Yamaha YUM1A UMAX RALLY 2021 Owner's/Operator's Manual
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Yamaha YUM1A UMAX RALLY 2021 Owner's/Operator's Manual

Yamaha YUM1A UMAX RALLY 2021 Owner's/Operator's Manual

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OWNER'S / OPERATOR'S MANUAL
Read this manual carefully before operating this vehicle.
UMAX RALLY
YUM1A UMAX RALLY
YUM2A UMAX RALLY
LIT-19626-A0-89
MODEL YEAR
UTILITY VEHICLE
2021
J0M-F8199-12

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  • Page 1 2021 MODEL YEAR OWNER’S / OPERATOR’S MANUAL UTILITY VEHICLE Read this manual carefully before operating this vehicle. UMAX RALLY YUM1A UMAX RALLY YUM2A UMAX RALLY LIT-19626-A0-89 J0M-F8199-12...
  • Page 2 Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your...
  • Page 3 INTRODUCTION Congratulations on your purchase of a Yamaha utility vehicle. This manual contains information you will need for proper operation, maintenance, and care of your utility vehicle. A thorough understanding of these simple instructions will help you to ob- tain maximum enjoyment from your new Yamaha.
  • Page 4 A TIP provides key information to make procedures eas- ier or clearer. Yamaha continually seeks advancements in product design and quality; therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your utility vehicle and this manual.

  • Page 5: Table Of Contents

    CONTENTS CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING DIAGRAM INDEX...

  • Page 6: Warranty

    Any charges incurred in transporting a golf car or charger to and from an authorized Yamaha golf car dealer for service or in performing field service are also excluded from this warranty.
  • Page 7 WARRANTY Yamaha Golf-Car Company makes no other warranty of any kind, expressed or implied. All implied warranties of merchantability and fitness of merchantability and fitness for a particular purpose which exceed the obligations and time limits stated in this warranty are hereby disclaimed by Yamaha Golf-Car Company and excluded from this Warranty.

  • Page 8: Important Labels

    IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS WARNING Read the following labels carefully before operating your utility vehicle, and promptly replace any labels which become damaged or removed. Death or se- rious personal injury can result from failing to read and comply with the safety instruction labels.
  • Page 9 Storage should not exceed 22lb (10kg) YAMAHA ***-F151F-** EMISSION CONTROL INFORMATION YAMAHA MOTOR CO.,LTD. THIS EQUIPMENT CONFORMS TO **** CALIFORNIA EVP/EXH EMISSION REGULATIONS AND THIS ENGINE MEETS U.S. EPA EXH/EVAP REGS FOR ****. EF:***********...
  • Page 10 IMPORTANT LABELS YEAR OF CONSTRUCTION: **** MY**** YAMAHA MOTOR POWERED PRODUCTS CO., LTD 200-1 SAKAGAWA, KAKEGAWA, JAPAN MODEL: ***************** GROSS POWER: ***** hp/***** kW LOAD CAP.: *** kg (*** lb) BATTERY WEIGHT MAX.: ** kg VEHICLE WEIGHT: *****kg (**** lb) NOMINAL BATTERY VOLTAGE: **V G.V.W.R.: ***** kg (****** lb)
  • Page 11 Top-heavy loads increase the risk of overturn. Tighten cap before putting fuel container in cargo bed. Avoid hills and rough terrain. Read Owner’s/Operator’s Manual before loading or towing. YAMAHA ***-K7766-** 7 YUM2A UMAX RALLY WARNING Improper use of cargo bed can result in SEVERE Injury or DEATH from loss of control, overturn or other accidents.
  • Page 12 Do not tamper with governor to increase speed. Do not modify fuel system. Services should be performed by dealer or qualified personnel. YAMAHA ***-K8297-** 11 YUM1A UMAX RALLY WARNING Improperly loading a trailer or pulling an object can affect handling, stability, Improper tire pressure or overloading can cause loss of control.
  • Page 13 The engine serial number is affixed in the location shown. Engine serial number EMISSION CONTROL INFORMATION YAMAHA MOTOR CO.,LTD. This engine meets **** California exhaust emission regulations for small off-road engines. THIS ENGINE MEETS U.S.EPA EXH REGS FOR ****. EMISSION COMPLIANCE PERIOD : 1000HOURS...

