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Yamaha G21A manual

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Table of contents for the manual

  • Page 1

    O WNER’S/ OPERA T OR’S MANU AL UTILITY CAR LIT-19626-11-00 YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA JR6-F8199-00 Printed in U.S.A. KCC G21A Y amaha Motor Corp., USA Cypress, Calif ornia made in 10/31/00 LIT196261100 USA *LIT196261100* 1PC - G21A O/M G21A O_M Cover 11/2/00, 10:22 PM 1[...]

  • Page 2

    LIT -CALIF-65-01 The engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects or other reproductive harm. Y AMAHA W ARNING G21A O_M IFC 8/8/00 7:56 AM Page 1[...]

  • Page 3

    LIT -CALIF-65-01 The engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects or other reproductive harm. Y AMAHA W ARNING G21A O_M IFC 8/8/00 7:56 AM Page 1[...]

  • Page 4

    1 2 3 4 5 6 7 8 9 10 11 i UTILITY INTR ODUCTION Congratulations on y our purchase of a Y amaha utility car . This manual con- tains inf or mation you will need f or proper operation, maintenance, and care of your utility car . A thorough understanding of these simple instructions will help you to obtain maximum enjo yment from your ne w Y amaha. If[...]

  • Page 5

    ii UTILITY IMPOR T ANT MANU AL INFORMA TION ● Y amaha continually seeks ad- vancements in product design and quality; theref ore, while this manual contains the most current product inf or mation av ailab le at the time of printing, there may be minor dis- crepancies between y our utility car and this manual. If you hav e any questions concerning[...]

  • Page 6

    iii UTILITY 1 W ARRANTY CONTENTS 1 IMPOR T ANT LABELS 2 MAINTENANCE SAFETY PR OGRAM 4 MAINTENANCE 8 ST ORA GE SPECIFICA TIONS 9 WIRING 11 OPERA TION 7 PRE-OPERA TION CHECKS 6 CONTR OLS 5 OPERA T OR SAFETY 3 10 LIT_19626_11_00 3/22/01 1:06 PM Page iii[...]

  • Page 7

    1 2 3 4 5 6 7 8 9 10 11 1-1 UTILITY W ARRANTY Y amaha Motor Corporation, U .S.A. hereby warr ants that any new G21A Utility V ehicle purchased from an authorized Y amaha dealer in the United States, will be free from defects in material and workman- ship for the period of time stated herein, subject to the stated limitations. THE PERIOD OF WARRANTY[...]

  • Page 8

    W ARRANTY 1-2 UTILITY In complance with the California Air Resources Board, Y amaha Motor Manuf acturing Cor poration of America is pleased to explain the emission control system warranty on y our 1996 or later specialty vehicle engine . New Y amaha speciality vehicle engines must be designed, built and equipped to meet stringent anti-smog standard[...]

  • Page 9

    W ARRANTY 1 2 3 4 5 6 7 8 9 10 11 1-3 UTILITY 3. Ignition System Spark plugs * Magneto or electronic ignition system Spark advance/retard system 4. Exhaust Gas Recirculation (EGR) System EGR valv e body , and carburetor spacer if applicable EGR rate f eedback and control system 5. Air Injection System Air pump or pulse valv e V alves affecting dist[...]

  • Page 10

    1 2 3 4 5 6 7 8 9 10 11 2-1 UTILITY IMPOR T ANT LABELS 1 2 Y-100 6 5 9 3 4 SAFETY AND INSTR UCTION LABELS Please read the follo wing labels carefully bef ore operating your utility car , and promptl y replace any labels which become dam- aged or removed. WARNING 2 1 3 6 5 4 LIT_19626_11_00 3/22/01 1:07 PM Page 2-1[...]

  • Page 11

    1 2 3 4 5 6 7 8 9 10 11 2-2 UTILITY IMPOR T ANT LABELS Y-101 7 8 Y-102a JR6-000000 UTILITY CAR SERIAL NUMBER The utility car serial number is stamped in the location shown. The first three digits of the serial num- ber are f or model identification; the remaining digits are the unit produc- tion number . K eep a record of these numbers f or ref ere[...]

