Related Manuals for Yamaha U-MAX G27A
Summary of Contents for Yamaha U-MAX G27A
- Page 1 READ THIS MANUAL CAREFULLY! It contains important safety information. OWNER’S/OPERATOR’S MANUAL G27A G28A JU7-F8199-10 LIT-19626-01-08...
- 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...
- Page 6 You are responsible for presenting your specialty Air Induction System to meet stringent anti-smog standards. Yamaha must vehicle engine to a Yamaha dealer as soon as a Controlled hot air intake system warrant the emission control system on your speciality problem exists.
- Page 7 This work, modification, misuse, alteration, or improper work must be done at an authorized Yamaha dealer. maintenance (see your Owner’s/Operator’s Manual). Give notice to an authorized Yamaha dealer of any...
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Page 8: Table Of Contents
Auxiliary DC jack......4-6 CONTENTS Cargo bed ........4-8 Trailer hitch bracket .......4-12 LOCATION OF THE WARNING AND SPECIFICATION LABELS..1-1 PRE-OPERATION CHECKS ....5-1 Pre-operation check list ....5-2 DESCRIPTION AND VEHICLE Brakes..........5-3 IDENTIFICATION ......2-1 Fuel ..........5-4 FEATURES ........2-1 Engine oil .........5-5 Utility vehicle serial number..... - Page 9 DRIVING YOUR VEHICLE....7-1 Drive belt........8-14 Getting to know your vehicle... 7-1 Battery ........... 8-15 Learning to operate your vehicle ..7-3 Fuse replacement......8-16 Turning your vehicle......7-3 Transmission oil......8-17 Braking ..........7-3 Wheel removal....... 8-18 Going uphill ........7-4 Wheel installation ......
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Page 10: Location Of The Warning And Specification Labels
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a re- placement label is available from your Yamaha dealer. G27A... - Page 12 . • K e e p e n t i r e b o d y i n s i d e v e h i c l e . YAMAHA 5UG-K7764-00 •...
- Page 13 • Be sure cargo is secured—a loose load could change handling unexpectedly. • Keep weight in the cargo bed centered, and as low and far forward as possible. Top-heavy loads increase the risk of overturn. YAMAHA JU7-K7766-00 Improperly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury.
- Page 14 G28A...
- Page 15 . YAMAHA JU9-K7761-00 Vehicle Rated Capacity: 1000 lb (454 kg)
- Page 16 ENGINE AIR INDEX (California only) MOST CLEAN LEAST CLEAN NOTE : THE LOWER THE AIR INDEX. THE LESS THE POLLUTION THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT FOR THE FOLLOWING USE : MODERATE INTERMEDIATE EXTENDED CHECK OWNERS MANUAL FOR FURTHER DETAILS THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY...
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Page 17: Description And Vehicle Identification
D ESCRIPTION AND VEHICLE IDENTIFICATION FEATURES 1. Steering wheel 2. Seat 3. Battery 4. Taillight 5. Rear tire 6. Fuel tank 7. Drive select lever 8. Starter (choke) 9. Front tire 10. Front bumper 11. Headlight 12. Accelerator pedal 13. Brake pedal 14. -
Page 18: 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 19: 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 20 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 21 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.
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Page 22: 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 23: Oil Level Warning Light
Oil level warning light Fuel tank cap This warning light comes on when the engine Remove the fuel tank cap by turning it coun- oil level is low. If the light comes on, stop terclockwise. the engine, check the engine oil level, and add oil as necessary. -
Page 24: Drive Select Lever
Drive select lever NOTE: The back-up buzzer will sound when the drive The drive select lever is used for driving the select lever is shifted to “R.” utility vehicle either forward or in reverse. After coming to a complete stop, shift the lever to the desired position. -
Page 25: 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 NOTE: The engine stops when the utility vehicle comes to a complete stop. -
Page 26: Parking Brake Pedal
Parking brake pedal Starter (choke) Press the parking brake pedal down whenev- Pull the starter (choke) knob out and hold it er parking the utility vehicle. when starting a cold engine. Release it after the engine starts. 1. Parking brake pedal 1. -
Page 27: Horn Button
Horn button Auxiliary DC jack Step on the horn button to sound the horn. The auxiliary DC jack is located in the front panel. The auxiliary DC jack can be used for acces- sories such as lights, radios, etc. The auxiliary DC jack should only be used for short periods if the utility vehicle is not being operated. - Page 28 1. Set the main switch to “ON”. CAUTION: 2. Open the auxiliary DC jack cap, and then Do not use accessories requiring insert the accessory power plug into the more than the maximum rated capaci- jack. ty for the auxiliary DC jack. This may overload the circuit and cause the fuse to blow.