  • Page 14: Safety Information

    SAFETY INFORMATION Yamaha utility vehicles are designed to be simple to operate. However, be sure to observe the following to reduce the risk of serious injury or death due to loss of control and other hazards: BEFORE OPERATING THE UTILITY VEHICLE •...
  • Page 15 SAFETY INFORMATION WHILE OPERATING THE UTILITY VEHICLE • Keep your entire body inside the utility vehicle, remain seated and hold on when the vehicle is in motion. • Do not start the utility vehicle until all occupants are seated. • Always keep both hands on the steering wheel when driving.
  • Page 16 • Choose only accessories designed for your utility vehicle. Your Yamaha dealer has a variety of gen- uine Yamaha accessories. Other accessories may also be available on the market. However, it is not...
  • Page 17 SAFETY INFORMATION Loading Cargo or a trailer can change the stability and han- dling of a utility vehicle. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the following points in mind: • Never exceed the weight limits shown on page 58.
  • Page 18 SAFETY INFORMATION MAINTENANCE REQUIRED FOR UTILITY VEHICLE SAFETY Practice the following to help ensure the safety of util- ity vehicle operators: • Preventative Maintenance. Perform all scheduled maintenance in accordance with manufacturer’s recommendations to provide a safe, properly oper- ating utility vehicle. •...
  • Page 19 • Maintain in a legible condition all nameplates, warnings, and instructions provided by the manu- facturer. • If new nameplates, warnings or instructions are needed, contact your Yamaha dealer. FUEL HANDLING/STORAGE AND BATTERY CHARGING Take the following precautions to ensure maintenance worker safety: •...

  • Page 20: Controls

    CONTROLS FEATURES 2 3,4,5 1. Storage compartment 2. Light switch 3. Engine/oil warning light 4. Fuel gauge 5. Hour meter 6. USB port 7. Main switch 8. Accelerator pedal 9. Brake pedal 10. Parking brake pedal 11. Horn switch 1. Storage compartment 2.
  • Page 21 NOTICE If the light is flashing, do not operate the vehicle. Contact your Yamaha Service representative to have the vehicle serviced. FUEL GAUGE The fuel gauge displays the fuel level in the fuel tank.
  • Page 22 CONTROLS HOUR METER The hour meter displays the total number of hours the utility vehicle has been run. Use the hour meter to de- termine when scheduled maintenance is due. 1. Hour meter LIGHT SWITCH “ ” Push the upper side (a) of the light switch to turn on the headlights and meter lighting.
  • Page 23 CONTROLS DRIVE SELECT LEVER The drive select lever is used to shift the utility vehicle into forward or reverse. After coming to a complete stop, move the lever to the desired position. Lever Position Vehicle Movement Forward Reverse The reverse alarm will sound when the drive select le- ver is turned to “R.”...
  • Page 24 CONTROLS PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the utility vehicle. Release the parking brake by depressing the acceler- ator pedal. 1. Parking brake pedal WARNING The parking brake will automatically release when the accelerator pedal is depressed. If the main switch is in the “ON”...
  • Page 25 CONTROLS STORAGE COMPARTMENTS This model is equipped with storage compartments in the locations shown. Maximum load limit: Under-hood storage compartment: 10 kg (22 lb) 1. Storage compartment 1. Storage compartment 1. Storage compartment CARGO BED 1. Cargo bed...
  • Page 26 CONTROLS OPENING AND CLOSING THE TAILGATE To open Pull the latch, and then lower the tailgate. To close Lift the tailgate to the original position, and then push 1. Tailgate the tailgate to securely lock it in place. 2. Latch LIFTING AND LOWERING THE CARGO BED To lift...
  • Page 27 CONTROLS WARNING Fall and Thrown Object Hazard • Do not carry passengers in the cargo bed. Death or serious personal injury can result from failing to comply with the safety instructions in this manual. WARNING Crush Hazard • Keep hands and fingers away from cargo bed and seat tracks.
  • Page 28 CONTROLS SEAT To remove Lift the front of the seat cushion, and then pull the cushion off. 1. Seat cushion Pull the tab on the under-seat panel lock up, and then turn the lock 1/4 turn clockwise. 1. Tab 2. Under-seat panel Remove the under-seat panel as shown.
  • Page 29 CONTROLS TRAILER HITCH RECEIVER BRACKET This vehicle is equipped with a 5 cm (2 in) receiv- er bracket for a standard trailer hitch. Trailer towing equipment can be obtained at a Yamaha dealer. 1. Trailer hitch receiver bracket...