  • Page 12

    1 2 3 4 5 6 7 8 9 10 11 3-1 UTILITY OPERA T OR SAFETY ! Y-123 Y-68 Y-8 Y amaha utility cars are designed to be simple to operate. Howe ver , be sure to obser v e the follo wing: BEFORE OPERA TING THE UTILITY CAR ● Read this Owner ’ s/Operator ’ s man- ual and all saf ety and instruction labels on the utility car bef ore oper- ating. ● P erf[...]

  • Page 13

    1 2 3 4 5 6 7 8 9 10 11 3-2 UTILITY ● K eep your hands on the steering wheel and your e yes on the path ahead. ● Use e xtra care in congested areas or when backing up . Always bac k up slowly , and watch carefully . ● A v oid star ting or stopping abr uptly . ● V ar y the speed of the utility car to match the terrain of y our surround- ings[...]

  • Page 14

    1 2 3 4 5 6 7 8 9 10 11 3-3 UTILITY LO ADING/T O WING ● Do not drive across the f ace of slope. ● A v oid poor driving conditions such as wet la wns and rough surfaces . V ehicle handling and stability ma y be reduced. ● Stop the engine, remo ve ignition k ey and make sure tr ailer is correctly installed bef ore towing trailer . ● Do not al[...]

  • Page 15

    1 2 3 4 5 6 7 8 9 10 11 4-1 UTILITY MAINTENANCE SAFETY PR OGRAM MAINTENANCE REQUIRED FOR UTILITY CAR SAFETY Practice the f ollowing to help ensure the saf ety of utility car operators: ● Preventative Maintenance . P er- f or m all scheduled maintenance in accordance with manuf acturer ’ s rec- ommendations to provide the user with a saf e, prop[...]

  • Page 16

    1 2 3 4 5 6 7 8 9 10 11 4-2 UTILITY MAINTENANCE SAFETY PR OGRAM FUEL HANDLING/ ST ORA GE AND B A TTER Y CHARGING T ake the f ollowing precautions to ensure maintenance worker saf ety: ● Super vise the storage and handling of liquid fuels in accordance with applicable fire and saf ety require- ments. ● Only use batter y changing and charging f a[...]

  • Page 17

    1 2 3 4 5 6 7 8 9 10 11 5-1 UTILITY CONTR OLS Y-12 4 5 6 1 9 8 Y-107 2 14 15 16 10 7 12 11 13 3 FEA TURES 1 Steering wheel 2 Seat 3 Batter y 4 Brak e pedal 5 P arking brake pedal 6 Accelerator pedal 7 Drive selector le v er 8 Main s witch 9 Oil warning light a Choke knob b F ront cowl c F ront tire d F ront b umper e Rear cowl f Rear tire g Fuel ca[...]

  • Page 18

    1 2 3 4 5 6 7 8 9 10 11 5-2 UTILITY CONTR OLS Y-15 OFF ON Y-16 OFF ON OFF OIL WARNING ON Y-17 A MAIN SWITCH The main s witch controls the follo wing items: OFF Ignition circuit is s witched off. The ke y can be remov ed only in this position. ON Electrical circuits are switched on. The utility car can be driven. OIL W ARNING LIGHT When the engine o[...]

  • Page 19

    1 2 3 4 5 6 7 8 9 10 11 5-3 UTILITY DRIVE SELECT LEVER The drive select le v er is used to shift the utility car into f orward or re verse . After coming to a complete stop , mov e the le ver to the desired posi- tion. Lever P osition Car Movement F FOR W ARD R REVERSE The back-up b uzzer will sound when the drive select le ver is turned to “ R. [...]

  • Page 20

    1 2 3 4 5 6 7 8 9 10 11 5-4 UTILITY P ARKING BRAKE PED AL Press down on the parking brak e pedal whene ver parking the utility car . å P arking brake pedal Release the parking brake b y de- pressing the accelerator pedal. CHOKE KNOB Pull and hold out choke knob when star ting a cold engine. Release the knob after the engine star ts. å Choke knob [...]

