Related Manuals for Yamaha U-MAX G23E
Summary of Contents for Yamaha U-MAX G23E
- Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S/OPERATOR’S MANUAL G23E JU6-F8199-10 LIT-19626-01-18...
- Page 3 A thorough understand- ing 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 vehicle, please con- sult a Yamaha dealer.
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Page 4: Important Manual Information
NOTE: 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 vehicle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. - Page 5 YAMAHA GOLF-CAR COMPANY MAKES NO OTHER new Utility Vehicle purchased from an authorized Acts of God (i.e. lightning, hail damage, flooding, WARRANTY OF ANY KIND, EXPRESSED OR Yamaha dealer in the United States, will be free from fire, etc.) IMPLIED. IMPLIED...
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Page 6: Table Of Contents
Trailer hitch bracket ......4-9 CONTENTS Transmitter unit ......4-10 LOCATION OF THE WARNING PRE-OPERATION CHECKS ....5-1 AND SPECIFICATION LABELS..1-1 Pre-operation check list ....5-2 Brakes..........5-3 DESCRIPTION AND VEHICLE Batteries ...........5-3 IDENTIFICATION ......2-1 Transmission oil .......5-4 Features .......... 2-1 Accelerator pedal ......5-4 Utility vehicle serial number..... - Page 7 Turning your vehicle......7-3 Brake pedal free play Braking ..........7-3 adjustment ........8-15 Going uphill ........7-4 Replacing a headlight bulb .... 8-17 Going downhill......... 7-5 Adjusting a headlight beam... 8-18 Rough terrain ........7-6 Replacing a taillight bulb ....8-19 Riding in brush or wooded areas..
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Page 8: Location Of The Warning And Specification Labels
L OCATION OF THE WARNING AND SPECIFICATION LABELS... - Page 9 Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. WARNING Improper use can result in SEVERE INJURY or DEATH FORWARD Vehicle capacity: 1 operator and 1 passenger.
- Page 10 Set fuel container on the ground and touch fuel nozzle to the unopened container before removing cap. Keep the fuel nozzle in contact with the container while refueling. Tighten cap before putting fuel container in cargo bed. YAMAHA JU7-K7767-00 WARNING...
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Page 11: Description And Vehicle Identification
D ESCRIPTION AND VEHICLE IDENTIFICATION FEATURES 1. Steering wheel 2. Seat 3. Batteries 4. Taillight 5. Rear tire 6. Receptacle 7. Transmitter unit 8. Front tire 9. Headlight 10. Accelerator pedal 11. Brake pedal 12. Parking brake pedal 13. Horn button 14. -
Page 12: Utility Vehicle Serial Number
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. 1. Key identification number... -
Page 13: Safety Information
SAFETY INFORMATION SEVERE INJURY OR DEATH can result if Never operate at speeds too fast for your you do not follow these instructions: skills or the conditions. Always go at a Read this manual and all labels carefully speed that is proper for the terrain, visibility, and follow the operating procedures de- and operating conditions, and your experi- scribed. - Page 14 Always go slowly and be extra careful when Always check for obstacles before operat- operating on unfamiliar terrain. Always be ing in a new area. alert to changing terrain conditions when Always be sure there are no obstacles or driving the vehicle. people behind you when you operate in re- Never operate on rough, slippery, or loose verse.
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Page 15: Control Functions
CONTROL FUNCTIONS All electrical circuits (except for the headlights Main switch and taillights) are switched on. The utility vehicle can be operated. All electrical circuits are switched on. The headlights and taillights come on. The utility vehicle can be operated. The main switch positions are as follows: OFF: All electrical circuits are switched off. -
Page 16: Drive Select Switch
Drive select switch NOTE: The back-up buzzer will sound when the drive The drive select switch is used for driving the select switch is set to “REVERSE.” utility vehicle either forward or in reverse. After coming to a complete stop, push the “FORWARD”... -
Page 17: Accelerator Pedal
Accelerator pedal Brake pedal The accelerator pedal controls the utility vehi- Press the brake pedal down to slow or stop cle’s speed. the utility vehicle. Action Vehicle speed Depress pedal Increase Release pedal Decrease 1. Brake pedal 1. Accelerator pedal... -
Page 18: Parking Brake Pedal
Parking brake pedal Horn button Press the parking brake pedal down whenev- Step on the horn button to sound the horn. er parking the utility vehicle. 1. Horn button 1. Parking brake pedal NOTE: Release the parking brake by depressing the accelerator pedal. -
Page 19: Auxiliary Dc Jack
Auxiliary DC jack 1. Set the main switch to “ON”. The auxiliary DC jack is located in the front 2. Open the auxiliary DC jack cap, and then panel. insert the accessory power plug into the The auxiliary DC jack can be used for acces- jack. -
Page 20: Cargo Bed
Cargo bed CAUTION: Do not use accessories requiring more than the maximum rated capaci- ty for the auxiliary DC jack. This may overload the circuit and cause the fuse to blow. If accessories are used for extended periods when the utility vehicle is not being operated or with the main switch set to “ON ”, the battery... - Page 21 Opening and closing the tailgate Lifting and lowering the cargo bed 1. Tailgate 2. Latch (× 2) 1. Cargo bed release lever To open: Unhook the latches, and then lower the tail- gate. To close: Place the tailgate in its original position, and then hook the latches.
