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Yamaha G11A Owner's/operator's Manual

Manual is about: UTILITY CAR

Summary of G11A

  • Page 1

    Owner’s/ operators manual yamaha motor manufacturing corp. Of america utility car g11a printed in u.S.A. Kcc yamaha motor corp., usa cypress, california made in 01/10/01 lit196261197 usa *lit196261197* 1pc - g11a o/m lit-19626-11-97 jr3-f8199-10

  • Page 2: Introduction

    I utility 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 of these simple instructions will help you to obtain maximum enjoyment from your...

  • Page 3: Important Manual

    Ii utility important manual information ● yamaha continually seeks ad- vancements 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 dis- crepancies between your utility car and this manual. ...

  • Page 4: Warranty

    Iii utility 1 warranty contents 1 important labels 2 maintenance safety program 4 maintenance 8 storage specifications 9 wiring 11 operation 7 pre-operation checks 6 controls 5 operator safety 3 10 lit_19626_11_97.Qxd 3/22/01 3:23 pm page iii.

  • Page 5: Warranty

    1 2 3 4 5 6 7 8 9 10 11 1-1 utility warranty yamaha motor corporation, u.S.A. Hereby warrants that any new g11a utility vehicle yamaha golf car 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 here- i...

  • Page 6: Warranty

    1 2 3 4 5 6 7 8 9 10 11 warranty 1-2 utility the california air resources board and yamaha motor manufacturing corporation of america are pleased to explain the emission control system war- ranty on your 1996 or later specialty vehicle engine. In california, new specialty vehicle engines must be des...

  • Page 7: Warranty

    Warranty 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 valve body, and carburetor spacer if applicable egr rate feedback and control system 5. Air injection system a...

  • Page 8: Important Labels

    1 2 3 4 5 6 7 8 9 10 11 2-1 utility important labels 1 2 y-100 6 5 9 3 4 safety and instruction labels please read the following labels carefully before operating your utility car, and promptly replace any labels which become dam- aged or removed. Warning 2 1 3 6 4 lit_19626_11_97.Qxd 3/22/01 3:23 p...

  • Page 9: Important Labels

    1 2 3 4 5 6 7 8 9 10 11 2-2 utility important labels y-101 7 8 y-102a 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 for model identification; the remaining digits are the unit produc- tion number. Keep a re...

  • Page 10: Operator Safety

    1 2 3 4 5 6 7 8 9 10 11 3-1 utility operator safety ! Y-123 y-68 y-8 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 ...

  • Page 11: Operator Safety

    1 2 3 4 5 6 7 8 9 10 11 3-2 utility ● 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 ter...

  • Page 12: Loading/towing

    1 2 3 4 5 6 7 8 9 10 11 3-3 utility 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 ...

  • Page 13: Maintenance Safety Program

    1 2 3 4 5 6 7 8 9 10 11 4-1 utility maintenance safety program maintenance required for utility car safety practice the following to help ensure the safety of utility car operators: ● preventative maintenance . Per- form all scheduled maintenance in accordance with manufacturer’s rec- ommendations t...

  • Page 14: Maintenance Safety Program

    1 2 3 4 5 6 7 8 9 10 11 4-2 utility 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...

  • Page 15: Controls

    1 2 3 4 5 6 7 8 9 10 11 5-1 utility controls y-12 4 5 6 1 9 8 y-107 2 14 15 16 10 7 12 11 13 3 features 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 bu...

  • Page 16: Controls

    1 2 3 4 5 6 7 8 9 10 11 5-2 utility controls y-15 off on y-16 off on off oil warning on y-17 a main switch the main switch controls the following items: off ignition circuit is switched off. The key can be removed only in this position. On electrical circuits are switched on. The utility car can be ...

  • Page 17: Drive Select Lever

    1 2 3 4 5 6 7 8 9 10 11 5-3 utility 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. Lever position car movement f forward r reverse the back-up buzzer will beep when the dri...