  • Page 21

    1 2 3 4 5 6 7 8 9 10 11 6-1 UTILITY PRE-OPERA TION CHECKS Y-115 B A Pre-operation chec ks should be made each time you use y our utility car . Get in the habit of perf or ming the f ollowing checks in the same w a y so that they become second nature. ● Be sure the main switch ke y is removed bef ore performing the pre-operation chec ks to prevent[...]

  • Page 22

    1 2 3 4 5 6 7 8 9 10 11 6-2 UTILITY PRE-OPERA TION CHECKS Y-112 Y-113 Y-114 A CARGO BED Lift the cargo bed f or engine ser vicing. 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. ● Remove the main s witch key and apply the parking brake bef[...]

  • Page 23

    1 2 3 4 5 6 7 8 9 10 11 6-3 UTILITY FUEL SYSTEM Make sure there is sufficient fuel in the tank, and check fuel line and connec- tions f or leakage. å Fuel le vel gauge ∫ “ F ” Full ç “ E ” Empty Gasoline and its vapor s are highly flammable and explosive. ● Do not smoke when refueling and keep awa y from sparks, flames, or other sourc[...]

  • Page 24

    1 2 3 4 5 6 7 8 9 10 11 6-4 UTILITY ENGINE OIL With the utility car parked on le vel ground, remov e the dipstick and make sure the engine oil is between the MIN and MAX marks (the crosshatched area on the end of the dipstick). å Oil le vel dipstic k ∫ Maximum oil le v el ç Saf e operating range If the oil le vel is belo w the MIN mark on the d[...]

  • Page 25

    1 2 3 4 5 6 7 8 9 10 11 6-5 UTILITY PRE-OPERA TION CHECKS Y-30 A Y-31 B A TTER Y Check that the battery is held secure- ly in place to pre vent the battery from being damaged from vibration or jar- ring. Also check that no battery caps are missing to pre vent battery acid from spilling from the batter y . Chec k the batter y terminals for corrosion[...]

  • Page 26

    1 2 3 4 5 6 7 8 9 10 11 6-6 UTILITY PRE-OPERA TION CHECKS Y-116 Y-33 Y-21 A STEERING SYSTEM Check the steering system f or exces- sive freepla y by: ● moving the steering wheel up and down, and bac k and f or th. ● turning the steer ing wheel slightly to the right and left. If you f eel excessiv e freeplay , or hear rattling sounds which ma y i[...]

  • Page 27

    1 2 3 4 5 6 7 8 9 10 11 6-7 UTILITY PRE-OPERA TION CHECKS Y-22 A Y-20 A P arking Brake P edal Make sure the parking brak e pedal locks in place with a positiv e clic k, and releases when the accelerator pedal is pressed. å P arking brake pedal Release the parking brake b y depressing the accelerator pedal. Accelerator P edal Before c hecking opera[...]

  • Page 28

    1 2 3 4 5 6 7 8 9 10 11 7-1 UTILITY OPERA TION Y-16 OFF ON Y-18 Y-23 A C H O K E Y-20 A ST AR TING 1. With the par king brak e applied, turn the dr ive select le ver to “ F ” for f orward, or “ R ” f or rev erse. Do not shift from “ F ” forwar d to “ R ” rever se while the utility car is mov- ing. 2. T ur n the main switch to “ ON[...]

  • Page 29

    1 2 3 4 5 6 7 8 9 10 11 7-2 UTILITY OPERA TION MAXIMUM LOADING LIMIT ● Maximum cargo bed load: 363 kg (800 lb) ● T ow hitch T ow weight (Including driv er , passenger , vehicle cargo and trailer and trailer cargo): 590 kg (1300 lb) T ongue weight: 68 kg (150 lb) Y-65 B A Y-117 Y-119 ST OPPING T o stop the utility car , gr adually press down on [...]

  • Page 30

    PERIODIC MAINTENANCE CHAR TS Regular maintenance is required f or the best performance and saf e operation of your utility car . Be sure to turn off the main switch and apply the parking brake when y ou perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Y amaha dealer o[...]

