts, labor, and diagnosis. This work must be done at an authorized Yamaha dealer. Give notice to an authorized Yamaha dealer of any apparent defect(s) within a reasonable period of time after discovery.

The specialty vehicle engine must be made available for inspection by an authorized Yamaha dealer.

OWNER’S RESPONSIBILITY: The owner of the specialty vehicle engine is responsible for the performance of required maintenance (see your

Owner’s/Operator’s Manual). Receipts and maintenance records covering the performance of regular maintenance should be retained in the event questions arise concerning maintenance. The receipts should be transferred to each subsequent owner of this specialty vehicle engine.

The emission control systems of your Yamaha specialty vehicle engine were designed, built, tested, and certified as being in conformity with California emission control regulations using genuine Yamaha parts.

Accordingly, it is recommended that any replacement part(s) used for maintenance, replacement, or repair of emission control systems be

Yamaha parts. The owner may elect to have maintenance, replacement, or repair of the emission control devices and systems performed by any repair establishment or individual, and may elect to use parts other than Yamaha 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

Motor Manufacturing Corporation of America expressly disclaims responsibility for any and all consequential damages, such as loss of time, inconvenience, loss of use of the specialty vehicle, or commercial loss.


America

1000 Hwy. 34 East

Newnan, GA 30265

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SAFETY AND

INSTRUCTION

LABELS

WARNING

Please read the following labels carefully before operating your utility car, and promptly replace any labels which become damaged or removed.

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Y-100 5

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7 8 Y-101

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2-2

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8

Y-852

Y-102a

Y-851

UTILITY CAR SERIAL

NUMBER

The utility car 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.

UTILITY

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UTILITY

!

OPERATOR SAFETY

Y-8

Y-68

Yamaha utility cars are designed to be simple to operate. However, be sure to observe the following:

BEFORE OPERATING

THE UTILITY CAR

● Read this Owner’s/Operator’s manual and all safety and instruction labels on the utility car before operating.

● Perform the pre-operation checks found in Section 6 of this manual.

● Only authorized people should drive the utility car, from the driver’s side only, and only in designated areas.

● Do not allow more than two people to ride in the utility car. This utility car is restricted to two occupants.

● Do not operate the utility car while under the influence of alcohol or drugs; their affect on vision and judgment make operating a utility car dangerous.

● Do not operate the utility car on public streets, roads or highways. Such use is prohibited by law, and dangerous. Operation on public roads can result in collision with other vehicles.

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WHILE OPERATING THE

UTILITY CAR

● Keep your entire body inside the utility car, remain seated, and hold on when the car is in motion.

● Do not start the utility car until all occupants are seated.

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Y-123

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OPERATOR SAFETY

Y-104

Y-103

● Keep your hands on the steering wheel and your eyes on the path ahead.

●

Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully.

● Avoid starting or stopping abruptly.

● Vary the speed of the utility car to match the terrain of the course.

● Avoid turning the steering wheel too sharply at higher speeds.

● Always drive slowly straight up or straight down slopes – never at an angle.

● Do not run the engine indoors.

Exhaust gas is poisonous.

● Do not make any modification or addition which affects capacity or safe operation, or make any changes not in accordance with the owner’s/operator’s manual.

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OPERATOR SAFETY

Y-105

Y-106

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 be reduced.

● Stop the engine, remove ignition key and make sure trailer is correctly installed before towing trailer.

● Do not allow people to ride in cargo bed or trailer.

● Reduce speed and exercise extreme caution when carrying cargo or towing a trailer, which could affect handling, control, stability, and braking performance.

● When driving on slopes, reduce speed and avoid sudden starts or stops.

Excessive speed or sudden starts or stops could cause loss of control and could lead to vehicle overturning.

Abrupt starts going uphill or abrupt braking backing down a slope could cause the front wheels to lift off the ground, reducing control and increasing the chance of an accident.

● Do not tow with any point except specified hitch point and never exceed maximum specified weight on hitch point.

●

Do not operate on steep hills when fully loaded.

● Do not exceed the maximum load limit.