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Page 29: Cargo Bed
Cargo bed Opening and closing the tailgate (For G28A) 1. Cargo bed 1. Tailgate 2. Latch (× 2) 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 30 Lifting and lowering the cargo bed To lift: Pull the cargo bed release lever towards the rear, and then slowly lift up the cargo bed until end of the prop rod hooks onto the prop rod guide to support the cargo bed. To lower: Slightly lift up the cargo bed, unhook the end of the prop rod, and then lower the cargo bed...
- Page 31 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Overloading the cargo bed. Carrying a passenger in the cargo bed. WHAT CAN HAPPEN WHAT CAN HAPPEN Could cause changes in vehicle han- The passenger could fall, be thrown out, dling which could lead to an accident. or be struck by objects in the cargo bed.
- Page 32 WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Pinch point. Fire or explosion while filling a portable fuel container. WHAT CAN HAPPEN You or someone else could be pinched WHAT CAN HAPPEN between the cargo bed and the frame or Static electricity sparks can ignite fuel the seat backs when the bed is being vapors.
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Page 33: Trailer Hitch Bracket
Trailer hitch bracket This vehicle is equipped with a 5 cm (2 in) re- ceiver bracket for a standard trailer hitch. Trailer towing equipment can be obtained at a Yamaha dealer. (See page 6-5 for precaution information.) 1. Trailer hitch bracket 4-12... -
Page 34: Pre-Operation Checks
P RE-OPERATION CHECKS Pre-operation checks should be made each WARNING time you use your utility vehicle. Get in the POTENTIAL HAZARD habit of performing the following checks in the Failure to inspect the vehicle before op- same way so that they become second na- erating. -
Page 35: Pre-Operation Check List
Pre-operation check list Before using this vehicle, check the following points: ITEM ROUTINE PAGE Brakes • Check for proper operation, condition and free play. 5-3, 8-20–8-22 Parking brake • Check for proper operation, condition and free play. 5-3, 8-20–8-22 • Check fuel level. Fuel 5-4–5-5 •... -
Page 36: Brakes
HOW TO AVOID THE HAZARD firm feeling when the brakes are applied. If Always check the brakes at the start of not, have the vehicle inspected by a Yamaha every ride. Do not operate the vehicle if dealer. you find any problem with the brakes. If... -
Page 37: Fuel
Yamaha because it may cause fuel system and piston rings, as well as to the exhaust damage or vehicle performance problems. -
Page 38: Engine Oil
Engine oil WARNING Make sure that the engine oil is at the speci- POTENTIAL HAZARD fied level. Add oil if necessary. (See pages Improper care when refueling. 8-9–8-10 for details.) WHAT CAN HAPPEN CAUTION: Fuel can spill, which can cause a fire and severe injury. -
Page 39: Accelerator Pedal
POTENTIAL HAZARD and fasteners before a ride. Take the utility Checking operation of the accelerator vehicle to a Yamaha dealer or refer to the Ser- pedal with the key in the main switch. vice Manual for the correct tightening torques. -
Page 40: Tires
HOW TO AVOID THE HAZARD 1. The tires listed below have been ap- proved by Yamaha Motor Manufac- turing Corporation of America for NOTE: Measure the tire pressure twice and use the this model. - Page 41 G28A 4. Use no more than the following Manufacturer Size pressures when seating the tire 22 × 11-10 / 6 PLY Front DURO beads. 22 × 11-10 / 6 PLY Rear DURO Front 250 kPa (2.5 kgf/cm , 36 psi) Rear 250 kPa (2.5 kgf/cm , 36 psi) 2.