  • Page 30: Pre-Operation Checks

    PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your utility vehicle. Get in the habit of performing the following checks in the same way so that they be- come second nature. WARNING To keep vehicle from moving while performing pre-operation checks: •...
  • Page 31 PRE-OPERATION CHECKS Stop engine and allow it to cool for several min- utes before refueling. Do not smoke when refueling and keep away from sparks, flames or other sources of ignition. Refuel in a well-ventilated area. Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags.
  • Page 32 PRE-OPERATION CHECKS 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. NOTICE Engine damage can result. • Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the 1.
  • Page 33 PRE-OPERATION CHECKS ENGINE COOLING INLET DUCT YUM1A UMAX RALLY Check the engine cooling inlet duct for debris. Re- move any debris present. To access the engine cooling inlet duct, remove the seat. 1. Engine cooling inlet duct YUM2A UMAX RALLY 1.
  • Page 34 • 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 free play, or hear rattling sounds which may indicate loose steering components, con- sult a Yamaha dealer.
  • Page 35 “R” for reverse. The alarm should sound. PEDAL OPERATION Check the following pedal controls for proper oper- ation. If a pedal does not work properly, consult a Yamaha dealer. Accelerator Pedal WARNING With the main switch in the “OFF” position, make sure the accelerator pedal operates smoothly.
  • Page 36 PRE-OPERATION CHECKS BODY AND CHASSIS Before each use, visually inspect the utility vehicle body and chassis for damage and/or missing parts. CARGO BED Make sure the cargo bed is lowered completely and is latched in the down position. Make sure the tailgate is latched in the closed posi- tion.
  • Page 37 OPERATION STARTING With the parking brake applied, turn the drive select lever to “F” for forward, or “R” for reverse. NOTICE Do not shift from “F” forward to “R” reverse while the utility vehicle is moving. Transmission damage can result. Turn the main switch to “ON.”...
  • Page 38 OPERATION LOADING Cargo or a trailer can change the stability and han- dling of a vehicle. You must use common sense and good judgment when carrying cargo or towing a trailer. Keep the fol- lowing points in mind: • Never exceed the weight limits shown. An over- loaded vehicle can be unstable.
  • Page 39 OPERATION • Drive more slowly than you would without a load. The more weight you carry, the slower you should • Allow more braking distance. A heavier vehicle takes longer to stop. • Avoid making sharp turns unless at very slow speeds to avoid tipping or rolling the vehicle.

