Yamaha G21A Operator`s manual

UTILITY
CAR
OWNER’S/
OPERATOR’S
MANUAL
G21A
10/31/00
1PC - G21A O/M
LIT196261100
*LIT196261100*
USA
Yamaha Motor Corp., USA
Cypress, California
made in
YAMAHA MOTOR
MANUFACTURING CORP.
OF AMERICA
LIT-19626-11-00
Printed in U.S.A.
KCC
G21A O_M Cover
1
11/2/00, 10:22 PM
JR6-F8199-00
G21A O_M IFC
8/8/00
7:56 AM
Page 1
WARNING
The engine exhaust from this product
contains chemicals known to the
State of California to cause cancer, birth
defects or other reproductive harm.
YAMAHA
LIT-CALIF-65-01
G21A O_M IFC
8/8/00
7:56 AM
Page 1
WARNING
The engine exhaust from this product
contains chemicals known to the
State of California to cause cancer, birth
defects or other reproductive harm.
YAMAHA
LIT-CALIF-65-01
LIT_19626_11_00
3/22/01
1:06 PM
Page i
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.
1
2
3
4
5
TECHNICAL SERVICE DEPT
GOLF CAR SALES GROUP
YAMAHA MOTOR
MANUFACTURING CORP OF
AMERICA
7
8
G21A
OWNER’S/OPERATOR’S
MANUAL
© 2000 by Yamaha Motor
Manufacturing Corporation
of America
1st edition
All rights reserved. Any reprinting
or unauthorized use without the
written permission of
Yamaha Motor Manufacturing
Corporation of America
is expressly prohibited.
Printed in U.S.A.
P/N LIT-19626-11-00
UTILITY
6
9
10
11
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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.
CAUTION
This message describes special
precautions that must be taken to
avoid damage to 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.
WARNING
Read and understand this manual
completely before operating your
utility car.
NOTE:
This message provides additional key
information.
ii
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Page iii
CONTENTS
WARRANTY
1
IMPORTANT LABELS
2
OPERATOR SAFETY
3
MAINTENANCE SAFETY PROGRAM
4
CONTROLS
5
PRE-OPERATION CHECKS
6
OPERATION
7
MAINTENANCE
8
1
STORAGE
9
SPECIFICATIONS
10
WIRING
11
UTILITY
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Page iv
WARRANTY
YAMAHA MOTOR
CORPORATION, U.S.A.
G21A UTILITY VEHICLE
LIMITED WARRANTY
1
2
Yamaha Motor Corporation, U.S.A. hereby warrants
that any new G21A Utility Vehicle purchased from
an authorized Yamaha dealer in the United States,
will be free from defects in material and workmanship for the period of time stated herein, subject to
the stated limitations.
3
THE PERIOD OF WARRANTY for any G21A Utility
Vehicle will be one year from date of purchase for
parts and labor.
4
The warranty shall cover the entire car except for
batteries, tires and rims, which are warranted by
their respective manufacturers.
5
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.
6
7
GENERAL EXCLUSIONS from this warranty shall
include any failures caused by:
8
a.
b.
c.
9
d.
e.
10
f.
g.
11
Abnormal strain, neglect, or abuse, including
lack of proper maintenance, and use contrary
to the owner’s manual instructions.
Accident or collision damage.
Installation of parts or accessories that are not
original equipment.
Fading, rust, or deterioration due to exposure
or ordinary wear and tear.
Modification or alteration that affects the Utility
Vehicle’s condition, operation, performance, or
durability.
Damage due to improper transportation.
Acts of God (i.e. lightning, hail damage, flooding,
fire, etc.)
SPECIFIC EXCLUSIONS from this warranty shall
include any parts replaced due to normal wear or
routine maintenance, including oil, air filter elements, brake shoes, spark 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.
1-1
THE CUSTOMER’S RESPONSIBILITY under this
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.
WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine
be inspected and registered for warranty by an
authorized Yamaha Golf Car Dealer. In order for this
warranty to remain in effect, this inspection and registration must take place within ten (10) days after
transfer. An inspection and registration fee will be
charged for this service.
YAMAHA MOTOR CORPORATION, U.S.A. MAKES
NO OTHER WARRANTY OF ANY KIND,
EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE WHICH EXCEED
THE OBLIGATIONS AND TIME LIMITS STATED IN
THIS WARRANTY ARE HEREBY DISCLAIMED
BY YAMAHA MOTOR CORPORATION, U.S.A.
