Yamaha U-MAX G27E Owner's/Operator's Manual
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Yamaha U-MAX G27E Owner's/Operator's Manual

Yamaha U-MAX G27E Owner's/Operator's Manual

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READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER'S/OPERATOR'S MANUAL
G27E
JU8-F8199-10
LIT-19626-01-09

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Summary of Contents for Yamaha U-MAX G27E

  • Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S/OPERATOR’S MANUAL G27E JU8-F8199-10 LIT-19626-01-09...
  • 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.

  • 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...

  • Page 6: Table Of Contents

    PRE-OPERATION CHECKS ....5-1 CONTENTS Pre-operation check list ....5-2 Brakes..........5-3 LOCATION OF THE WARNING Batteries ...........5-3 AND SPECIFICATION LABELS..1-1 Transmission oil .......5-4 Accelerator pedal ......5-4 DESCRIPTION AND VEHICLE Steering..........5-5 IDENTIFICATION ......2-1 Fittings and fasteners ......5-5 FEATURES ........2-1 Lights..........5-5 Utility vehicle serial number.....
  • Page 7 Going downhill......... 7-5 Replacing a taillight bulb ....8-18 Crossing through shallow water..7-6 Rough terrain ........7-7 CLEANING AND STORAGE .... 9-1 Riding in brush or wooded areas..7-7 Chassis preparation ......9-1 Battery storage care ......9-1 PERIODIC MAINTENANCE AND ADJUSTMENT .........

  • Page 8: Location Of The Warning And Specification Labels

    L OCATION OF THE WARNING AND SPECIFICATION LABELS...
  • Page 9 Yamaha dealer. I m p r o p e r u s e c a n r e s u l t i n S E V E R E I N J U R Y o r D E AT H FORWARD •...
  • Page 10 • Keep weight in the cargo bed centered, and as low and far forward as possible. Top-heavy loads increase the risk of overturn. (trailer plus cargo). YAMAHA JU7-K7766-00 Allow for increased braking distance and use extreme caution when operating on inclines.

  • 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. Front tire 8. Front bumper 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 Never operate the vehicle in fast flowing driving the vehicle. water or water deeper than 15 cm (6 in).
  • Page 15 Never exceed the stated load capacity. Cargo should be as far forward in the bed as possible, and distributed evenly from side to side. Be sure cargo is secured so that it cannot move around during opera- tion. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer.

  • Page 16: 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 17: Drive Select Switch

    Drive select switch NOTE: The drive select switch is used for driving the The back-up buzzer will sound when the drive select switch is set to “REVERSE.” utility vehicle either forward or in reverse. After coming to a complete stop, push the “FORWARD”...

  • Page 18: 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 19: 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 20: Cargo Bed

    Cargo bed Lifting and lowering the cargo bed 1. Cargo bed 1. Cargo bed release lever 1. Prop rod...
  • Page 21 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.

  • Page 22: 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.) CAUTION / AVERTISSEMENT 1. Tow switch...

  • Page 23: 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 24: 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, 8-4–8-10 • Charge batteries. Brakes • Check for proper operation, condition and free play. 5-3, 8-14–8-16 Parking brake • Check for proper operation, condition and free play. 5-3, 8-14–8-16 Transmission oil •...

  • Page 25: 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 26: 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 27: 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 28 HOW TO AVOID THE HAZARD riding conditions. The following are 1. The tires listed below have been ap- minimums: proved by Yamaha Motor Manufac- Front 70 kPa (0.70 kgf/cm , 10 psi) turing Corporation of America for Rear 70 kPa (0.70 kgf/cm , 10 psi) this model.
  • Page 29 Tire wear limit 4. Use no more than the following When the tire groove decreases to 1 mm pressures when seating the tire (0.04 in) due to wear, replace the tire. beads. Front 250 kPa (2.5 kgf/cm , 36 psi) Rear 250 kPa (2.5 kgf/cm , 36 psi) Higher pressures may cause the...