  • Page 40: Operation

    * Items without 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.
  • Page 41 * Items without 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.
  • Page 42 Adjust parking brake release * Items without 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.
  • Page 43 CS R or replace if nec- essary * Items without 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.
  • Page 44 The abbreviations conform to the latest version of the SAE’s recommended prac- tice 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 qual- ified mechanic. TROUBLESHOOTING If the vehicle’s engine will not start, use the following chart:...
  • Page 45 MAINTENANCE AND ADJUSTMENT RECOMMENDED JACKING POINTS Front Jack up the vehicle at the indicated jacking points. Rear SPARK PLUG INSPECTION You should periodically remove and inspect the spark plug. Dirty or worn spark plugs can cause poor per- formance. WARNING When removing or installing the spark plug, be careful not to damage the insulator.
  • Page 46 MAINTENANCE AND ADJUSTMENT Check for discoloration and remove carbon de- YUM1A UMAX RALLY posits with a spark plug cleaner or wire brush. The normal electrode color will be tan. 1. Spark plug cap 2. Spark plug YUM2A UMAX RALLY 1. Spark plug cap 2.
  • Page 47 MAINTENANCE AND ADJUSTMENT ENGINE OIL REPLACEMENT For information on the jacking points, see page 40. Remove the bottom panel by removing the bolts and quick fasteners. Warm up the engine for several minutes, place the utility vehicle on a level surface, and then stop the engine.
  • Page 48 Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the crank- case. Serious engine damage can result. After replacing engine oil, check for oil leaks around the drain plug. If oil leaks are found, consult a Yamaha dealer.
  • Page 49 MAINTENANCE AND ADJUSTMENT WHY YAMALUBE YAMALUBE oil is a Genuine YAMAHA Part born of the engineers’ passion and belief that engine oil is an important liquid engine component. We form teams of specialists in the fields of mechanical engineering, chemistry, electronics and track testing, and have them develop the engine together with the oil it will use.
  • Page 50 MAINTENANCE AND ADJUSTMENT AIR FILTER To remove the air filter elements: YUM1A UMAX RALLY: To access the air filter case, remove the seat. YUM2A UMAX RALLY: To access the air filter case, remove the seat and lift the cargo bed up. Unlatch the air filter cover clips and remove cov- YUM1A UMAX RALLY 1.
  • Page 51 MAINTENANCE AND ADJUSTMENT Inspection and cleaning: Wash the foam pre-filter in soap and water. Allow it to dry. 1. Soap and water 2. Pre-filter Check the pre-filter. If damaged or dirty, replace NOTICE Do not wring out the foam pre-filter, this could cause it to tear.
  • Page 52 MAINTENANCE AND ADJUSTMENT Turn the secondary sheave clockwise and the drive belt will roll off the sheave. 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.
  • Page 53 MAINTENANCE AND ADJUSTMENT FUSE REPLACEMENT WARNING Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and cre- ate a fire hazard. Death or serious personal injury can result from failing to comply with the warning labels in this manual.
  • Page 54 MAINTENANCE AND ADJUSTMENT Pull the fuse out and inspect it. Replace the fuse if necessary. To install the seat, reverse the above steps. 1. Fuse holder cover 2. Locking tab To access the USB fuse Remove the front frame covers. 1.
  • Page 55 MAINTENANCE AND ADJUSTMENT Disconnect the light switch leads and meter coupler. 1. Light switch lead 2. Meter coupler Remove the ornament, and then remove the bolt. 1. Ornament 2. Bolt Remove the front panel by removing the bolts and quick fasteners. 1.
  • Page 56 Transaxle oil change quantity: 400 cc (400 mL, 0.42 US qt) Allow excess gear oil to flow out of the hole until it stops. Install the oil level plug. For transaxle oil replacement, consult a Yamaha deal- er or other qualified mechanic.
  • Page 57 WARNING Consult your Yamaha dealer before using your util- ity vehicle if you suspect brake problems. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.
  • Page 58 MAINTENANCE AND ADJUSTMENT BRAKE PEDAL FREE PLAY ADJUSTMENT Check the brake pedal free play by pressing against the pedal with two fingers (using light force) and mea- suring the distance the pedal travels before resistance is felt. Brake pedal free play: 1.
  • Page 59 MAINTENANCE AND ADJUSTMENT If the free play distance needs adjusting, loosen YUM1A UMAX RALLY the locknut(s) and turn the adjusting nut(s) in or out until the free play specification is met. Then tighten the locknut(s) in place. WARNING Do not over-tighten the brake cables. Over-tight- ening will increase brake wear and affect the over- all performance of the vehicle.
  • Page 60 MAINTENANCE AND ADJUSTMENT HEADLIGHTS This model is equipped with LED-type headlights. If a headlight does not come on, check the fuses and then have a Yamaha dealer check the vehicle. ADJUSTING A HEADLIGHT NOTICE It is recommended to have the headlight adjust- ment performed by a Yamaha dealer.