AND EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, SO
THE ABOVE LIMITATION MAY NOT APPLY TO
YOU. ALSO EXCLUDED FROM THIS WARRANTY
ARE ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES INCLUDING LOSS OF USE. SOME
STATES DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION
MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER
RIGHTS WHICH VARY FROM STATE TO STATE.
YAMAHA MOTOR MANUFACTURING
CORPORATION OF AMERICA
Newnan, Georgia 30265-1320
Effective Date: 10/1/00
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WARRANTY
YAMAHA MOTOR MANUFACTURING
CORPORATION OF AMERICA
SPECIALTY VEHICLE ENGINES
EMISSION CONTROL WARRANTY
1
2
YOUR WARRANTY RIGHTS AND OBLIGATIONS
In complance with the California Air Resources
Board, Yamaha Motor Manufacturing Corporation of
America is pleased to explain the emission control
system warranty on your 1996 or later specialty
vehicle engine. New Yamaha speciality vehicle
engines must be designed, built and equipped to
meet stringent anti-smog standards. Yamaha must
warrant the emission control system on your speciality vehicle engine for the periods of time listed
below provided there has been no abuse, neglect or
improper maintenance of your speciality vehicle
engine.
Your emission control system may include parts
such as the carburetor or fuel-injection system, the
ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.
4
If you have any questions regarding your warranty
rights and responsibilities, you should contact the
Yamaha Customer Relations Department at
(770) 254-4164.
5
Yamaha Motor Manufacturing Corporation of
America warrants to the ultimate purchaser and
each subsequent purchaser thereafter that each
new 1996 and later model year specialty vehicle
engine certified for sale is:
1.
Where a warrantable condition exists, Yamaha will
repair your specialty vehicle engine at no cost to you
including diagnosis, parts and labor.
2.
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.
●
UTILITY
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.
●
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
All warranted parts are free from defects in
material and workmanship for the warranty
period of the specialty vehicle engine or the
period prior to the first scheduled replacement
point of the warranted part as required by the
maintenance schedule, if applicable, whichever
is less. A defect exists when a deficiency in
material or workmanship is such that an emission-related warranted part does not function
as designed.
The warranty period begins on the date that the
specialty vehicle engine is delivered to an ultimate
purchaser or on the date it is first placed in service.
WARRANTED PARTS INCLUDE the following:
1. Fuel Metering System
Carburetor and internal parts (or fuel injection)
Air/fuel ratio feedback and control system
Cold start enrichment system
2.
Air Induction System
Controlled hot air intake system
Intake manifold
1-2
6
7
8
9
10
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Page vi
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
1
2
3
4
5
6
9.
7
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).
8
DURING THE PERIOD OF THIS WARRANTY
9
Yamaha Motor Manufacturing Corporation of
America will repair or replace any warranted part
deemed defective by Yamaha during the scope of
the warranty without charge to the owner, including
parts, labor, and diagnosis. This work must be done
at an authorized Yamaha dealer. Give notice to an
authorized Yamaha dealer of any apparent defect(s)
within a reasonable period of time after discovery.
The specialty vehicle engine must be made available for inspection by an authorized Yamaha dealer.
10
11
1-3
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.
Yamaha Motor Manufacturing Corporation of
America
1000 Hwy. 34 East
Newnan, GA 30265
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IMPORTANT LABELS
SAFETY AND
INSTRUCTION
LABELS
4
1
6
5
1
2
WARNING
2
9
Please read the following
labels carefully before
operating your utility car,
and promptly replace any
labels which become damaged or removed.
3
4
3
5
Y-100
1
6
2
7
8
3
4
9
10
5
11
6
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IMPORTANT LABELS
9
1
2
3
4
7
8
Y-852
Y-101
8
7
5
9
6
7
8
9
Y-851
UTILITY CAR SERIAL
NUMBER
0000
0
10
JR6-0
The utility car serial number is
stamped in the location shown.
11
Y-102a
2-2
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.
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Page 3-1
! OPERATOR SAFETY
Yamaha utility cars are designed to be
simple to operate. However, be sure to
observe the following:
BEFORE OPERATING
THE UTILITY CAR
1
2
●
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.