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WARNING

Be sure to check “LOADING/

TRAILER TOWING” carefully before loading or towing (See page 7-2).

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MAINTENANCE

REQUIRED FOR UTILITY

CAR SAFETY

Practice the following to help ensure the safety of utility car operators:

● Preventative Maintenance . Perform all scheduled maintenance in accordance with manufacturer’s recommendations to provide the user with a safe, properly operating utility car.

● Personnel . Allow only qualified, trained, and authorized personnel to inspect, adjust, and maintain utility cars.

● Parts and Materials . Use only replacement parts and materials recommended by Yamaha.

● Ventilation . Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards. Ventilation is required to remove flammable vapors and fumes from gasoline powered car storage areas.

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SAFETY PRECAUTIONS

DURING MAINTENANCE

When performing maintenance, follow all safety instructions contained in the manufacturer’s operation and service manuals, as well as the following safety procedures:

● Properly immobilize utility car before beginning any maintenance.

● Properly block chassis before working underneath utility car.

● Before disconnecting any part of the fuel system, drain the applicable part of the system to prevent fuel leaks.

● Avoid fire hazards, and have appropriate fire protection equipment available.

● Maintain all safety devices including brakes, steering mechanisms, warning devices, and governors, in a safe operating condition. Do not modify these safety devices as supplied by the manufacturer.

● After each maintenance or repair, the car must be driven by a qualified, trained, and authorized person

– in an area free of pedestrian traffic

– to ensure proper operation and adjustment.

● Record all maintenance performed in a maintenance record log by date, name of person performing maintenance, and type of maintenance.

Periodically inspect maintenance log to ensure accurate and complete entries.

● Maintain in a legible condition all nameplates, warnings, and instructions provided by the manufacturer.

●

If new nameplates, warnings, or instructions are needed, contact your Yamaha dealer.

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FUEL HANDLING/

STORAGE AND

BATTERY CHARGING

Take the following precautions to ensure maintenance worker safety:

● Supervise the storage and handling of liquid fuels in accordance with applicable fire and safety requirements.

● Only use battery changing and charging facilities and procedures that are in accordance with applicable ordinances and regulations.

● Periodically inspect fueling and charging facilities and procedures to be certain that applicable safety codes, regulations, and procedures are being followed.

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CONTROLS

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9 8

Y-12

FEATURES

1 Steering wheel

2 Seat

3

Battery

4

Brake pedal

5

Parking brake pedal

6

Accelerator pedal

7

Drive selector lever

8

Main switch

9

Oil warning light a

Choke knob b Front cowl c Front tire d

Front bumper e

Rear cowl f

Rear tire g

Fuel cap

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2

3

9

10

13

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11

12

7

10

16

15

Y-107

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A

OFF

ON

OFF

ON

OFF

ON

CONTROLS

MAIN SWITCH

The main switch controls the following items:

OFF

Ignition circuit is switched off.

The key can be removed only in this position.

1

2

3

Y-15

ON

Electrical circuits are switched on.

The utility car can be driven.

6

7

Y-16

Y-17

OIL WARNING LIGHT

When the engine oil level falls below an acceptable level, this light comes on.

If the light comes on, stop the engine, check the engine oil level, and add oil as necessary. (See page

6-4).

å

Oil warning light

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9

10

11

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5

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CONTROLS

5-3

A

DRIVE SELECT LEVER

The drive select lever is used to shift the utility car into forward or reverse.

After coming to a complete stop, move the lever to the desired position.

Y-18

Lever Position

F

R

Car Movement

FORWARD

REVERSE

NOTE

:

The back-up buzzer will beep when the drive select lever is turned to “R.”

A

Y-109

ACCELERATOR PEDAL

The accelerator pedal controls the utility car’s speed.

Y-20

Action

Depress pedal

Release pedal

å

Accelerator pedal

Car Speed

Increase

Decrease

BRAKE PEDAL

Press down on the brake pedal to stop the utility car.

å

Brake pedal

Y-21

UTILITY

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A

CHOKE

A

Y-22

CONTROLS

PARKING BRAKE PEDAL

Press down on the parking brake pedal whenever parking the utility car.