  • Page 31

    C - CHECK CA - CHECK AND ADJUST R - REPLACE S - SER VICE CL - CLEAN AND LUBRICA TE L - LUBRICA TE 20 Rounds 125 rds 250 rds 500 rds 1000 rds Pre- 20 hour s 125 hrs 250 hrs 500 hrs 1000 hrs Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mls tion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms (Every (Every 6 (Every (Every (Every month) months) y[...]

  • Page 32

    8-3 UTILITY MAINTENANCE EXHA UST EMISSION CONTROL SYSTEM AND COMPONENTS Item Acron ym • CARB. ASSY ., LH., JT ., CARB (Carburetor) CARBURET OR 2 & JT ., CARBURET OR 1 • T .C.I. MA GNET O ASSY . & El (Electronic Ignition) PLUG, SP ARK • CRANKCASE 1 & HEAD , PCV (P ositive Crankcase CYLINDER 1 V entilation) • AIR FIL TER ASSY . A [...]

  • Page 33

    1 2 3 4 5 6 7 8 9 10 11 8-4 UTILITY MAINTENANCE Spark Plug Inspection Y ou should per iodically remov e and inspect the spark plug. Dirty or wor n spark plugs can cause poor perfor- mance. å Spark plug ∫ Spark plug cap 1. Check f or discoloration and hea vy carbon deposits. The nor mal electrode color will be tan. If it is not, replace it. 2. Ch[...]

  • Page 34

    1 2 3 4 5 6 7 8 9 10 11 8-5 UTILITY MAINTENANCE Engine Oil Replacement 1. W ar m up the engine f or sev eral minutes, place the utility car on a le vel surf ace, then stop the engine. Use caution not to touch hot engine oil or hot engine parts, during the follo wing procedure. 2. Place an oil pan under the engine drain plug. 3. Remove the oil dr ai[...]

  • Page 35

    8-6 UTILITY MAINTENANCE Y-515 A Y-518 A A A B Y-519 A B å Oil filler hole Use care not to fill past the MAX dipstick mark, and be sure no for- eign material enters the crank- case. After replacing engine oil, chec k for oil leaks ar ound the drain plug. If oil leaks are found, consult a Y amaha dealer . Air Filter T o remov e the air filter elemen[...]

  • Page 36

    1 2 3 4 5 6 7 8 9 10 11 8-7 UTILITY MAINTENANCE B A Y-508 Inspection and cleaning: 3. W ash the foam pre-filter in soap and water . Allow it to dry . å Soap and water ∫ F oam element 4. Chec k the filter element. If dam- aged or dir ty , replace it. Do not wring out the foam pre-fil- ter , this could cause it to tear . 5. T o replace the element[...]

  • Page 37

    1 2 3 4 5 6 7 8 9 10 11 8-8 UTILITY MAINTENANCE Y-60 B A Y-44 Drive Belt T o remov e the drive belt: 1. Set the dr ive select le ver halfwa y between f orward and re v erse. 2. Pull up on the dr ive belt and push it outward o ver the edge of the secondar y sheav e. 3. T ur n the secondar y sheav e clock- wise and the drive belt will roll off the sh[...]

  • Page 38

    1 2 3 4 5 6 7 8 9 10 11 8-9 UTILITY MAINTENANCE Y-45 + + – – Battery Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. A void contact with skin, ey es, or clothing. Antidote: EXTERNAL: Flush with water . INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten eg[...]

  • Page 39

    1 2 3 4 5 6 7 8 9 10 11 8-10 UTILITY MAINTENANCE Fuse Replacement Be sure to use the specified fuse. Using a wrong fuse can cause elec- trical system damage and create a fire hazard. When replacing a fuse be sure the main switch is turned off to pre vent accidental short-circuiting. å Fuse case ∫ Fuse ç Replacement fuse Gear Bo x Oil T o check [...]