4
●
Only authorized people should drive
the utility car, from the driver’s side
only, and only in designated areas.
5
Do not allow more than two people
to ride in the utility car. This utility car
is restricted to two occupants.
6
Y-8
●
●
●
Y-68
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.
3
7
8
9
WHILE OPERATING THE 10
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.
Y-123
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! OPERATOR SAFETY
1
2
3
●
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 your surroundings.
●
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.
●
All occupants should remain inside
the vehicle. Remain seated, and
hold on when the car is in motion.
Y-104
4
5
6
7
Y-103
8
9
10
11
3-2
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! OPERATOR SAFETY
LOADING/TOWING
●
●
●
●
●
Y-105
●
Y-106
●
●
●
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.
WARNING
Be sure to check “LOADING/ TRAILER TOWING” carefully before loading or towing (See page 7-2).
UTILITY
3-3
1
2
3
4
5
6
7
8
9
10
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MAINTENANCE SAFETY PROGRAM
1
2
3
MAINTENANCE
REQUIRED FOR UTILITY
CAR SAFETY
6
7
●
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.
8
9
SAFETY PRECAUTIONS
10 DURING MAINTENANCE
11
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.
Practice the following to help ensure
the safety of utility car operators:
4
5
●
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.
4-1
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MAINTENANCE SAFETY PROGRAM
FUEL HANDLING/
STORAGE AND
BATTERY CHARGING
1
2
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.
●
3
4
5
Periodically inspect fueling and
charging facilities and procedures to
be certain that applicable safety
codes, regulations, and procedures
are being followed.
6
7
8
9
10
11
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CONTROLS
FEATURES
1
1
9
8
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
6
5
2
4
3
Y-12
4
5
6
7
2
3
8
14
9
15
10
13
7
11
10
16
Y-107
11
12
5-1
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CONTROLS
MAIN SWITCH
1
The main switch controls the following
items:
OFF
Ignition circuit is switched off.
The key can be removed only in this
position.
OF
F
2
3
ON
4
Y-15
5
ON
Electrical circuits are switched on.
The utility car can be driven.
OF
F
6
ON
7
Y-16
8
OIL WARNING LIGHT
W AO I L
RN
ING
ON
A
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).
OF
F
Y-17
9
10
å Oil warning light
11
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CONTROLS
DRIVE SELECT LEVER
1
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.
2
3
Y-18
4
Lever Position
Car Movement
F
R
FORWARD
REVERSE
NOTE:
The back-up buzzer will sound when
the drive select lever is turned to “R.”
5
6
Y-109
7
ACCELERATOR PEDAL
A
8
The accelerator pedal controls the utility car’s speed.
Action
9
Car Speed
Depress pedal
Increase
Release pedal
Decrease
Y-20
10
å Accelerator pedal
BRAKE PEDAL
11
Press down on the brake pedal to stop
the utility car.
å Brake pedal
A
Y-21
5-3
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CONTROLS
PARKING BRAKE PEDAL
1
Press down on the parking brake pedal
whenever parking the utility car.
A
Y-22
å Parking brake pedal
2
NOTE:
Release the parking brake by depressing the accelerator pedal.
3
CHOKE KNOB
4
Pull and hold out choke knob when
starting a cold engine. Release the
knob after the engine starts.
5
å Choke knob
A
E
OK
CH
6
Y-23
TOW HITCH
7
Use the tow point within the specified
weight limits.
8
1 Tow point
* Tow weight
Y-110
Tongue weight
590 kg (1300 lb)
10
WARNING
Do not drive the machine over a
walking speed of 5 km/h (3 mph)
while towing. Otherwise, an accident could result.
*
UTILITY
9
68 kg (150 lb)
Including driver, passenger, vehicle
cargo and trailer cargo, on level
ground.
5-4
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Page 3-10
PRE-OPERATION CHECKS
1
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.
2
WARNING
3
●
4
5
●
6
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
7
Before each use check the following:
✔ Fuel system
✔ Engine oil level
✔ Battery
✔ Tire condition
✔ Steering system
✔ Back-up buzzer
✔ Pedal operation
✔ Body and chassis
8
9
10
A
11
SEAT
B
Open the seat and lift the cargo bed
for checking and servicing.
å Seat
∫ Prop rod
Y-115
6-1
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PRE-OPERATION CHECKS
CARGO BED
1
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.