å

Parking brake pedal

NOTE :

Release the parking brake by depressing the accelerator pedal.

1

2

3

CHOKE KNOB

Pull and hold out choke knob when starting a cold engine. Release the knob after the engine starts.

å

Choke knob

4

5

6

Y-23

Y-110

TOW HITCH

Use the tow point within the specified weight limits.

1

Tow point

7

8

* Tow weight 454 kg (1000 lb)

Tongue weight 68 kg (150 lb)

9

WARNING

Do not drive the machine over a walking speed of 5 km/h (3 mph) while towing. Otherwise, an accident could result.

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* Including driver, passenger, vehicle cargo and trailer cargo.

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Pre-operation checks should be made each time you use your utility car. Get in the habit of performing the following checks in the same way so that they become second nature.

A

B

WARNING

●

●

Be sure the main switch key is removed before performing the pre-operation checks to prevent accidental starting, and apply the parking brake to keep the car from moving.

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

PRE-OPERATION

CHECKLIST

Before each use check the following:

✔ Fuel system

✔ Engine oil level

✔ Battery

✔ Tire condition

✔ Steering system

✔ Back-up buzzer

✔ Pedal operation

✔ Body and chassis

SEAT

Open the seat and lift the cargo bed for checking and servicing.

å Seat

∫

Prop rod

Y-115

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Y-112

CARGO BED

Lift 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.

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2

3

Y-113

A

Y-114

4

WARNING

●

●

●

Remove the main switch key and apply the parking brake before lifting the cargo bed. Otherwise the vehicle could unexpectedly move.

Never drive the car with the bed in the up position. Injury could occur if the bed fell accidentally.

Before closing the bed, be sure others are standing away from the car and that no one is sitting on the seat. Keep hands and fingers away from the pinch point between the bed and seat back.

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å

Prop rod

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C

E

F

B

A

Y-850

FUEL SYSTEM

Make sure there is sufficient fuel in the tank, and check fuel line and connections for leakage.

å

Fuel level gauge

∫

“F” Full

ç

“E” Empty

WARNING

Gasoline and its vapors are highly flammable and explosive.

● Do not smoke when refueling and keep away from sparks, flames,

● or other sources of ignition.

Stop engine and allow it to cool for several minutes before 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 dispose of gasoline-soaked rags properly.

Tighten the filler cap securely after refueling.

If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.

If any gasoline gets on your skin, immediately wash with soap and water. Change clothing if gasoline spills on it.

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Recommended fuel:

Unleaded gasoline

Fuel tank capacity:

6.3 US gal

(24.0 L, 5.3 Imp gal)

CAUTION

Avoid using gasoline blended with methyl alcohol which can damage fuel system parts.

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MIN

A

C

B

Recommended oil:

YAMALUBE 4-cycle oil or

SAE 10W-30

Engine oil capacity:

1.16 US qt

(1.1 L, 0.24 Imp gal)

Oil change quantity:

1.0 US qt

(0.9 L, 0.19 Imp gal)


MAX

A

Y-514

Y-28

Y-515

ENGINE OIL

With the utility car parked on level ground, remove the dipstick and make sure the engine oil is between the MIN and MAX marks (the crosshatched area on the end of the dipstick).

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2

3

å

Oil level dipstick

∫

Maximum oil level

ç Safe operating range

If the oil level is below the MIN mark on the dipstick, add oil through the oil filler hole until the oil level is between the MIN and MAX marks.

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6

å Oil filler hole

CAUTION

●

●

Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the crankcase.

Use care not to get oil on the starter belt.

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8

9

NOTE :

The distance between the dipstick marks represents approx. 1/2 US qt

(1/2 L) of oil.

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NOTE :

Recommended engine oil classification: API Service SE, SF, or SG.

Engine oils labeled “Energy Con-serving II” are recommended.

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BATTERY

Check that the battery is held securely in place to prevent the battery from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the battery. Check the battery terminals for corrosion.

A

TIRE CONDITION

Tire Air Pressure

Check the tire air pressure before operating the utility car.

