1. Manuals
  2. Brands
  3. Yamaha Manuals
  4. Offroad Vehicle
  5. G-Max G22A
  6. Owner's and operator's manual

Yamaha G-Max G22A Owner's And Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

OWNER'S / OPERATOR'S
MANUAL
GOLF CAR
LIT-19626-16-04
G 22 A
JU0-F8199-12

Advertisement

Table of Contents
loading

Related Manuals for Yamaha G-Max G22A

Summary of Contents for Yamaha G-Max G22A

  • Page 1 OWNER'S / OPERATOR’S MANUAL GOLF CAR G 22 A JU0-F8199-12 LIT-19626-16-04...
  • 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: Lit-19626

    INTRODUCTION Congratulations on your purchase of a Yamaha golf car. This manual contains information you will need for proper operation, maintenance, and care of your golf car. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha.
  • Page 4 IMPORTANT MANUAL INFORMATION Particularly important information is NOTE distinguished in this manual by the Yamaha continually seeks ad- ● following notations: vancements in product design and quality; therefore, while this manual contains the most current product information available at the time of...

  • Page 5: Table Of Contents

    CONTENTS WARRANTY IMPORTANT LABELS OPERATOR SAFETY MAINTENANCE SAFETY PROGRAM CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE STORAGE SPECIFICATIONS WIRING G22A...

  • Page 6: Warranty

    EFFECTIVE DATE: 06/01/02 clutch drive belts. Any charges incurred in transporting LIT-13710-03-02 a golf car to and from an authorized Yamaha Golf Car Dealer for service or in performing field service are also excluded from this warranty. G22A...

  • Page 7: Important Labels

    à une blessure grave, voire fatale. Y-500 YAMAHA JN3-K8299-10 Y-502 G22A...
  • Page 8 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. The engine serial number 2 is affixed in the location shown. SM-03-399 3 Engine Information THIS ENGINE MEETS **** - **** CALIFORNIA EMISSION REGULATIONS FOR OFF-ROAD ENGINES.

  • Page 9: Operator Safety

    OPERATOR SAFETY Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following: BEFORE OPERATING THE GOLF CAR Read this Owner’s/Operator’s man- ● ual and all safety and instruction labels on the golf car before operat- ing.
  • Page 10 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. ●...
  • Page 11 GOLF COURSE SAFETY PROGRAM Like all machines, golf cars can Do Not Operate Golf Cars When cause injury if improperly used or Under The Influence Of Alcohol Or maintained. This section contains Drugs broad safety practices required for safe golf car operation. Before golf GOLF COURSE SAFETY cars are operated, golf course per- SURVEY...
  • Page 12 GOLF COURSE SAFETY PROGRAM Loose Terrain. Loose terrain may Parts and Materials. Use only ● ● cause a golf car to lose traction and replacement parts and materials may affect stability. Repair loose recommended by the manufacturer. terrain, chain or rope off these areas, or identify loose terrain with Ventilation.

  • Page 13: Battery Charging

    If new nameplates, warnings, or ● ble part of the system to prevent instructions are needed, contact fuel leaks. your Yamaha dealer. Avoid fire hazards, and have ● appropriate fire protection equip- FUEL HANDLING/ ment available.

  • Page 14: Controls

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

  • Page 15: Main Switch

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

  • Page 16: Drive Select Lever

    CONTROLS DRIVE SELECT LEVER The drive select lever is used to shift the golf car into forward or reverse. After coming to a complete stop, move the lever to the desired posi- tion. Lever Position Car Movement Y-18 FORWARD REVERSE NOTE The back-up buzzer will beep when the drive select lever is turned to “R.”...

  • Page 17: Choke Knob

    CONTROLS PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the golf car. ç Parking brake pedal NOTE Y-22a Release parking brake depressing the accelerator pedal. WARNING The parking brake will automatically release when the accelerator pedal is depressed.

  • Page 18: Pre-Operation Checks

    PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your golf 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 ●...
  • Page 19 PRE-OPERATION CHECKS FUEL SYSTEM Make sure there is sufficient fuel in the tank, and check fuel line and con- nections for leakage. å Fuel tank ∫ Fuel cap Y-513 WARNING Gasoline and its vapors are highly flammable and explosive. Do not smoke when refueling ●...

  • Page 20: Engine Oil

    PRE-OPERATION CHECKS ENGINE OIL With the golf car parked on level ground, remove the dipstick and make sure the engine oil is between the MIN and MAX marks (the cross- hatched area on the end of the dip- stick). Y-514 å...

  • Page 21: Tire Air Pressure

    PRE-OPERATION CHECKS Engine Cooling Inlet Duct Check the engine cooling inlet duct for debris. Remove any debris present. å Engine cooling inlet duct BATTERY Check that the battery is held secure- ly in place to prevent the battery from being damaged from vibration or jar- ring.