2
3
Y-112
4
WARNING
●
Y-113
●
●
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.
A
Y-114
5
6
7
8
9
å Prop rod
10
11
UTILITY
6-2
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Page 3-12
PRE-OPERATION CHECKS
1
FUEL SYSTEM
A
C
E
F
B
Make sure there is sufficient fuel in the
tank, and check fuel line and connections for leakage.
2
3
Y-850
WARNING
4
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.
5
6
7
8
9
10
11
å Fuel level gauge
∫ “F” Full
ç “E” Empty
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
6.3 US gal
(24.0 L, 5.3 Imp gal)
6-3
CAUTION
Avoid using gasoline blended with
methyl alcohol which can damage
fuel system parts.
UTILITY
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Page 3-13
PRE-OPERATION CHECKS
ENGINE OIL
1
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).
3
Y-514
å Oil level dipstick
∫ Maximum oil level
ç Safe operating range
B
MIN
C
4
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.
MAX
A
2
Y-28
5
6
å Oil filler hole
A
CAUTION
●
●
Y-515
7
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.
8
9
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)
UTILITY
NOTE:
The distance between the dipstick
marks represents approx. 1/2 US qt
(1/2 L) of oil.
NOTE:
Recommended engine oil classification: API Service SE, SF, or SG.
Engine oils labeled “Energy Con-serving II” are recommended.
6-4
10
11
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PRE-OPERATION CHECKS
BATTERY
1
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.
2
3
4
TIRE CONDITION
Tire Air Pressure
5
Check the tire air pressure before
operating the utility car.
6
Tire pressure:
For G21-A:
7
Y-30
8
A
9
Front Tires
20 - 23 psi
(140 - 160 kPa, 1.4 - 1.6 kgf/cm2)
Rear Tires
29 - 31 psi
(197 - 217 kPa, 2.0 - 2.2 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.
10
Y-31
å Wear limit
11
6-5
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Page 3-15
PRE-OPERATION CHECKS
1
STEERING SYSTEM
Check the steering system for excessive freeplay by:
●
moving the steering wheel up and
down, and back and forth.
●
turning the steering wheel slightly to
the right and left.
Y-116
If you feel excessive freeplay, or hear
rattling sounds which may indicate
loose steering components, consult a
Yamaha dealer.
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
8
PEDAL OPERATION
Check the following pedal controls for
proper operation. If a pedal does not
work properly, consult a Yamaha dealer.
9
10
Brake Pedal
Make sure the brake pedal feels firm
when pressed and returns to its original position when released.
å Brake pedal
A
Y-21
UTILITY
6-6
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PRE-OPERATION CHECKS
1
Parking Brake Pedal
A
Make sure the parking brake pedal
locks in place with a positive click, and
releases when the accelerator pedal is
pressed.
2
å Parking brake pedal
3
Y-22
NOTE:
Release the parking brake by
depressing the accelerator pedal.
4
Accelerator Pedal
5
WARNING
Before checking operation of the
accelerator pedal, be sure the main
switch is in the “OFF” position.
6
7
Make sure the accelerator pedal operates smoothly.
A
å Accelerator pedal
8
9
Y-20
10
BODY AND CHASSIS
11
Before each use, visually inspect the
utility car body and chassis for damage and/or missing parts.
6-7
UTILITY
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Page 7-1
OPERATION
1
STARTING
1. With the parking brake applied,
turn the drive select lever to “F” for
forward, or “R” for reverse.
CAUTION
Y-18
Do not shift from “F” forward to “R”
reverse while the utility car is moving.
3
4
2. Turn the main switch to “ON.”
OF
F
2
WARNING
ON
Do not depress the accelerator
pedal when turning on the main
switch or the utility car may suddenly start moving.
5
6
Y-16
3. Pull the choke knob out and hold it
while starting. Release the choke
knob after the engine starts.
7
å Choke knob
8
NOTE:
The choke is not required when the
engine is warm.
9
A
E
OK
CH
Y-23
A
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.
11
å Accelerator pedal
Y-20
UTILITY
10
NOTE:
The parking brake automatically
releases when the accelerator pedal is
depressed.
7-1
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Page 7-2
OPERATION
STOPPING
1
B
To stop the utility car, gradually press
down on the brake pedal.