Y-30

Tire pressure:

For G11-A:

20 - 23 psi

(140 - 160 kPa, 1.4 - 1.6 kgf/cm2)

Tire Wear Limit

Check the tire surface for damage, cracks or embedded objects. When tire tread wears down to 0.04 in. (1 mm), replace the tire.

å

Wear limit

Y-31

6-5

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 3-15


Y-116

STEERING SYSTEM

Check the steering system for excessive freeplay by:

● moving the steering wheel up and down, and back and forth.

● turning the steering wheel slightly to the right and left.

If you feel excessive freeplay, or hear rattling sounds which may indicate loose steering components, consult a

Yamaha dealer.

1

2

3

4

5

BACK-UP BUZZER

Check the back up buzzer by moving the drive select lever to “R” for reverse.

The buzzer should sound.

6

7

Y-33

PEDAL OPERATION

Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha dealer.

8

9

Brake Pedal

Make sure the brake pedal feels firm when pressed and returns to its original position when released.

å

Brake pedal

10

11

Y-21

6-6

UTILITY

A

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 3-16

9

10

11

1

2

3

4

5

6

7


A

Y-22

Parking Brake Pedal

Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed.

å Parking brake pedal

NOTE :

Release the parking brake by depressing the accelerator pedal.

A

Accelerator Pedal

WARNING

Before checking operation of the accelerator pedal, be sure the main switch is in the “OFF” position.

Make sure the accelerator pedal operates smoothly.

å Accelerator pedal

8

Y-20

BODY AND CHASSIS

Before each use, visually inspect the utility car body and chassis for damage and/or missing parts.

6-7

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 7-1

A

CH

OK

E

OFF

ON

A

Y-18

Y-16

Y-23

Y-20

OPERATION

STARTING

1. With the parking brake applied, turn the drive select lever to “F” for forward, or “R” for reverse.

1

2

CAUTION

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

3

2. Turn the main switch to “ON.”

WARNING

Do not depress the accelerator pedal when turning on the main switch or the utility car may suddenly start moving.

4

5

6

3. Pull the choke knob out and hold it while starting. Release the choke knob after the engine starts.

å

Choke knob

7

8

NOTE :

The choke is not required when the engine is warm.

9

4. Check that your path is clear in the direction you plan to go, and slowly depress the accelerator pedal.

The utility car will start to move.

10

å

Accelerator pedal 11

NOTE :

The parking brake automatically releases when the accelerator pedal is depressed.

7-1

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 7-2

OPERATION

1

2

3

4

5

6

7

8

9

A

B

10

11

MAXIMUM LOADING LIMIT

●

●

Maximum cargo bed load

227 kg (500 lb)

Tow hitch

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

454 kg (1000 lb)

Tongue weight:

68 kg (150 lb)

7-2

Y-65

Y-117

Y-119

STOPPING

To stop the utility car, gradually press down on the brake pedal.

å Brake pedal

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

∫ Parking brake pedal

CAUTION

Do not hold the utility car on an incline with the accelerator – use the brake.

LOADING/TRAILER

TOWING

WARNING

Be sure to check “SAFETY INFOR-

MATION” carefully before loading or towing. (See page 3-3)

WARNING

●

●

●

●

●

Do not exceed the maximum loading limits. An overloaded vehicle can be unstable.

Keep load as low as possible.

Drive slowly when cargo is loaded. No top heavy loads.

Secure loads to prevent shifting.

Cargo should be evenly spread in cargo bed as far forward as possible the center of gravity may affect the handling, steering, and braking performance.

Make sure cargo in the trailer cannot move around. A shifting load can cause an accident.

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-1

MAINTENANCE

PERIODIC MAINTENANCE CHARTS

Regular maintenance is required for the best performance and safe operation of your utility car.

1

WARNING

Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a

Yamaha dealer or other qualified mechanic.