  • Page 18: Parking Brake Pedal

    1 2 3 4 5 6 7 8 9 10 11 5-4 utility parking brake pedal press down on the parking brake pedal whenever parking the utility car. å parking brake pedal release the parking brake by de- pressing the accelerator pedal. Choke knob pull and hold out choke knob when starting a cold engine. Release the knob...

  • Page 19: Pre-Operation Checks

    1 2 3 4 5 6 7 8 9 10 11 6-1 utility pre-operation checks y-115 b a 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. ● be sure the main switch key is removed before performing...

  • Page 20: Pre-Operation Checks

    1 2 3 4 5 6 7 8 9 10 11 6-2 utility pre-operation checks y-112 y-113 y-114 a 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. ● remove the mai...

  • Page 21: Fuel System

    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 for leakage. å fuel level gauge ∫ “f” full ç “e” empty gasoline and its vapors are highly flammable and explosive. ● do not smoke when refueling and keep away from sp...

  • Page 22: Engine Oil

    1 2 3 4 5 6 7 8 9 10 11 6-4 utility 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). å oil level dipstick ∫ maximum oil level ç safe operating range if the oil...

  • Page 23: Pre-Operation Checks

    1 2 3 4 5 6 7 8 9 10 11 6-5 utility pre-operation checks y-30 a y-31 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. C...

  • Page 24: Pre-Operation Checks

    1 2 3 4 5 6 7 8 9 10 11 6-6 utility pre-operation checks y-116 y-33 y-21 a steering system check the steering system for exces- sive freeplay by: ● 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 freeplay, ...

  • Page 25: Pre-Operation Checks

    1 2 3 4 5 6 7 8 9 10 11 6-7 utility pre-operation checks y-22 a y-20 a 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 release the parking brake by depressing the accelerator pedal. ...

  • Page 26: Operation

    1 2 3 4 5 6 7 8 9 10 11 7-1 utility operation y-16 off on y-18 y-23 a ch ok e y-20 a starting 1. With the parking brake applied, turn the drive select lever to “f” for forward, or “r” for reverse. Do not shift from “f” forward to “r” reverse while the utility car is mov- ing. 2. Turn the main switch...

  • Page 27: Operation

    1 2 3 4 5 6 7 8 9 10 11 7-2 utility operation maximum loading limit ● maximum cargo bed load 227 kg (500 lb) ● tow hitch tow weight (including driver, passenger, vehicle cargo and trailer and trailer cargo): 454 kg (1000 lb) tongue weight: 68 kg (150 lb) y-65 b a y-117 y-119 stopping to stop the uti...

  • Page 28: Periodic Maintenance Charts

    1 2 3 4 5 6 7 8 9 10 11 8-1 utility periodic maintenance charts regular maintenance is required for the best performance and safe operation of your utility car. Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified. If the owner is no...

  • Page 29: Maintenance

    1 2 3 4 5 6 7 8 9 10 11 8-2 utility maintenance for g11a every pre- 20 rounds 125 rds 250 rds 500 rds 1000 rds opera- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs item remarks tion 100 miles 600 mls 1200 mls 2500 mls 5000mls page 160 kms 1000 kms 2000 kms 4000 kms 8000 kms (1 month) (6 months) (1 year)...

  • Page 30: Maintenance

    1 2 3 4 5 6 7 8 9 10 11 8-3 utility maintenance for g11a every pre- 20 rounds 125 rds 250 rds 500 rds 1000 rds opera- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs item remarks tion 100 miles 600 mls 1200 mls 2500 mls 5000mls page 160 kms 1000 kms 2000 kms 4000 kms 8000 kms (1 month) (6 months) (1 year)...

  • Page 31: Maintenance

    Maintenance 1 2 3 4 5 6 7 8 9 10 11 8-4 utility exhaust emission control system and components item acronym • carb. Assy., lh., jt., carb (carburetor) carburetor 2 & jt., carburetor 1 • t.C.I. Magneto assy. & el (electronic ignition) plug, spark • crankcase 1 & head, pcv (positive crankcase cylinder...

