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Yamaha G21A Owner's/Operator's Manual

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OWNER'S/
OPERATOR'S
MANUAL
LIT-19626-11-00
UTILITY
CAR
G21A
JR6-F8199-00

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Summary of Contents for Yamaha G21A

  • Page 1 UTILITY OWNER’S/ OPERATOR’S MANUAL G21A LIT-19626-11-00 JR6-F8199-00...
  • Page 2 WARNING The engine exhaust from this product contains chemicals known State of California to cause cancer, birth defects or other reproductive harm. YAMAHA LIT-CALIF-65-01...
  • Page 3 WARNING The engine exhaust from this product contains chemicals known State of California to cause cancer, birth defects or other reproductive harm. YAMAHA LIT-CALIF-65-01...
  • Page 4 INTRODUCTION Congratulations on your purchase of a Yamaha utility car. This manual con- tains information you will need for proper operation, maintenance, and care of your utility car. A thorough understanding these simple instructions will help you to obtain maximum enjoyment from your new Yamaha.
  • Page 5 IMPORTANT MANUAL INFORMATION Particularly important information is NOTE distinguished in this manual by the fol- Yamaha continually seeks ad- lowing notations: vancements in product design and quality; therefore, while this manual contains the most current product information available at the time of...

  • Page 6: Table Of Contents

    CONTENTS WARRANTY IMPORTANT LABELS OPERATOR SAFETY MAINTENANCE SAFETY PROGRAM CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE STORAGE SPECIFICATIONS WIRING UTILITY...

  • Page 7: Warranty

    Any charges incurred in Newnan, Georgia 30265-1320 transporting a Utility Vehicle to and from an autho- Effective Date: 10/1/00 rized Yamaha Golf Car Dealer for service or in per- forming field service is also excluded from this war- ranty. UTILITY...
  • Page 8 In complance with the California Air Resources You are responsible for presenting your specialty Board, Yamaha Motor Manufacturing Corporation of vehicle engine to a Yamaha dealer as soon as a America is pleased to explain the emission control problem exists. The warranty repairs should be...
  • Page 9 Catalytic converter ment, or repair of emission control systems be Thermal reactor Yamaha parts. The owner may elect to have main- Exhaust manifold tenance, replacement, or repair of the emission control devices and systems performed by any...

  • Page 10: Important Labels

    IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS WARNING Please read the following labels carefully before operating your utility car, and promptly replace any labels which become dam- aged or removed. Y-100 UTILITY...

  • Page 11: Important Labels

    NOTE The first three digits of the serial num- ber are for model identification; the Y-102a remaining digits are the unit produc- tion number. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer. UTILITY...

  • Page 12: Operator Safety

    OPERATOR SAFETY 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 man- ual and all safety and instruction labels on the utility car before oper- ating.
  • Page 13 OPERATOR SAFETY 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. Y-104 Vary the speed of the utility car to match the terrain of your surround- ings.
  • Page 14 OPERATOR SAFETY 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.

  • Page 15: Maintenance Safety Program

    Parts and Materials. Use only the car must be driven by a quali- replacement parts and materials fied, trained, and authorized person recommended by Yamaha. – in an area free of pedestrian traffic – to ensure proper operation and Ventilation. Properly ventilate all adjustment.

  • Page 16: Battery Charging

    MAINTENANCE SAFETY PROGRAM 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 require- ments. Only use battery changing and charging facilities and procedures that are in accordance with applica- ble ordinances and regulations.

  • Page 17: Controls

    CONTROLS FEATURES 1 Steering wheel 2 Seat 3 Battery 4 Brake pedal 5 Parking brake pedal 6 Accelerator pedal Y-12 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...

  • Page 18: Main Switch

    CONTROLS MAIN SWITCH The main switch controls the following items: Ignition circuit is switched off. The key can be removed only in this position. Y-15 Electrical circuits are switched on. The utility car can be driven. Y-16 OIL WARNING LIGHT When the engine oil level falls below an acceptable level, this light comes on.

  • Page 19: Accelerator Pedal

    CONTROLS 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 posi- tion. Y-18 Lever Position Car Movement FORWARD REVERSE NOTE The back-up buzzer will sound when the drive select lever is turned to “R.”...

  • Page 20: Parking Brake Pedal

    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 de- Y-22 pressing the accelerator pedal. CHOKE KNOB Pull and hold out choke knob when starting a cold engine.

  • Page 21: Pre-Operation Checks

    PRE-OPERATION CHECKS 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. WARNING Be sure the main switch key is removed before performing the pre-operation checks to prevent accidental starting, and apply the...

  • Page 22: Cargo Bed

    PRE-OPERATION CHECKS 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. Y-112 WARNING Remove the main switch key and...

  • Page 23: Fuel System

    PRE-OPERATION CHECKS FUEL SYSTEM Make sure there is sufficient fuel in the tank, and check fuel line and connec- tions for leakage. å Fuel level gauge ∫ “F” Full ç “E” Empty Y-850 WARNING Gasoline and its vapors are highly flammable and explosive.

  • Page 24: Engine Oil

    PRE-OPERATION CHECKS 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). Y-514 å Oil level dipstick ∫...