2

3

FOR G11A

Item Remarks

Check or Adjust Lubricate R Replace

Every

Pre20 Rounds 125 rds

Opera- 20 hours 125 hrs tion 100 miles

160 kms

600 mls

1000 kms

250 rds

250 hrs

1200 mls

500 rds

500 hrs

1000 rds

1000 hrs

2500 mls 5000mls

2000 kms 4000 kms 8000 kms

Page

(1 month) (6 months) (1 year) (2 yrs) (4 yrs)

Engine Adjust valve clearance (cold)**

*

Check tightness of cylinder head

*

Check condition of air filter foam cover**

Wash the air filter cover with soap and water and allow it to dry**

Check condition of air filter paper element assembly**

Check spark plug for condition of electrode**

Adjust the engine bracket tensioner

Check engine oil

R

R

8-7

8-7

8-7

8-5

*

6-4

Replace engine oil

R 8-6

Check compression pressure

*

Fuel system

Adjust throttle cable

*

Adjust choke cable**

*

Check carburetor for dirt or wear**

Check fuel lines for leakage

*

6-3

Replace fuel hoses

R *

Check fuel filter for clogging

*

Replace fuel filter

R *

Check fuel level

6-3

Starter Check starter V-belt for damage and tension

Check brushes for wear

*

*

Check commutator for dirt

*

* 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.

UTILITY

8-1

4

5

6

7

8

9

10

11

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-2

9

10

11

MAINTENANCE

1

2

3

4

5

6

FOR G11A

Item Remarks

Primary and secondary sheaves

Check drive belt for slippage, wear, or scratches

Grease secondary sheave bearing

Check for operation and wear of sliding sheave

Check for wear of ramp shoes on secondary spring seat

Grease primary sheave

Every


Opera- 20 hours 125 hrs tion 100 miles

160 kms

600 mls

1000 kms

250 rds

250 hrs

1200 mls

500 rds

500 hrs

1000 rds

1000 hrs

2500 mls 5000mls

2000 kms 4000 kms 8000 kms

Page


8-9

Gear box

Check opeartion of speed limiter

*

*

*

*

*

6-6

Check operation of forwardreverse shifting

Check for damage to shifting cable

Check gear box oil level and leakage

Replace gear box oil

Battery Check for looseness of battery terminals and hold downs

R

R

*

8-11

*

6-5

7

8

8-2

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-3

MAINTENANCE

FOR G11A

Item

Brakes

Remarks

Check and adjust if necessary

Check brake pedal free play

Check shoe lining thickness

Steering Check and adjust if necessary

Check gearbox for leakage

Adjust wheel alignment

Check kingpin play, seal, and cap

Lubricate kingpin

Wheel Check tire pressure

Check tire tread depth

Check tire surface for damage

Check wheel nut tightness

Check front wheel bearing play

Check rear axel bearing play

Check rear axel for damage

Body and chassis

Check body and chassis for damage

Check tightness of all bolts, nuts, and screws

Check shock absorbers for oil leaks

Check coil springs for cracks or damage

Accelerator stop switch

Check operation and adjust pedal stop if necessary

Back-up Check operation buzzer

Every


Opera- 20 hours 125 hrs tion 100 miles 600 mls

250 rds 500 rds 1000 rds

250 hrs 500 hrs 1000 hrs

1200 mls 2500 mls 5000mls Page

160 kms 1000 kms 2000 kms 4000 kms 8000 kms


6-5/

8-12

8-12

*

6-6

6-5

6-5

6-6

*

*

*

*

6-5

8-12

*

*

*

6-7

*

*

*

*

1

2

3

4

5

6

7

8

9

10

11

8-3

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-4

MAINTENANCE

1

2

3

4

EXHAUST EMISSION CONTROL SYSTEM

AND COMPONENTS

Item

• CARB. ASSY., LH., JT.,

CARBURETOR 2 & JT.,

CARBURETOR 1

• T.C.I. MAGNETO ASSY. &

PLUG, SPARK

• CRANKCASE 1 & HEAD,

CYLINDER 1

• AIR FILTER ASSY.

• MUFF., 2

Acronym

CARB (Carburetor)

El (Electronic Ignition)

PCV (Positive Crankcase

Ventilation)

ACL (Air Cleaner)

5

6

7

8

9

10

The above items and the corresponding acronyms are provided in accordance with U.S. EPA REGULATIONS

FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULA-

TIONS 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.