  • Page 40

    1 2 3 4 5 6 7 8 9 10 11 8-11 UTILITY MAINTENANCE Wheel nut tightening torque: 58 ft . lb (80 Nm, 8.0 m . kg) Consult your Y amaha dealer before using your utility car if y ou suspect brake prob lems. Brake failure could result in a serious accident. WARNING Y-57 ● Add gear oil little by little until oil flows from the plug hole (B). 4. Allow exce[...]

  • Page 41

    1 2 3 4 5 6 7 8 9 10 11 8-12 UTILITY MAINTENANCE Brake P edal Free Pla y Adjustment Before adjusting brake pedal free play , pump the brake pedal se veral times to self-adjust the brakes. T o adjust the brake pedal free pla y: 1. Remove the service lid from the floor of the utility car . 2. Check the brak e pedal free play b y pressing against the [...]

  • Page 42

    1 2 3 4 5 6 7 8 9 10 11 9-1 UTILITY ST ORA GE P erform the following prepar ations when storing your utility car f or extend- ed periods of time: T ur n main s witch ke y to “ OFF ” position, remov e ke y , and store key in a saf e place. DRAINING FUEL Gasoline and its vapor s are highly flammable and explosive. ● Do not smoke when refueling [...]

  • Page 43

    1 2 3 4 5 6 7 8 9 10 11 9-2 UTILITY ST ORA GE ENGINE PREP ARA TION With the ke y remov ed and the spark plug lead disconnected, turn the clutch by hand until compression is f elt. This puts the valv es in the closed position. CHASSIS PREP ARA TION 1. Increase the front tire pressure to 23 psi (160 kP a, 1.6 kgf/cm 2 ) and increase the rear tire pre[...]

  • Page 44

    1 2 3 4 5 6 7 8 9 10 11 10-1 UTILITY SPECIFICA TIONS GENERAL SPECIFICA TIONS Items G21A Dimensions: Over all length 120.0 in. (3050 mm) Over all width 51.5 in. (1308 mm) Over all height (steering height) 47.2 in. (1200 mm) Height of floor 11.8 in. (300 mm) Wheelbase 74.8 in. (1900 mm) T read: F ront 38.6 in. (980 mm) Rear 38.6 in. (980 mm) Min. gro[...]

  • Page 45

    1 2 3 4 5 6 7 8 9 10 11 10-2 UTILITY SPECIFICA TIONS ENGINE Items G21A Description: Engine type 4-strok e, Gasoline, OHV Number of cylinders Single Displacement 357 cm 3 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 r pm Cooling system F orced air cooled Star ting system Star ter Ignition syst[...]

  • Page 46

    1 2 3 4 5 6 7 8 9 10 11 10-3 UTILITY SPECIFICA TIONS CHASSIS Items G21A Steering system: T ype W or m and pin Steering angle (L.H.) 1.5 tur n Steering angle (R.H.) 1.5 tur n Lubricant/capacity Grease/3.0 US oz (0.09 L, 3.17 Imp oz) Brak es: Brak e system Me ch a nical drum brak e on front and rear wheels with self-adjusters. T ype of brake Dual int[...]

  • Page 47

    R B R B P B R REV FWD R P B B P P B P Br R/W Br R/W Br A1 F2 B B RW RW R R R R R/W R/W G B RW G G G G G B Br B B R/W Br R/W OFF ON Br R/Y L BB L G Br P B R/W R/W L L L BB B B B — + Y-509 GG Br Br B RW R Br R RY Br Br 16 1 2 3 4 5 6 7 8 9 10 14 15 13 12 11 17 18 R R P 1 Engine stop relay a Battery 2 Engine ground b Pilot lamp (12V , 3.4W) 3 Pickup[...]

  • Page 48

    O WNER’S/ OPERA T OR’S MANU AL UTILITY CAR LIT-19626-11-00 YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA JR6-F8199-00 Printed in U.S.A. KCC G21A Y amaha Motor Corp., USA Cypress, Calif ornia made in 10/31/00 LIT196261100 USA *LIT196261100* 1PC - G21A O/M G21A O_M Cover 11/2/00, 10:22 PM 1[...]