  • Page 32: Maintenance

    1 2 3 4 5 6 7 8 9 10 11 maintenance 8-5 utility 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 carbon deposits. The normal electrode color will...

  • Page 33: Maintenance

    Maintenance 1 2 3 4 5 6 7 8 9 10 11 8-6 utility engine oil replacement 1. Warm up the engine for several minutes, place the utility car on a level surface, then stop the engine. Use caution not to touch hot engine oil or hot engine parts, during the following procedure. 2. Place an oil pan under the...

  • Page 34: Maintenance

    1 2 3 4 5 6 7 8 9 10 11 maintenance 8-7 utility 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, check for oil leaks around the drain plug. If oil leaks are found, ...

  • Page 35: Maintenance

    Maintenance 1 2 3 4 5 6 7 8 9 10 11 8-8 utility b a y-508 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- aged or dirty, replace it. Do not wring out the foam pre-fil- ter, this could cause ...

  • Page 36: Maintenance

    1 2 3 4 5 6 7 8 9 10 11 maintenance 8-9 utility y-60 b a y-44 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 t...

  • Page 37: Maintenance

    Maintenance 1 2 3 4 5 6 7 8 9 10 11 8-10 utility y-45 + + – – battery 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 m...

  • Page 38: Maintenance

    1 2 3 4 5 6 7 8 9 10 11 maintenance 8-11 utility 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 prevent accidental short-circuiting. å fuse case ∫ fuse ç replacement f...

  • Page 39: Maintenance

    Maintenance 1 2 3 4 5 6 7 8 9 10 11 8-12 utility wheel nut tightening torque: 58 ft.Lb (80 nm, 8.0 m.Kg) consult your yamaha dealer before using your utility car if you suspect brake problems. Brake failure could result in a serious accident. Warning y-57 ● add gear oil little by little until oil fl...

  • Page 40: Maintenance

    1 2 3 4 5 6 7 8 9 10 11 maintenance 8-13 utility brake pedal free play adjustment 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. 2. Check the brake...

  • Page 41: Storage

    Storage 1 2 3 4 5 6 7 8 9 10 11 9-1 utility perform the following preparations when storing your utility car for extend- ed periods of time: turn main switch key to “off” position, remove key, and store key in a safe place. Draining fuel gasoline and its vapors are highly flammable and explosive. ● ...

  • Page 42: Storage

    1 2 3 4 5 6 7 8 9 10 11 storage 9-2 utility 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 tire pressure to 23 psi (160 kpa, 1.6 kgf/cm2)...

  • Page 43: Specifications

    Specifications 1 2 3 4 5 6 7 8 9 10 11 10-1 utility general specifications items g11a dimensions: overall length 120.0 in. (3050 mm) overall width 50.4 in. (1280 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 34.3 i...

  • Page 44: Specifications

    1 2 3 4 5 6 7 8 9 10 11 specifications 10-2 utility engine items g11a description: engine type 4-stroke, gasoline, ohv number of cylinders single displacement 301 cm 3 bore x stroke 3.07 x 2.48 in. (78 x 63 mm) compression ratio 8.1:1 rated output 9.5 hp (7.1 kw)/4000 rpm cooling system forced air c...

  • Page 45: Specifications

    Specifications 1 2 3 4 5 6 7 8 9 10 11 10-3 utility chassis items g11a steering system: type worm and pin steering angle (l.H.) 1.5 turn steering angle (r.H.) 1.5 turn lubricant/capacity grease/3.0 us oz (0.09 l, 3.17 imp oz) brakes: brake system mechanical drum brake on each rear wheel with self-ad...

  • Page 46: Wiring

    1 2 3 4 5 6 7 8 9 10 11 wiring 11-1 utility g11a wiring diagram 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 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 ...

  • Page 48: Owner’S/

    Owner’s/ operators manual yamaha motor manufacturing corp. Of america utility car g11a printed in u.S.A. Kcc yamaha motor corp., usa cypress, california made in 01/10/01 lit196261197 usa *lit196261197* 1pc - g11a o/m lit-19626-11-97 jr3-f8199-10