11

8-4

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-5

B

UTILITY

A

A

Y-516

Y-37

MAINTENANCE

Spark Plug Inspection

You should periodically remove and inspect the spark plug. Dirty or worn spark plugs can cause poor performance.

å

Spark plug

∫ 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.

1

2

3

4

5

Standard spark plug:

BPR2ES or BPR4ES

Spark plug gap:

0.028 ˜ 0.031 in (0.7 ˜ 0.8 mm)

6

7

å

Gap

3. Clean the gasket and plug surfaces and install the spark plug finger tight before tightening to the following torque:

8

9

Spark plug torque:

14.5 ft.lb

(20 Nm, 2.0 m.kg)

10

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.

11

8-5

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-6

MAINTENANCE

1

2

Engine Oil Replacement

1. Warm up the engine for several minutes, place the utility car on a level surface, then stop the engine.

3

4

5

6

7

8

9

10

11

Recommended oil:

YAMALUBE 4-cycle oil or

SAE 10W-30

Engine oil capacity:

1.16 US qt

(1.1 L, 0.24 Imp gal)

Oil change quantity:

1.0 US qt

(0.9 L, 0.19 Imp gal)

Y-624

WARNING

Use caution not to touch hot engine oil or hot engine parts, during the following procedure.

2. Place an oil pan under the engine drain plug.

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

NOTE :

Dispose of used oil in an environmentally safe way, such as taking oil to an oil collection station.

4. Install the drain plug, along with a new drain plug gasket, finger tight before tightening to the following torque:

Drain plug torque:

23 ft.lb

(31 Nm, 3.1 m.kg)

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

NOTE

:

Recommended engine oil classification: API Service SE, SF, or SG.

Engine oils labeled “Energy Con-serving II” are recommended.

8-6

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-7

A

A

B

B

A

Y-515

A

A

Y-518

Y-519

MAINTENANCE

å

Oil filler hole

1

CAUTION

Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the crankcase. After replacing engine oil, check for oil leaks around the drain plug. If oil leaks are found, consult a Yamaha dealer.

2

3

4

Air Filter

To remove the air filter elements:

1. Unlatch the air filter cover clips and remove cover.

å Air filter cover clips

∫

Air filter cover

5

6

7

2. Lift the air filter and pre-filter out of the air filter case.

å

Air filter

∫

Pre-filter

8

9

CAUTION

Be careful not to drop anything into the air inlet.

10

11

8-7

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-8

9

10

11

1

2

3

4

5

6

7

MAINTENANCE

A

B

Y-508

Inspection and cleaning:

3.

Wash the foam pre-filter in soap and water. Allow it to dry.

å

Soap and water

∫

Foam element

4.

Check the filter element. If damaged or dirty, replace it.

CAUTION

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

5.

To replace the elements, reverse the above steps.

CAUTION

The pre-filter has a notch on one side. It will only fit in the case one way.

8

8-8

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-9

A

B

Y-60

Y-44

MAINTENANCE

Drive Belt

To remove the drive belt:

1. Set the drive select lever halfway between forward and reverse.

2. Pull up on the drive belt and push it outward over the edge of the secondary sheave.

3. Turn the secondary sheave clockwise and the drive belt will roll off the sheave.

4. Remove the drive belt from the primary sheave.

Inspection:

To inspect the drive belt, check for frayed edges or tears, and measure drive belt against the following specification. If the belt shows excessive wear or damage, replace the belt with a new one.

å

New: 1.22 in. (31.0 mm)

∫ Replace when belt reaches:

1.06 in. (27 mm)

5. To install the drive belt, reverse the above steps, rolling the belt back over the secondary sheave.

1

2

3

4

5

6

7

8

9

10

11

8-9

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-10

6

7

8

4

5

1

2

3

9

10

11

MAINTENANCE

– –

+ +

Y-45

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 CHIL-

DREN.

The 12-volt battery that provides starting power to your gas car normally doesn’t require the addition of water during the one year warranty period provided by the battery manufacturer.