å Brake pedal
2
When the car has come to a stop,
apply the parking brake pedal and turn
the main switch to “OFF.”
A
3
Y-65
∫ Parking brake pedal
4
CAUTION
Do not hold the utility car on an
incline with the accelerator – use
the brake.
5
6
Y-117
LOADING/TRAILER
TOWING
WARNING
7
Be sure to check “SAFETY INFORMATION” carefully before loading
or towing. (See page 3-3)
8
WARNING
9
10
Y-119
●
MAXIMUM LOADING LIMIT
●
11
●
●
7-2
Maximum cargo bed load:
363 kg (800 lb)
Tow hitch
Tow weight (Including driver,
passenger, vehicle cargo
and trailer and trailer cargo):
590 kg (1300 lb)
Tongue weight:
68 kg (150 lb)
●
●
●
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
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Page 8-1
MAINTENANCE
PERIODIC MAINTENANCE CHARTS
Regular maintenance is required for the best performance and safe operation of
your utility car.
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.
CA - CHECK AND ADJUST
R - REPLACE
Remarks
PreOperation
S - SERVICE
CL - CLEAN AND LUBRICATE
20 Rounds
20 hours
100 miles
160 kms
(Every
month)
125 rds
125 hrs
600 mls
1000 kms
(Every 6
months)
L - LUBRICATE
250 rds
250 hrs
1200 mls
2000 kms
(Every
year)
500 rds
500 hrs
2500 mls
4000 kms
(Every
2 years)
1000 rds
1000 hrs
5000mls
8000 kms
(Every
4 years)
4
Page
PRE-
Check engine oil
C
C
C
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
C
C
C
C
C
C
6-3
Check for looseness
and corrosion of battery
terminals and hold downs
C
C
C
C
C
C
6-5
Check brake pedal freeplay
and adjust if necessary
C
CA
CA
CA
CA
CA
8-12
Check steering operation
C
C
C
C
C
Check tire pressure, tread
depth, tire surface for damage
C
CA
CA
CA
CA
CHECKS Check fuel level
6-4
6-6
CA
C
C
C
C
C
C
Check tightness of all bolts,
nuts, and screws
C
C
C
C
C
C
*
Check reverse buzzer
operation
C
C
C
C
C
C
6-6
6-7
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 of
Forward / Reverse shifting
C
C
C
C
C
–
Clean / Lube pedal control area
CL
EVERY 6 Wash pre-filter, check air
MONTHS cleaner element
5
6
7
6-5
Check body and chassis for
damage
EVERY
8
9
10
–
S
S
S
S
8-6
Check spark plug and plug cap
condition** / Check compression
C
C
C
C
8-4/*
Check shock absorbers for oil
leaks and damaged springs
C
C
C
*
* 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
2
3
FOR G21A
C - CHECK
1
8-1
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Page 8-2
MAINTENANCE
1
C - CHECK
CA - CHECK AND ADJUST
R - REPLACE
1000 rds
1000 hrs
5000mls
8000 kms
(Every
4 years)
Page
R
R
R
8-5
CA
CA
CA
*
Check starter V-belt for
damage and tension
C
C
C
*
Check drive belt for slippage,
wear or scratches
C
C
C
8-8
Check sliding sheave and
ramp shoes; Grease secondary
sheave bearing.
CL
CL
CL
*
Replace engine oil
YEAR
Adjust throttle cables,**
choke cable, check carburetor
throttle shaft for wear**
4
125 rds
125 hrs
600 mls
1000 kms
(Every 6
months)
L - LUBRICATE
500 rds
500 hrs
2500 mls
4000 kms
(Every
2 years)
EVERY
3
CL - CLEAN AND LUBRICATE
250 rds
250 hrs
1200 mls
2000 kms
(Every
year)
Remarks
2
S - SERVICE
20 Rounds
Pre20 hours
Opera- 100 miles
tion
160 kms
(Every
month)
5
Grease primary sheave
L
L
L
*
Check operation of speed limiter
C
C
C
*
Apply battery terminal protectant
S
S
S
–
6
Check wiring connections
and insulation
C
C
C
–
Check shoe lining thickness
and rear axle bearing play
C
C
C
*
Check kingpin play, seal, and
cap / Adjust wheel alignment
CA
CA
CA
*
Check wheel nut tightness,
front wheel bearing play
C
C
C
*
Check gear box oil level
and leakage
C
C
C
8-10
CA
CA
CA
*
C
S
*
R
*
7
8
Check operation and adjust
pedal stop if necessary
9
EVERY Check brushes for wear and
2 YEARS commutator for dirt
EVERY Replace fuel filter and
4 YEARS fuel hoses
Check tightness of cylinder
head / Adjust valves
10
Replace gear box oil
Check for grease leakage;
adjust gearbox if necessary
11
CA
*
R
8-10
CA
*
* 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.