  • Page 61: Storage

    Fill the fuel tank with fresh fuel and add the spec- ified amount of Fuel Med RX, which is available from your Yamaha dealer, or equivalent product. Operate the vehicle for at least five minutes to distribute treated fuel through the fuel system.
  • Page 62 STORAGE Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system. Consult a Yamaha deal- er if the fuel system needs to be drained instead. ENGINE PREPARATION With the key removed and the spark plug lead discon- nected, turn the clutch by hand until compression is felt.

  • Page 63: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS YUM1A UMAX YUM2A UMAX Items RALLY RALLY Dimensions: Overall length 2910 mm (114.5 in) 3115 mm (122.6 in) Overall width 1360 mm (53.5 in) Overall height (steering height) 1290 mm (50.8 in) Overall height (sun top height) 1880 mm (74.0 in) Height of floor 385 mm (15.2 in)
  • Page 64 SPECIFICATIONS YUM1A UMAX YUM2A UMAX Items RALLY RALLY Maximum towing capacity 363 kg (800 lb) 680 kg (1500 lb) Vehicle rated capacity 317 kg (700 lb) 544 kg (1200 lb) Gross vehicle weight rating 787 kg (1735 lb) 1045 kg (2303 lb) Maximum gross combination 832 kg (1835 lb) 1181 kg (2603 lb)
  • Page 65 SPECIFICATIONS YUM1A UMAX YUM2A UMAX Items RALLY RALLY Available viscosity index 10W-30 or 10W-40 0 10 30 50 70 90 110130 °F SAE 10W-30 SAE 10W-40 -20 -10 0 10 20 30 40 50 °C Engine oil capacity 1.1 L (1100 cc, 1.16 US qt) TRANSMISSION YUM1A UMAX YUM2A UMAX...
  • Page 66 SPECIFICATIONS CHASSIS YUM1A UMAX YUM2A UMAX Items RALLY RALLY Suspension: Front Independent (oil-over strut type) Rear Pivoted trailing arm (mono-link) Lighting: Headlight Steering system: Type Rack and Pinion Steering angle (L.H.) 1.85 turn Steering angle (R.H.) 1.85 turn Brakes: Brake system Mechanical drum Mechanical drum brake on each rear...
  • Page 67 SPECIFICATIONS YUM1A UMAX YUM2A UMAX Items RALLY RALLY Minimum: Front 124 kPa (1.24 kgf/cm , 18 psi) Rear 124 kPa (1.24 kgf/cm , 18 psi)

  • Page 68: Wiring Diagram

    WIRING DIAGRAM...

  • Page 69: Index

    INDEX Accelerator pedal ..................15, 18 Air filter ..................... 15, 45 Battery ...................... 15, 47 Battery preparation ..................57 Brake adjustment ................... 52 Brake pedal ....................15, 18 Brake pedal free play adjustment ..............53 Cargo bed ....................15, 20 Chassis preparation ..................
  • Page 70 INDEX Features ......................15 Fuel ......................... 56 Fuel cap ......................15 Fuel gauge ....................15, 16 Fuse replacement ................... 48 Fuses ......................15 Headlight, adjusting ..................55 Headlights ...................... 55 Horn switch ....................15, 17 Hour meter ....................15, 17 Important labels ....................
  • Page 71 INDEX Parking brake pedal ................. 15, 19 Parking brake release adjustment ..............54 Periodic maintenance and adjustment charts ..........35 Pre-operation checks ..................25 Seat ........................ 23 Spark plug ...................... 15 Spark plug inspection ..................40 Specifications ....................58 Starting ......................32 Stopping ......................
  • Page 76 CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING DIAGRAM INDEX PRINTED IN USA 2020.06-0.3×1 CR...

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