  • Page 25: Tire Condition

    PRE-OPERATION CHECKS BATTERY Check that the battery is held secure- ly in place to prevent the battery from being damaged from vibration or jar- ring. Also check that no battery caps are missing to prevent battery acid from spilling from the battery. Check the battery terminals for corrosion.

  • Page 26: Steering System

    Y-33 PEDAL OPERATION Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha deal- Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its origi- nal position when released.
  • Page 27 PRE-OPERATION CHECKS 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 Y-22 NOTE Release parking brake depressing the accelerator pedal. Accelerator Pedal WARNING Before checking operation of the accelerator pedal, be sure the main...

  • Page 28: Operation

    OPERATION STARTING 1. With the parking brake applied, turn the drive select lever to “F” for forward, or “R” for reverse. CAUTION Do not shift from “F” forward to “R” Y-18 reverse while the utility car is mov- ing. 2. Turn the main switch to “ON.” WARNING Do not depress the accelerator pedal when turning on the main...
  • Page 29 OPERATION 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.” Y-65 ∫ Parking brake pedal CAUTION Do not hold the utility car on an incline with the accelerator –...

  • Page 30: Maintenance

    Check shock absorbers for oil leaks and damaged springs Items with out a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does not contain these procedures. They are contained in the Service Manual.
  • Page 31 Check for grease leakage; adjust gearbox if necessary Items with out a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does not contain these procedures. They are contained in the Service Manual.
  • Page 32 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. UTILITY...

  • Page 33: Spark Plug Inspection

    MAINTENANCE Spark Plug Inspection You should periodically remove and inspect the spark plug. Dirty or worn spark plugs can cause poor perfor- mance. å Spark plug ∫ Spark plug cap 1. Check for discoloration and heavy Y-516 carbon deposits. The normal electrode color will be tan.

  • Page 34: Engine Oil Replacement

    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 Use caution not to touch hot engine oil or hot engine parts, during the following procedure. 2.

  • Page 35: Air Filter

    After replacing engine oil, check for oil leaks around the drain plug. If oil leaks are found, consult Y-515 a Yamaha dealer. Air Filter To remove the air filter elements: 1. Unlatch the air filter cover clips and remove cover.
  • Page 36 MAINTENANCE 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 dam- Y-508 aged or dirty, replace it. CAUTION Do not wring out the foam pre-fil- ter, this could cause it to tear.

  • Page 37: Drive Belt

    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 clock- wise and the drive belt will roll off the sheave.
  • Page 38 MAINTENANCE 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.

  • Page 39: Fuse Replacement

    MAINTENANCE Fuse Replacement WARNING Be sure to use the specified fuse. Using a wrong fuse can cause elec- trical system damage and create a fire hazard. CAUTION Y-35 When replacing a fuse be sure the main switch is turned off to prevent accidental short-circuiting.

  • Page 40: Wheel Replacement

    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.
  • Page 41 MAINTENANCE Brake Pedal Free Play Adjustment CAUTION Before adjusting brake pedal free play, pump the brake pedal several times to self-adjust the brakes. To adjust the brake pedal free play: 1. Remove the service lid from the floor of the utility car. Y-61 2.

  • Page 42: Storage

    STORAGE Perform the following preparations when storing your utility car for extend- ed periods of time: NOTE Turn main switch key to “OFF” position, remove key, and store key in a safe place. DRAINING FUEL WARNING Gasoline and its vapors are highly flammable and explosive.

  • Page 43: Engine Preparation

    STORAGE ENGINE PREPARATION BATTERY PREPARATION With the key removed and the spark plug lead disconnected, turn the 1. Remove the battery from the utility clutch by hand until compression is car and store it in a cool, dry place felt. This puts the valves in the closed that stays between 32˚F (0˚C) and position.

  • Page 44: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Items G21A Dimensions: Overall length 120.0 in. (3050 mm) Overall width 51.5 in. (1308 mm) Overall height (steering height) 47.2 in. (1200 mm) Height of floor 11.8 in. (300 mm) Wheelbase 74.8 in. (1900 mm) Tread: Front 38.6 in.
  • Page 45 SPECIFICATIONS ENGINE Items G21A Description: Engine type 4-stroke, Gasoline, OHV Number of cylinders Single Displacement 357 cm Bore x stroke 3.30 x 2.48 in. (85 x 63 mm) Compression ratio 8.1:1 Rated output 11.4 hp (8.5 kw)/3500 rpm Cooling system...
  • Page 46 18 x 8.50–8.00/TURF Rim size: 7.00–I–8.00 Tire pressure: For G21A: 20 - 23 psi (140 - 160 kPa, 1.4 - 1.6 kgf/cm 2 ) Front 29 - 31 psi (197 - 217 kPa, 2.0 - 2.2 kgf/cm 2 ) Rear...

  • Page 47: Wiring

    WIRING G21A WIRING DIAGRAM 11-1 UTILITY...
  • Page 48 10/31/00 1PC - G21A O/M LIT196261100 *LIT196261100* Yamaha Motor Corp., USA made in Cypress, California YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA Printed in U.S.A.

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