- Page 42 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 43: Operation
O PERATION 2. Turn the main switch to “ON” or “ON ”. Starting a cold engine 1. With the parking brake applied, shift the drive select lever to “F” for forward, or “R” for reverse. WARNING POTENTIAL HAZARD Depressing accelerator pedal while turning on the main switch. - Page 44 3. Pull the starter (choke) knob out and hold 4. Check that your path is clear in the direc- it while starting a cold engine. Release tion you plan to go, and slowly depress the starter (choke) knob after the engine the accelerator pedal.
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Page 45: Starting A Warm Engine
Starting a warm engine Stopping To start a warm engine, refer to the “Starting a To stop the utility vehicle, gradually press cold engine” section. The starter (choke) down on the brake pedal. should not be used. Press the accelerator When the utility vehicle has come to a stop, pedal slightly. -
Page 46: 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 47 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 48 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.
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Page 49: 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 50 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.
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Page 51: 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 52: 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 53: 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 54: 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 55: 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 56: Periodic Maintenance And Adjustment
Electrical components cause your vehicle to a Yamaha dealer to check the shocks or can start fires. torque settings and adjust them as necessary. HOW TO AVOID THE HAZARD Turn off the engine and remove the main switch key when performing mainte- nance unless otherwise specified. - Page 57 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.
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Page 58: Periodic Maintenance/Lubrication
PERIODIC MAINTENANCE/LUBRICATION NOTE: G For vehicles not equipped with an odometer or an hour meter, follow the month maintenance intervals. G For vehicles equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the vehicle isn’t used for a long period of time, the month maintenance intervals should be followed. - Page 59 • Check for cracks or damage. Engine mounts* • Check bolt tightness. • 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.
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Page 60: Exhaust Emission Control System And Components
FOR NEW 1995 AND LATER OFF-HIGHWAY RECREATIONAL 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. -
Page 61: Seat
Seat 3. Lift the cargo bed up until the end of the Lift the seat to check the fuel level and add fu- prop rod hooks onto the prop rod guide to el. To service the engine for the G27A, the support the cargo bed. - Page 62 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 63: Spark Plug Inspection
Spark plug inspection Specified spark plug: Periodically remove and inspect the spark BPR2ES (NGK) plug. Dirty or worn spark plugs can cause Spark plug gap: poor engine performance. 0.7–0.8 mm (0.028–0.031 in) 1. Spark plug 2. Spark plug cap 1. Check for discoloration and heavy car- a. -
Page 64: Engine Oil
3. Clean the gasket and plug surfaces and Engine oil Checking the engine oil level install the spark plug, and then tighten it to the specified torque. 1. Place the utility vehicle on a level sur- face. Spark plug torque: 2. - Page 65 NOTE: CAUTION: Insert the dipstick into the crankcase until it Be sure no foreign material enters the firmly seats in place. crankcase. 4. Remove the dipstick and check the oil level. Replacing the engine oil 1. Place the utility vehicle on a level sur- face.
- Page 66 4. Install the drain bolt along with a new drain bolt gasket, and then tighten it to the specified torque. Tightening torque: Drain bolt: 30 Nm (3.0 m·kgf, 22 ft·lbf) 5. Add the specified amount of engine oil, and then install the oil filler cap. 1.
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Page 67: Air Filter Element Cleaning
6. Operate the utility vehicle for several min- 2. Lift the air filter element and pre-air filter utes to warm up the engine, and then element out of the air filter case. check for oil leakage. CAUTION: If oil leakage is found, check for the cause. Air filter element cleaning To remove the air filter elements: 1. - Page 68 Inspection and cleaning: CAUTION: 3. Wash the pre-air filter element in soap Do not attempt to clean the air filter ele- and water. Allow it to dry. ment with compressed air. It could be damaged. 5. To replace the elements, reverse the above steps.