If the battery loses its charge, have an experienced mechanic charge it.

Fuse Replacement

8-10

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-11

A

B

C

Replacement Fuse:

10 Amp, Blade Style

UTILITY

B

Y-35

MAINTENANCE

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.

å

Fuse case

∫ Fuse

ç

Replacement fuse

4

5

Gear Box Oil

To check gear box oil level:

1. Place the utility car on a level surface.

2. Lift the seat and cargo bed.

6

7

8

Y-111

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)

A

Y-520

9

10

11

8-11

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-12

MAINTENANCE

1

● Add gear oil little by little until oil flows from the plug hole (B).

2

3

4

5

6

7

8

9

10

Wheel nut tightening torque:

58 ft.lb (80 Nm, 8.0 m.kg)

Y-57

11 WARNING

Consult your Yamaha dealer before using your utility car if you suspect brake problems. Brake failure could result in a serious accident.

4. Allow excess gear oil to flow out until it stops.

CAUTION

Do not allow foreign material to enter the gear box.

5. Reinstall the oil plug.

NOTE :

For gear oil replacement, consult a

Yamaha dealer or other qualified mechanic.

Wheel Replacement

To remove and install a wheel on your utility car:

1. With the wheels blocked to prevent the utility car from moving, loosen the wheel nuts.

2. Elevate the utility car with a jack and remove the wheel nuts and the wheel.

3. Reverse the removal steps when installing the wheel.

Brake Adjustment

The brakes on your utility car are selfadjusting.

Before you operate the car, press down on the brake pedal several times to make sure the brakes are functioning properly.

8-12

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-13

25-30 mm

7

8

9

10

11

12

13

14

15

16

17

18

MAINTENANCE

Brake Pedal Free Play

Adjustment

1

CAUTION

Before adjusting brake pedal free play, pump the brake pedal several times to self-adjust the brakes.

2

3

To adjust the brake pedal free play:

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

4

5

Y-61

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.

6

7

Y-63

Y-62

Brake pedal free play:

25-30 mm (0.98-1.18 in.)

8

3. If the free play distance needs adjusting, loosen the lock nut and turn the adjusting nut in or out (in

180° increments only, due to the cam shape of adjuster), until the free play specification is met. Then tighten the lock nut in place.

9

10

11

WARNING

Do not overtighten the brake cables. The self adjusters may not operate properly, reducing braking performance.

8-13

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-14

STORAGE

6

7

8

4

5

1

2

3

9

10

11

A

9-1

Perform the following preparations when storing your utility car for extended periods of time:

NOTE :

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

Y-521

DRAINING FUEL

WARNING

Gasoline and its vapors are highly flammable and explosive.

●

●

●

●

●

●

●

Do not smoke when refueling and keep away from sparks, flames, or other sources of ignition.

Stop engine and allow it to cool for several minutes before refueling.

Refuel in a well-ventilated area.

Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Always dispose of gasoline-soaked rags properly.

Tighten the filler cap securely after refueling.

If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.

If any gasoline gets on your skin, immediately wash with soap and water. Change clothing if gasoline spills on it.

1. Fill the fuel tank.

å

Float bowl drain screw

2. Drain the carburetor float bowl into a suitable container by turning the screw located on the bottom of the carburetor.

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-15

STORAGE

ENGINE PREPARATION

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.

CHASSIS

PREPARATION

1. Increase the tire pressure to 23 psi

(160 kPa, 1.6 kgf/cm2).

2. Clean exterior of the utility car and apply a rust inhibitor.

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

BATTERY

PREPARATION

1. Remove the battery from the utility car and store it in a cool, dry place that stays between 32˚F (0˚C) and

90˚F (30˚C).

2. Have the battery recharged every

60-90 days to keep it fully charged. The battery must be kept fully charged to avoid damage.