- Page 22 To lift: WARNING Pull the cargo bed release lever towards the Apply the parking brake and remove rear, and then slowly lift up the cargo bed until the key from the main switch before end of the prop rod hooks onto the prop rod lifting the cargo bed.
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Page 23: Tow Switch
This vehicle is equipped with a 5 cm (2 in) re- tow switch is in the “RUN” position. ceiver bracket for a standard trailer hitch. Trailer towing equipment can be obtained at a Yamaha dealer. (See page 6-4 for precaution information.) 1. Tow switch NOTE: Anytime the tow switch is moved from the “RUN”... -
Page 24: Transmitter Unit
Transmitter unit The transmitter unit allows you to monitor, di- agnose, and program features in the motor control unit (MCU) by way of a personal digital assistant (PDA). The unit allows information from the MCU of a utility vehicle to be trans- ferred by way of infrared technology to and from the PDA. -
Page 25: Pre-Operation Checks
P RE-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 become second na- ture. WARNING Be sure the main switch key is removed before performing pre-operation... -
Page 26: Pre-Operation Check List
Pre-operation check list Before using this vehicle, check the following points: ITEM ROUTINE PAGE • Check battery condition. Batteries 5-3, 8-5–8-10 • Charge batteries. Brakes • Check for proper operation, condition and free play. 5-3, 8-15–8-17 Parking brake • Check for proper operation, condition and free play. 5-3, 8-15–8-17 Transmission oil •... -
Page 27: Brakes
Check the firm feeling when the brakes are applied. If battery terminals for corrosion. not, have the vehicle inspected by a Yamaha dealer. Brake operation Test the brakes at slow speed after starting out to make sure they are working properly. -
Page 28: Transmission Oil
Remove the key from the main switch Make sure that the accelerator pedal operates before checking accelerator pedal oper- properly. It must operate smoothly and fully ation. spring back when released. If the accelerator pedal does not operate properly, have a Yamaha dealer check the pedal. -
Page 29: Steering
Fittings and fasteners Always check the tightness of chassis fittings and fasteners before a ride. Take the utility vehicle to a Yamaha dealer or refer to the Ser- vice Manual for the correct tightening torques. Lights Check the headlights and taillights to make NOTE: sure they are working properly. - Page 30 , 36 psi) 1. The tires listed below have been ap- Rear 250 kPa (2.5 kgf/cm , 36 psi) proved by Yamaha Motor Manufac- Higher pressures may cause the turing Corporation of America for tire to burst. Inflate the tires very this model.
- Page 31 Tire wear limit When the tire groove decreases to 1 mm (0.04 in) due to wear, replace the tire. a. Tire wear limit...
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Page 32: Operation
O PERATION 2. Turn the main switch to “ON” or “ON ”. Starting 1. With the parking brake applied, push the “FORWARD” or “REVERSE” side of the drive select switch. 1. Drive select switch CAUTION: Do not shift from forward to reverse while the utility vehicle is moving. -
Page 33: Stopping
3. Check that your path is clear in the direc- Stopping tion you plan to go, and slowly depress To stop the utility vehicle, gradually press the accelerator pedal. down on the brake pedal. The utility vehicle will start to move. When the utility vehicle has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.”... -
Page 34: Accessories And Loading
Choose only accessories designed for your cle. Examples include (but are not limited vehicle. Your Yamaha dealer has a variety to) an object that limits your ability to turn of genuine Yamaha accessories. Other ac-... - Page 35 Tow weight (Including driver, ries. All parts and accessories added to passenger, vehicle cargo and trailer this vehicle should be genuine Yamaha and trailer cargo): or equivalent components designed for 590 kg (1300 lb)
- Page 36 Do not exceed the maximum tongue Make sure the load does not interfere with weight. You can measure tongue weight controls or your ability to see where you are with a bathroom scale. Put the tongue of going. the loaded trailer on the scale with the Drive more slowly than you would without a tongue at hitch height.