8-2
UTILITY
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Page 8-3
MAINTENANCE
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
1
Acronym
CARB (Carburetor)
2
El (Electronic Ignition)
3
PCV (Positive Crankcase
Ventilation)
ACL (Air Cleaner)
4
5
The above items and the corresponding acronyms are provided in accordance with U.S. EPA REGULATIONS
FOR SMALL NONROAD ENGINES
and the CALIFORNIA REGULATIONS FOR NEW 1995 AND LATER
OFF-HIGHWAY
RECREATIONAL
VEHICLES AND ENGINES.
The acronyms conform to the latest
version of the SAE’s recommended
practice document J1930, “Diagnostic
Acronyms, Terms, and Definitions For
Electrical/Electronic System”.
It is recommended that these items
be serviced by a Yamaha dealer or
other qualified mechanic.
6
7
8
9
10
11
UTILITY
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Page 8-4
MAINTENANCE
Spark Plug Inspection
1
2
You should periodically remove and
inspect the spark plug. Dirty or worn
spark plugs can cause poor performance.
B
å Spark plug
∫ Spark plug cap
3
A
Y-516
4
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.
5
A
Standard spark plug:
BPR2ES or BPR4ES
6
Y-37
7
Spark plug gap:
0.028 ˜ 0.031 in (0.7 ˜ 0.8 mm)
å Gap
8
3. Clean the gasket and plug surfaces and install the spark plug finger tight before tightening to the
following torque:
9
10
Spark plug torque:
14.5 ft.lb
(20 Nm, 2.0 m.kg)
11
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.
8-4
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Page 8-5
MAINTENANCE
Engine Oil Replacement
1. Warm up the engine for several
minutes, place the utility car on a
level surface, then stop the
engine.
WARNING
1
2
3
Use caution not to touch hot engine
oil or hot engine parts, during the
following procedure.
4
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.
Y-624
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)
UTILITY
4. Install the drain plug, along with a
new drain plug gasket, finger tight
before tightening to the following
torque:
5
6
7
8
9
Drain plug torque:
23 ft.lb
(31 Nm, 3.1 m.kg)
5. Add the correct quantity of oil
through the oil filler hole.
10
NOTE:
Recommended engine oil classification: API Service SE, SF, or SG.
Engine oils labeled “Energy Conserving II” are recommended.
11
8-5
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Page 8-6
MAINTENANCE
1
å Oil filler hole
A
CAUTION
2
3
Y-515
4
Air Filter
To remove the air filter elements:
A
5
B
A
1. Unlatch the air filter cover clips
and remove cover.
A
å Air filter cover clips
∫ Air filter cover
6
7
Y-518
2. Lift the air filter and pre-filter out
of the air filter case.
8
9
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.
å Air filter
∫ Pre-filter
A
CAUTION
10
B
Y-519
Be careful not to drop anything
into the air inlet.
11
8-6
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Page 8-7
MAINTENANCE
A
Inspection and cleaning:
B
1
3. Wash the foam pre-filter in soap
and water. Allow it to dry.
Y-508
å Soap and water
∫ Foam element
2
4. Check the filter element. If damaged or dirty, replace it.
3
CAUTION
4
Do not wring out the foam pre-filter, this could cause it to tear.
5. To replace the elements, reverse
the above steps.
5
6
CAUTION
The pre-filter has a notch on one
side. It will only fit in the case one
way.
7
8
9
10
11
UTILITY
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Page 8-8
MAINTENANCE
Drive Belt
1
To remove the drive belt:
2
1. Set the drive select lever halfway
between forward and reverse.
3
2. Pull up on the drive belt and push
it outward over the edge of the
secondary sheave.
4
3. Turn the secondary sheave clockwise and the drive belt will roll off
the sheave.
5
Y-60
4. Remove the drive belt from the primary sheave.
Inspection:
6
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.