  • Page 30: 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 31: 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 32: 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 33 EBU09600 Loading Do not exceed the maximum tongue Cargo or a trailer can change the stability and weight. You can measure tongue weight handling of a vehicle. with a bathroom scale. Put the tongue of You must use common sense and good judg- the loaded trailer on the scale with the ment when carrying cargo or towing a trailer.
  • Page 34 Make sure the load does not interfere with WARNING controls or your ability to see where you are POTENTIAL HAZARD going. Overloading this vehicle or carrying or Drive more slowly than you would without a towing cargo improperly. load. The more weight you carry, the slow- WHAT CAN HAPPEN er you should go.

  • Page 35: 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 36 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 vehicle itself must not exceed the maxi- WHAT CAN HAPPEN mum load limit.

  • Page 37: 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 38: 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 39: 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 40: Crossing Through Shallow Water

    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 this vehicle through deep or direction if there are no obstacles in your path. fast-flowing water.

  • Page 41: Rough Terrain

    ROUGH TERRAIN RIDING IN BRUSH OR WOODED AREAS Avoid operating over very rough terrain. Look When operating in areas with brush or trees, for obstacles that could cause damage to the watch carefully on both sides and above the vehicle or could lead to a rollover or accident. vehicle for obstacles such as branches that Avoid jumping the vehicle as injury, loss of the vehicle might hit, causing an accident, or...

  • Page 42: 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 43 Never modify this vehicle through im- proper installation or use of accesso- ries. All parts and accessories added to this vehicle should be genuine Yamaha or equivalent components designed for use on this vehicle and should be in- stalled and used according to instruc- tions.

  • Page 44: 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 45: Batteries

    Batteries Battery care Lift the seat to service the batteries. WARNING Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. It con- tains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.
  • Page 46 Six 8-volt deep cycle batteries provide power Before charging: only add distilled water if for your electric utility vehicle and must be fluid is below the top of the plates, and then properly maintained and recharged for maxi- add just enough to cover plates. mum performance and service life.
  • Page 47 15.6 1.268 against the readings on the following 10.0 1.272 1.276 chart. Consult a Yamaha dealer if any -1.1 1.280 low readings are found, or if readings vary more than one point between cells.

  • Page 48: Battery Charging

    Battery charging 1. Turn the key to the “OFF” position. WARNING Read and understand the owner’s manual provided with your utility vehicle’s battery charger before charging batteries. WARNING Explosive hydrogen gas is produced while batteries are being charged. Only charge batteries in well ventilated areas (a mini- mum of 5 air changes per hour is recom- mended).
  • Page 49 CAUTION: body and pulling the plug straight out of Use only battery chargers that are rated the receptacle. for use with 48 volt Yamaha Utility Vehi- cles. Thoroughly read and understand the user manual supplied with your 48 volt charger.

  • Page 50: Battery Installation

    Battery installation 2. Connect the wire leads as shown. WARNING When working with batteries, do not put wrenches or other metal objects across the battery terminals. An arc can occur causing explosion of the battery. 1. Install the battery brackets by installing and tightening the nuts.

  • Page 51: Fuses

    The fuses are located under the cargo bed, Do not overtighten the battery bracket but cannot be serviced easily. Therefore, if a nuts. Excessive force will damage the bat- fuse seems to have blown, have a Yamaha tery casing. dealer inspect the vehicle. Specified fuses:...

  • Page 52: 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 53: 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 8-12...

  • Page 54: 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 55: 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 56 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.

  • Page 57: 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 58: 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 59: Replacing A Taillight Bulb

    Replacing a taillight bulb If a taillight bulb burns out, have a Yamaha dealer replace it. 8-18...

  • Page 60: 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 61: Specifications

    S PECIFICATIONS Model G27E Dimensions: Overall length 2492 mm (98.1 in) Overall width 1232 mm (48.5 in) Overall height (steering height) 1275 mm (50.2 in) Height of floor 391 mm (15.4 in) Wheelbase 1637 mm (64.4 in) Tread: Front 941 mm (37.0 in) Rear 979 mm (38.5 in) Ground clearance...
  • Page 62 Model G27E Steering system: Type Rack and pinion Brakes: Brake system Mechanical drum brake on 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 63 Model G27E Bulb voltage, wattage × quantity: 12 V, 30 W / 30 W × 2 Headlight Sealed beam × 2 Taillight Specified fuses: Main fuse Lighting system fuse 10 A 10-3...

  • Page 64: 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 65 11-2...
  • Page 68 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2004.06-0.3×2 CR...

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