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Page 69: Drive Belt
Drive belt Inspection: To remove the drive belt: To inspect the drive belt, check for frayed edges 1. Set the drive select lever halfway be- or tears, and measure the drive belt as shown. tween forward and reverse. If the belt shows excessive wear or damage or 2. -
Page 70: Battery
Battery The battery doesn’t require the addition of wa- ter. If the battery loses its charge, have an ex- WARNING perienced mechanic charge it. Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. It con- tains sulfuric acid. Avoid contact with skin, eyes, or clothing. -
Page 71: Fuse Replacement
Fuse replacement The fuses are located under the driver’s side of the seat for the G27A and the passenger’s side of the seat for the G28A. (See page 8-6 for seat opening and closing procedures.) If a fuse is blown, replace it. WARNING Be sure to use the specified fuse. -
Page 72: 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 73: Wheel Removal
To remove and install a wheel on your utility vehicle: NOTE: For transmission oil replacement, consult a Yamaha dealer. 1. Nut (× 4) 1. With the wheels blocked to prevent the utility vehicle from moving, loosen the wheel nuts. -
Page 74: 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 75: 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 76 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 77: Replacing A Headlight Bulb
Replacing a headlight bulb G28A If a headlight bulb burns out, replace it as fol- lows. 1. Remove the headlight bulb holder by turning it counterclockwise. 1. Locknut 2. Adjusting nut Tightening torque: 17 N·m (1.7 m·kgf, 12 ft·lbf) 1. Headlight bulb holder WARNING 2. -
Page 78: 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 tab (× 2) 3. -
Page 79: Replacing A Taillight Bulb
Replacing a taillight bulb If a taillight bulb burns out, have a Yamaha dealer replace it. 8-24... -
Page 80: Cleaning And Storage
Turn main switch key to “OFF” position, re- nates the need to drain the fuel system. Con- move key, and store key in a safe place. sult a Yamaha dealer if the fuel system needs to be drained instead. Draining the fuel 1. -
Page 81: Chassis Preparation
Chassis preparation NOTE: 1. Block up the frame to raise all wheels off Batteries like the one supplied with your vehi- cle normally do not require you to check the the ground. water level inside the battery for the one year 2. -
Page 82: Specifications
S PECIFICATIONS Model G27A/G28A Dimensions: Overall length 2492 mm (98.1 in) (G27A) 3011 mm (118.5 in) (G28A) Overall width 1232 mm (48.5 in) (G27A) 1289 mm (50.7 in) (G28A) Overall height (steering height) 1275 mm (50.2 in) (G27A) 1353 mm (53.3 in) (G28A) Height of floor 391 mm (15.4 in) (G27A) 463 mm (18.2 in) (G28A) - Page 83 Model G27A/G28A Weight: Dry weight (without battery) 329 kg (725 lb) (G27A) 442 kg (974 lb) (G28A) Performance: Maximum speed 24 km/h (15 mph) Minimum turning radius 3.0 m (118.1 in) (G27A) 4.3 m (169.3 in) (G28A) Seating capacity 2 persons Engine: Engine type Air-cooled 4-stroke, OHV...
- Page 84 Model G27A/G28A Engine oil: Type YAMALUBE 4 (10W30) or SAE 10W30 Recommended engine oil classification API Service SE type or higher Quantity: Oil change 0.9 L (0.79 Imp qt, 0.95 US qt) Transmission: Type V-belt automatic centrifugal V-belt width and outer line length 31 x 1010 mm (1.22 x 39.76 in) V-belt wear limit 27.9 mm (1.10 in)
- Page 85 Model G27A/G28A Brakes: Brake system Mechanical drum brake on rear wheels with self- adjusters (G27A) Mechanical drum brake on front and rear wheels with self-adjusters (G28A) 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...
- Page 86 Model G27A/G28A Bulb voltage, wattage × quantity: 12 V, 30 W / 30 W × 2 Headlight Sealed beam × 2 Taillight Indicator light: 12 V, 3.4 W × 1 Engine oil level warning light Specified fuses: Main fuse 20 A Headlight/signaling system fuse 10 A Auxiliary DC jack fuse...
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Page 87: 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 90 YAMAHA MOTOR CO., LTD. PRINTED IN USA 2004.06-0.3×2 CR...