A
B
7
8
Y-44
9
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.
10
11
8-8
UTILITY
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Page 8-9
MAINTENANCE
Battery
1
WARNING
Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes, or clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of
water or milk. Follow with milk of
magnesia, beaten egg, or vegetable
oil. Call physician immediately.
EYES: Flush with water for 15
minutes and get prompt medical
attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc.,
away.
Ventilate when charging or using in
enclosed space. Always shield eyes
when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
The 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.
++
–
–
2
3
4
5
6
7
8
9
10
11
Y-45
UTILITY
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Page 8-10
MAINTENANCE
Fuse Replacement
1
WARNING
B
2
Be sure to use the specified fuse.
Using a wrong fuse can cause electrical system damage and create a
fire hazard.
A
3
C
CAUTION
Y-35
4
5
Replacement Fuse:
10 Amp, Blade Style
When replacing a fuse be sure the
main switch is turned off to prevent
accidental short-circuiting.
å Fuse case
∫ Fuse
ç Replacement fuse
6
Gear Box Oil
To check gear box oil level:
7
1. Place the utility car on a level surface.
8
2. Lift the seat and cargo bed.
9
10
Y-111
3. Remove the oil plug (A).
11
Recommended oil:
SAE 90 gear oil
A
B
8-10
Gearcase capacity:
0.44 US qt
(0.42 L, 0.09 Imp gal)
Y-520
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Page 8-11
MAINTENANCE
Add gear oil little by little until oil
flows from the plug hole (B).
1
4. Allow excess gear oil to flow out
until it stops.
2
●
CAUTION
Do not allow foreign material to
enter the gear box.
5. Reinstall the oil plug.
4
NOTE:
For gear oil replacement, consult a
Yamaha dealer or other qualified
mechanic.
5
6
Wheel Replacement
Y-57
Wheel nut tightening torque:
58 ft.lb (80 Nm, 8.0 m.kg)
3
To remove and install a wheel on your
utility car:
7
1. With the wheels blocked to prevent
the utility car from moving, loosen
the wheel nuts.
8
2. Elevate the utility car with a jack
and remove the wheel nuts and
the wheel.
9
3. Reverse the removal steps when
installing the wheel.
10
Brake Adjustment
WARNING
Consult your Yamaha dealer before
using your utility car if you suspect
brake problems. Brake failure could
result in a serious accident.
UTILITY
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.
8-11
11
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Page 8-12
MAINTENANCE
Brake Pedal Free Play
Adjustment
1
CAUTION
2
Before adjusting brake pedal free
play, pump the brake pedal several
times to self-adjust the brakes.
3
To adjust the brake pedal free play:
4
1. Remove the service lid from the
floor of the utility car.
5
Y-61
6
7
25
-30
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.
mm
7
8
9 10
11
12
13
14
15
16
17
18
8
Brake pedal free play:
25-30 mm (0.98-1.18 in.)
Y-62
9
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.
10
11
WARNING
Y-63A
8-12
Do not overtighten the brake
cables. The self adjusters may not
operate properly, reducing braking
performance.
UTILITY
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Page 9-1
STORAGE
Perform the following preparations
when storing your utility car for extended periods of time:
1
NOTE:
Turn main switch key to “OFF” position,
remove key, and store key in a safe
place.
2
3
DRAINING FUEL
4
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.
A
å Float bowl drain screw
Y-521
UTILITY
2. Drain the carburetor float bowl into
a suitable container by turning the
screw located on the bottom of the
carburetor.
9-1
5
6
7
8
9
10
11
LIT_19626_11_00
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1:07 PM
Page 9-2
STORAGE
1
2
3
4
5
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 front tire pressure to
23 psi (160 kPa, 1.6 kgf/cm2) and
increase the rear tire pressure to
31 psi (217 kPa, 2.2 kgf/cm2).
2. Clean exterior of the utility car and
apply a rust inhibitor.
6
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.
3. Cover the utility car with a breathable cover and store it in a dry,
well-ventilated area.