- Page 37 WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle han- dling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached.
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Page 38: Driving Your Vehicle
D RIVING YOUR VEHICLE WARNING POTENTIAL HAZARD GETTING TO KNOW YOUR VEHICLE Carrying a passenger in the cargo bed. This off-highway utility vehicle will handle and maneuver differently from an ordinary pas- WHAT CAN HAPPEN senger car or other vehicle. The passenger could fall or be struck by objects in the cargo bed. - Page 39 Carrying a passenger and cargo can affect WARNING vehicle handling. POTENTIAL HAZARD The total weight of operator, passenger, ac- Overloading this vehicle or carrying or cessories, cargo, trailer tongue weight, and towing cargo improperly. the trailer must not exceed the maximum load WHAT CAN HAPPEN limit.
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Page 40: Learning To Operate Your Vehicle
LEARNING TO OPERATE YOUR VEHICLE When slowing down or stopping, take your You should become familiar with the perfor- foot off the accelerator pedal and smoothly mance characteristics of the vehicle in a large, press the brake pedal. Improper use of the flat area that is free of obstacles and other ve- brakes can cause the tires to lose traction, re- hicles. -
Page 41: Going Uphill
GOING UPHILL WARNING Do not attempt to climb slopes until you have POTENTIAL HAZARD mastered basic maneuvers on flat ground. Operating on steep slopes. Use proper driving techniques to avoid over- WHAT CAN HAPPEN turns on hills and slopes. Drive straight up The utility vehicle can overturn more slopes, and avoid crossing the side of a slope, easily on steep slopes than on level sur-... -
Page 42: Going Downhill
If you start to lose traction or momentum WARNING when going up a slope, and you decide you POTENTIAL HAZARD will be unable to continue, use the brakes to Going down a slope improperly. come to a stop. Do not attempt to turn the ve- WHAT CAN HAPPEN hicle around. -
Page 43: Rough Terrain
If you must turn on the slope to avoid an ob- WARNING stacle, do so slowly and carefully. If the vehi- POTENTIAL HAZARD cle starts to tip, gradually steer in the downhill Operating in rough terrain. direction if there are no obstacles in your path. WHAT CAN HAPPEN As you regain proper balance, gradually steer The vehicle can overturn or go out of... -
Page 44: Periodic Maintenance And Adjustment
Be sure to turn off the main switch and ap- your vehicle to a Yamaha dealer to check the ply the parking brake when you perform torque settings and adjust them as necessary. -
Page 45: Periodic Maintenance/Lubrication
• Check operation and for looseness/Replace if damaged. Steering system* • Check toe-in/Adjust if necessary. • Check all chassis fittings and fasteners. Fittings and fasteners* • Correct if necessary. * Since these items require special tools, data and technical skills have a Yamaha dealer perform the service. -
Page 46: Seat
Seat 3. Lift the cargo bed up until the end of the Lift the seat to service the batteries. prop rod hooks onto the prop rod guide to support the cargo bed. 1. Seat 2. Prop rod Cargo bed 1. Cargo bed release lever Lift the cargo bed to service the batteries. - Page 47 WARNING Remove the key from the main switch and apply the parking brake before lifting the cargo bed. Otherwise, the utility vehicle could move unexpect- edly. Never operate the utility vehicle with the cargo bed in the up position. Inju- ry could occur if the cargo bed falls 1.
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Page 48: Batteries
Batteries Eight 6-volt deep cycle batteries provide pow- Battery care er for your electric utility vehicle and must be properly maintained and recharged for maxi- WARNING mum performance and service life. Battery electrolyte is poisonous and dan- To maintain your batteries: gerous, causing severe burns, etc. - Page 49 If the fluid level is low, carefully against the readings on the following add distilled water. Adding distilled water chart. Consult a Yamaha dealer if any after charging helps prevent boil over. low readings are found, or if readings vary more than one point between cells.
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Page 50: Battery Charging
Battery charging Temperature Satisfactory Uncorrected Hydrometer Reading °F °C WARNING 48.9 1.244 43.3 1.248 Read and understand the Owner’s Manual 37.8 1.252 provided with your utility vehicle’s battery 32.2 1.256 charger before charging batteries. 26.7 1.260 21.1 1.264 15.6 1.268 WARNING 10.0 1.272... - Page 51 1. DC output plug 2. Receptacle CAUTION: Use only battery chargers that are rated for use with 48 volt Yamaha Utility Vehi- cles. Thoroughly read and understand the user manual supplied with your 48 volt charger. 2. With the charger properly connected and grounded (see charger’s owner’s manu-...