NOTE :

Batteries like the one supplied with your car 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

7

8

9

10

11

9-2

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-16

9

10

11

SPECIFICATIONS

1

2

3

4

5

6

GENERAL SPECIFICATIONS

Items

Dimensions:

Overall length

Overall width

Overall height (steering height)

Height of floor

Wheelbase

Tread:

Front

Rear

Min. ground clearance

Weight:

Dry weight (without battery)

Performance:

Maximum speed

7

Minimum turning radius

Seating capacity

Hill climbing ability

8

G11A

120.0 in. (3050 mm)

50.4 in. (1280 mm)

47.2 in. (1200 mm)

11.8 in. (300 mm)

74.8 in. (1900 mm)

34.3 in. (870 mm)

38.6 in. (980 mm)

4.5 in. (115 mm)

838 lb (380 kg)

12 mph

(19 km/h)

138.0 in. (3.5 m)

2 persons

27˚ (50% grade) on pavement

10-1

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-17

SPECIFICATIONS

ENGINE

Items

Description:

Engine type

Number of cylinders

Displacement

Bore x stroke

Compression ratio

Rated output

Cooling system

Starting system

Ignition system

Spark plug type

Spark plug gap

Lubrication system

Engine oil type

Engine oil capacity

Oil change quantity

TRANSMISSION

Items

Transmission:

Type

V-belt width and outer line length

V-belt wear limit

Governor:

Type

Factory speed setting

Differential/reduction gear:

Differential type

Lubricant/capacity

G11A

4-stroke, Gasoline, OHV

Single

301 cm 3

3.07 x 2.48 in. (78 x 63 mm)

8.1:1

9.5 hp (7.1 kw)/4000 rpm

Forced air cooled

Starter

TCI Magneto

BPR2ES

0.028-0.031 in. (0.7-0.8 mm)

Splash

YAMALUBE 4 cycle oil or SAE 10W30

1.16 US qt (1.1 L, 0.24 Imp gal)

1.0 US qt (0.9 L, 0.19 Imp gal)

1

2

3

4

5

6

G11A

V-belt automatic centrifugal engagement

1.22 x 39.76 in. (31 x 1010 mm)

1.06 in. (27 mm)

Oil bath flyweight

12 mph (19 km/h)

G11A

Bevel gear

SAE 90 gear oil/0.44 US qt

(0.42 L, 0.09 Imp gal)

7

8

9

10

11

BATTERIES

Items

Battery:

G11A

BCI group 24,

RC: minimum 75 min

CCA: minimum 400A

UTILITY

10-2

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 8-18

SPECIFICATIONS

1

2

3

4

5

6

CHASSIS

Items

Steering system:

Type

Steering angle (L.H.)

Steering angle (R.H.)

Lubricant/capacity

Brakes:

Brake system

Type of brake

Brake pedal freeplay linkage adjustment

(Brake cable end play)

Parking brake:

Type

7

8

Release timing

(Bolt heads round parallel to arm)

Wheel:

Tire size:

Front

Rear

Rim size:

Tire pressure:

9

G11A

Worm and pin

1.5 turn

1.5 turn

Grease/3.0 US oz (0.09 L, 3.17 Imp oz)

Mechanical drum brake on each rear wheel with self-adjusters.

Dual internal expanding shoe.

Leading/trailing shoes (self-adjusting)

25-30 mm

0.004-0.02 in. (0.1-0.5 mm)

Foot type; parking brake with automatic release.

0.04 in. (1 mm)

18 x 8.50–8.00/4 PR

18 x 8.50–8.00/TURF

7.00–I–8.00

For G11A:

20 - 23 psi (140 - 160 kPa, 1.4 - 1.6 kgf/cm2)

10

11

10-3

UTILITY

LIT_19626_11_97.qxd 3/22/01 3:24 PM Page 11-1

G11A WIRING DIAGRAM

WIRING

6

7

8

4

5

1

2

3

9

10

11

11-1

UTILITY

OWNER’S/

OPERATORS

MANUAL

UTILITY

CAR

01/10/01

1PC - G11A O/M

LIT196261197

*LIT196261197*

USA Yamaha Motor Corp., USA

Cypress, California made in

YAMAHA MOTOR

MANUFACTURING CORP.

OF AMERICA


KCC

LIT-19626-11-97

G11A

JR3-F8199-10

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