7
8
9
10
11
9-2
UTILITY
LIT_19626_11_00
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1:07 PM
Page 10-1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Items
Dimensions:
Overall length
Overall width
Overall height (steering height)
Height of floor
Wheelbase
Tread:
Front
Rear
Min. ground clearance
1
G21A
2
120.0 in. (3050 mm)
51.5 in. (1308 mm)
47.2 in. (1200 mm)
11.8 in. (300 mm)
74.8 in. (1900 mm)
3
38.6 in. (980 mm)
38.6 in. (980 mm)
4.5 in. (115 mm)
4
Weight:
Dry weight (without battery)
5
851 lb (386 kg)
Performance:
Maximum speed
12 mph
6
(19 km/h)
Minimum turning radius
Seating capacity
Hill climbing ability
129.92 in. (3.3 m)
7
2 persons
22˚ (40% grade)
on pavement
8
9
10
11
UTILITY
10-1
LIT_19626_11_00
3/22/01
1:07 PM
Page 10-2
SPECIFICATIONS
1
ENGINE
Items
2
3
4
5
6
7
8
9
10
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
G21A
4-stroke, Gasoline, OHV
Single
357 cm3
3.30 x 2.48 in. (85 x 63 mm)
8.1:1
11.4 hp (8.5 kw)/3500 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)
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
G21A
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)
G21A
Bevel gear
SAE 90 gear oil/0.44 US qt
(0.42 L, 0.09 Imp gal)
11
BATTERIES
10-2
Items
G21A
Battery:
BCI group 24,
RC: minimum 75 min
CCA: minimum 400A
UTILITY
LIT_19626_11_00
3/22/01
1:07 PM
Page 10-3
SPECIFICATIONS
CHASSIS
1
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
Release timing
(Bolt heads round parallel to arm)
Wheel:
Tire size:
Front
Rear
Rim size:
Tire pressure:
Front
Rear
G21A
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 front and rear wheels
with self-adjusters.
Dual internal expanding shoe.
Leading/trailing shoes (self-adjusting)
2
3
4
25-30 mm
0.004-0.02 in. (0.1-0.5 mm)
5
Foot type; parking brake with automatic
release.
6
0.04 in. (1 mm)
7
18 x 8.50–8.00/4 PR
18 x 8.50–8.00/TURF
7.00–I–8.00
For G21A:
20 - 23 psi (140 - 160 kPa, 1.4 - 1.6 kgf/cm2)
29 - 31 psi (197 - 217 kPa, 2.0 - 2.2 kgf/cm2)
8
9
10
11
UTILITY
10-3
11-1
a
b
c
d
e
f
g
h
i
G
Br
Br
G
Br
R
Br
G
Br
Battery
Pilot lamp (12V, 3.4W)
Main switch
Accelerator stop switch
Back switch
Buzzer
Body ground
Horn
Horn sw.
R
P
P
R
R
Br
RY
9
1 Engine stop relay
2 Engine ground
3 Pickup
4 Rotor
5 Oil level gauge
6 Blade fuse (10A)
7 Voltage regulator
8 Starter generator
9 Relay
18
ON
Br
—
8
10
+
R
R
9
RW B
RW B
F2
6
L B
8
R
R
RW
A1
G
G
G
G
L
R/W
B
L
B
5
17
OFF
Br
Br
B
B
4
R/W
B
L
RW
G
B
G
R/W B
L
4
7
B
B
B
6
B
Br
5
Y-509
B.........................Black
L...........................Blue
G .......................Green
Y .......................Yellow
R...........................Red
P ..........................Pink
Br ......................Brown
W .......................White
B/R .............Black/Red
Y/B ..........Yellow/Black
R/Y ............Red/Yellow
R/W ............Red/White
COLOR CODE
3
R/W
B
R/W
WIRING
11
R/Y
Br
R/W
R/W
P
R
2
1
1:08 PM
12
R/W
Br
P
R
R
B
P
3
3/22/01
13
REV
R
B
B
P
10
14
B
P
1
7
B
B
2
FWD
15
11
16
LIT_19626_11_00
Page 10-4
G21A WIRING DIAGRAM
UTILITY
UTILITY
CAR
OWNER’S/
OPERATOR’S
MANUAL
G21A
10/31/00
1PC - G21A O/M
LIT196261100
*LIT196261100*
USA
Yamaha Motor Corp., USA
Cypress, California
made in
YAMAHA MOTOR
MANUFACTURING CORP.
OF AMERICA
LIT-19626-11-00
Printed in U.S.A.
KCC
G21A O_M Cover
1
11/2/00, 10:22 PM
JR6-F8199-00