  • Page 22: Steering System

    The buzzer should sound. Y-33 PEDAL OPERATION Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha dealer. Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its orig- inal position when released.
  • Page 23 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. ç Parking brake pedal Y-22a NOTE Release the parking brake by depressing the accelerator pedal. Accelerator Pedal WARNING Before checking operation of the...

  • Page 24: 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” reverse while the golf car is Y-18 moving. 2. Turn the main switch to “ON.” WARNING Do not depress the accelerator pedal when turning on the main...

  • Page 25: Troubleshooting

    Cause Remedy Fuel System No fuel in tank Fill fuel tank Clogged fuel Clean fuel line line – Consult Yamaha dealer Foreign matter Clean fuel in fuel filter fiter – Consult Yamaha dealer Clogged Clean carburetor carburetor – Consult...

  • Page 26: 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 27 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 28: Exhaust Emission Control System

    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. G22A...

  • Page 29: 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 Y-516 1. Check for discoloration and remove carbon deposits with a spark plug cleaner or wire brush.

  • Page 30: Engine Oil Replacement

    MAINTENANCE Engine Oil Replacement 1. Warm up the engine for several minutes, place the golf car on a level surface, then stop the engine. WARNING Use caution not to touch hot engine oil or hot engine parts, dur- ing the following procedure. 2.

  • Page 31: Air Filter

    After replacing engine oil, check for oil leaks around the Y-515 drain plug. If oil leaks are found, consult a Yamaha dealer. Air Filter To remove the air filter elements: 1. Unlatch the air filter cover clips and remove cover.

  • Page 32: Drive Belt

    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- aged or dirty, replace it. Y-508 CAUTION Do not wring out the foam pre-fil- ter, this could cause it to tear.
  • Page 33 MAINTENANCE Inspection: To inspect the drive belt, check for frayed edges or tears, and measure drive belt against the following speci- fication. If the belt shows excessive wear or damage, replace the belt with a new one. å New: 1.22 in. (31.0 mm) ∫...

  • Page 34: Fuse Replacement

    MAINTENANCE The 12-volt battery that provides start- ing power to your gas car normally doesn’t require the addition of water during the one year period provided by the battery manufacturer. If the bat- tery loses its charge, have an experi- enced mechanic charge it.
  • Page 35 Recommended oil: SAE 90 gear oil 6. Reinstall the oil level plug. Gearcase capacity: G22A: 0.44 US qt NOTE (415 mL, 415 cc) For gear oil replacement, consult a Yamaha dealer or other qualified mechanic. 8-10 G22A...

  • Page 36: Brake Adjustment

    Before you operate the car, press down on the brake pedal several times to make sure the brakes are functioning properly. WARNING Consult your Yamaha dealer before using your golf car if you suspect brake problems. Brake failure could result in a serious accident. 8-11...
  • Page 37 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 golf car. Y-61a 2.

  • Page 38: Storage

    STORAGE Perform the following preparations when storing your golf car for extend- ed periods of time: NOTE Turn main switch key to “OFF” posi- tion, remove key, and store key in a safe place. DRAINING FUEL WARNING Gasoline and its vapors are highly flammable and explosive.
  • Page 39 STORAGE ENGINE PREPARATION 2. Have the battery recharged every 60-90 days to keep it fully With the key removed and the spark charged. The battery must be plug lead disconnected, turn the kept fully charged to avoid dam- clutch by hand until compression is age.

  • Page 40: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Items G22A Dimensions: Overall length 93.9 in. (2385 mm) Overall width 47.2 in. (1200 mm) Overall height (steering height) 46.8 in. (1190 mm) Height of floor 11.8 in. (300 mm) Wheelbase 64.3 in. (1632 mm) Tread: Front 34.3 in.
  • Page 41 SPECIFICATIONS ENGINE Items G22A 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 Forced air cooled Starting system Starter...
  • Page 42 SPECIFICATIONS CHASSIS Items G22A Steering system: Type Rack and Pinion Steering angle (L.H.) 1.55 turn Steering angle (R.H.) 1.55 turn Brakes: Brake system Mechanical drum brake on each rear wheel with self-adjusters. Type of brake Dual internal expanding shoe. Leading/trailing shoes (self-adjusting) Brake pedal freeplay linkage adjustment 20-25 mm...

  • Page 43: Wiring

    WIRING G22A WIRING DIAGRAM 11-1 G22A...
  • Page 44 NOTES G22A...
  • Page 45 NOTES G22A...
  • Page 46 NOTES G22A...
  • Page 47 YAMAHA MOTOR Printed in U.S.A MANUFACTURING CORP. 2004-KCC OF AMERICA 1000 HWY 34 East Newnan, GA 30265 770-254-4000...

Table of Contents