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Page 52: Battery Installation
Battery installation WARNING Do not disconnect the DC output cord WARNING from the battery receptacle when the When working with batteries, do not put charger is on or an arc could occur that wrenches or other metal objects across may cause an explosion. the battery terminals. - Page 53 2. Connect the wire leads as shown. CAUTION: Do not overtighten the battery bracket nuts. Excessive force will damage the bat- tery casing. a. Forward 1. To receptacle 2. To motor control unit 3. To relay 4. Between batteries WARNING When installing batteries: Carefully place battery cables and brackets making sure that cables do...
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Page 54: Fuse Replacement
Fuse replacement The fuse is located under the seat. (See page 8-3 for seat opening and closing procedures.) If a fuse is blown, replace it. WARNING Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and create a fire hazard. -
Page 55: Transmission Oil
Transmission oil Transmission oil measurement 1. Place the vehicle on a level surface. 1. Transmission oil plug CAUTION: Be sure no foreign material enters the transmission case. 2. Remove the transmission oil filler plug 3. Install the transmission oil filler plug. and check the oil level. -
Page 56: Wheel Removal
1. Loosen the wheel nuts. 2. Elevate the vehicle and place a suitable NOTE: For transmission oil replacement, consult a stand under the frame. Yamaha dealer. 3. Remove the nuts from the wheel. 4. Remove the wheel. Y-57 8-13... -
Page 57: Wheel Installation
Wheel installation 2. Lower the vehicle so that the wheel is on 1. Install the wheel and the nuts. the ground. 3. Tighten the wheel nuts to the specified NOTE: torque. Tapered nuts are used for both the front and rear wheels. -
Page 58: Brake Adjustment
To adjust the brake pedal free play: 1. Remove the service lid from the floor of WARNING the utility vehicle. Consult your Yamaha dealer before using your utility vehicle if you suspect brake problems. Brake failure could result in a serious accident. - Page 59 2. Check the brake pedal free play by 3. If the free play distance needs adjusting, pressing against the pedal with two fin- loosen the locknut and turn the adjusting gers (using light force) and measuring nut in or out (in 180° increments only, the distance the pedal travels before re- due to the cam shape of adjuster), until sistance is felt.
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Page 60: Replacing A Headlight Bulb
Replacing a headlight bulb WARNING If a headlight bulb burns out, replace it as fol- Do not overtighten the locknut. The self lows. adjusters may not operate properly, reduc- 1. Remove the headlight bulb holder by ing braking performance. turning it counterclockwise. 1. -
Page 61: Adjusting A Headlight Beam
Adjusting a headlight beam CAUTION: It is advisable to have a Yamaha dealer make this adjustment. To raise the beam, turn the adjusting screw in direction a. To lower the beam, turn the adjusting screw in direction b. 1. Headlight bulb holder projection (× 2) 3. -
Page 62: Replacing A Taillight Bulb
Replacing a taillight bulb If a taillight bulb burns out, have a Yamaha dealer replace it. 8-19... -
Page 63: Cleaning And Storage
C LEANING AND STORAGE Battery storage care 1. Recharge the batteries and check the flu- Perform the following preparations when stor- id levels at least once a month. ing your utility vehicle for extended periods of 2. Clean the tops of the batteries with a so- time: lution of baking soda and water, as nec- essary, to remove corrosion. -
Page 64: Specifications
S PECIFICATIONS Model G23E Dimensions: Overall length 2915 mm (114.7 in) Overall width 1243 mm (48.9 in) Overall height (steering height) 1155 mm (45.5 in) Height of floor 300 mm (11.8 in) Wheelbase 1900 mm (74.8 in) Tread: Front 980 mm (38.6 in) Rear 980 mm (38.6 in) Ground clearance... - Page 65 Model G23E Steering system: Type Worm and pin Brakes: Brake system Mechanical drum brake on front and rear wheels with self-adjusters Type of brake Dual internal expanding shoe Leading/trailing shoes (self-adjusting) Brake pedal freeplay linkage adjustment 20–25 mm (0.79–0.98 in) Parking brake: Type Foot type;...
- Page 66 Model G23E Bulb voltage, wattage × quantity: 12 V, 30 W / 30 W × 2 Headlight Sealed beam × 2 Taillight Specified fuses: Main fuse 10 A 10-3...
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Page 67: Maintenance Record
M AINTENANCE RECORD Copies of work orders and/or receipts for parts you purchase and install will be required to docu- ment maintenance done in accordance with the warranty. The chart below is printed only as a re- minder to you that the maintenance work is required. It is not acceptable proof of maintenance work. - Page 70 PRINTED IN USA 2004.06-0.3×2 CR...