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Yamaha G11A Owner's/Operator's Manual

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Table of Contents
OWNER'S/
OPERATORS
MANUAL
LIT-19626-11-97
UTILITY
CAR
G11A
JR3-F8199-10

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  Summary of Contents for Yamaha G11A

  • Page 1 UTILITY OWNER’S/ OPERATORS MANUAL G11A LIT-19626-11-97 JR3-F8199-10...
  • Page 2 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 these simple instructions will help you to obtain maximum enjoyment from your new Yamaha.
  • Page 3 IMPORTANT MANUAL INFORMATION Particularly important information is NOTE distinguished in this manual by the fol- Yamaha continually seeks ad- lowing notations: vancements in product design and quality; therefore, while this manual contains the most current product information available at the time of...

  • Page 4: Table Of Contents

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

  • Page 5: Warranty

    G11A UTILITY VEHICLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants warranty shall be to: that any new G11A Utility Vehicle Yamaha Golf Car Operate and maintain the Utility Vehicle as purchased from an authorized Yamaha dealer in the specified appropriate Owner’s/...

  • Page 6: California Emission Control Warranty

    The California Air Resources Board and Yamaha You are responsible for presenting your specialty Motor Manufacturing Corporation of America are vehicle engine to a Yamaha dealer as soon as a pleased to explain the emission control system war- problem exists. The warranty repairs should be ranty on your 1996 or later specialty vehicle engine.
  • Page 7 Catalyst or Thermal Reactor System ment, or repair of emission control systems be Catalytic converter Yamaha parts. The owner may elect to have main- Thermal reactor tenance, replacement, or repair of the emission Exhaust manifold...

  • Page 8: Important Labels

    IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS WARNING Please read the following labels carefully before operating your utility car, and promptly replace any labels which become dam- aged or removed. Y-100 UTILITY...

  • Page 9: Important Labels

    NOTE The first three digits of the serial num- ber are for model identification; the 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. UTILITY...

  • Page 10: Operator Safety

    OPERATOR SAFETY 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 before oper- ating.
  • Page 11 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. Y-104 Vary the speed of the utility car to match the terrain of the course.
  • Page 12 OPERATOR SAFETY 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 towing trailer.

  • Page 13: Maintenance Safety Program

    Parts and Materials. Use only the car must be driven by a quali- replacement parts and materials fied, trained, and authorized person recommended by Yamaha. – in an area free of pedestrian traffic – to ensure proper operation and Ventilation. Properly ventilate all adjustment.

  • Page 14: Battery Charging

    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 battery changing and charging facilities and procedures that are in accordance with applica- ble ordinances and regulations.

  • Page 15: Controls

    CONTROLS FEATURES 1 Steering wheel 2 Seat 3 Battery 4 Brake pedal 5 Parking brake pedal 6 Accelerator pedal 7 Drive selector lever Y-12 8 Main switch 9 Oil warning light a Choke knob b Front cowl c Front tire d Front bumper e Rear cowl f Rear tire...

  • Page 16: Main Switch

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

  • Page 17: Accelerator Pedal

    CONTROLS 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. Y-18 Lever Position Car Movement FORWARD REVERSE NOTE The back-up buzzer will beep when the drive select lever is turned to “R.”...

  • Page 18: Parking Brake Pedal

    CONTROLS PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the utility car. å Parking brake pedal NOTE Release the parking brake by de- Y-22 pressing the accelerator pedal. CHOKE KNOB Pull and hold out choke knob when starting a cold engine.

  • Page 19: Pre-Operation Checks

    PRE-OPERATION CHECKS 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. WARNING Be sure the main switch key is removed before performing the pre-operation checks to prevent accidental starting, and apply the...

  • Page 20: Cargo Bed

    PRE-OPERATION CHECKS 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. Y-112 WARNING Remove the main switch key and...

  • Page 21: Fuel System

    PRE-OPERATION CHECKS 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 Y-850 WARNING Gasoline and its vapors are highly flammable and explosive.

  • Page 22: Engine Oil

    PRE-OPERATION CHECKS 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). Y-514 å Oil level dipstick ∫...

  • Page 23: Tire Condition

    PRE-OPERATION CHECKS 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. Check the battery terminals for corrosion.

  • Page 24: Steering System

    Y-33 PEDAL OPERATION Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha deal- Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its origi- nal position when released.
  • Page 25 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. å Parking brake pedal Y-22 NOTE Release parking brake depressing the accelerator pedal. Accelerator Pedal WARNING Before checking operation of the accelerator pedal, be sure the main...

  • Page 26: 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 utility car is mov- Y-18 ing. 2. Turn the main switch to “ON.” WARNING Do not depress the accelerator pedal when turning on the main...
  • Page 27 OPERATION STOPPING To stop the utility car, gradually press down on the brake pedal. å Brake pedal When the car has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.” Y-65 ∫ Parking brake pedal CAUTION Do not hold the utility car on an incline with the accelerator –...

  • Page 28: Maintenance

    Check brushes for wear Check commutator for dirt 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 29 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...
  • Page 30 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...

  • Page 31: 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. UTILITY...

  • Page 32: 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 1. Check for discoloration and heavy Y-516 carbon deposits. The normal electrode color will be tan.

  • Page 33: Engine Oil Replacement

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

  • Page 34: Air Filter

    After replacing engine oil, check for oil leaks around the drain plug. If oil leaks are found, consult Y-515 a Yamaha dealer. Air Filter To remove the air filter elements: 1. Unlatch the air filter cover clips and remove cover.
  • Page 35 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- Y-508 aged or dirty, replace it. CAUTION Do not wring out the foam pre-fil- ter, this could cause it to tear.

  • Page 36: Drive Belt

    MAINTENANCE 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 the drive belt will roll off the sheave.

  • Page 37: Fuse Replacement

    MAINTENANCE Battery WARNING 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 milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 38 MAINTENANCE WARNING Be sure to use the specified fuse. Using a wrong fuse can cause elec- trical system damage and create a fire hazard. CAUTION When replacing a fuse be sure the Y-35 main switch is turned off to prevent accidental short-circuiting.

  • Page 39: Wheel Replacement

    Do not allow foreign material to enter the gear box. 5. Reinstall the oil plug. NOTE For gear oil replacement, consult a Yamaha dealer or other qualified mechanic. Wheel Replacement To remove and install a wheel on your utility car: 1.

  • Page 40: Brake Pedal Free Play

    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 utility car. Y-61 2.

  • Page 41: Storage

    STORAGE Perform the following preparations when storing your utility car for extend- ed periods of time: NOTE Turn main switch key to “OFF” position, remove key, and store key in a safe place. DRAINING FUEL WARNING Gasoline and its vapors are highly flammable and explosive.

  • Page 42: Engine Preparation

    STORAGE ENGINE PREPARATION BATTERY With the key removed and the spark PREPARATION plug lead disconnected, turn the clutch by hand until compression is 1. Remove the battery from the utility felt. This puts the valves in the closed car and store it in a cool, dry place position.

  • Page 43: Specifications

    SPECIFICATIONS 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 in.
  • Page 44 SPECIFICATIONS ENGINE Items G11A Description: Engine type 4-stroke, Gasoline, OHV Number of cylinders Single Displacement 301 cm 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...
  • Page 45 (Bolt heads round parallel to arm) 0.04 in. (1 mm) Wheel: Tire size: Front 18 x 8.50–8.00/4 PR Rear 18 x 8.50–8.00/TURF Rim size: 7.00–I–8.00 Tire pressure: For G11A: 20 - 23 psi (140 - 160 kPa, 1.4 - 1.6 kgf/cm 2 ) 10-3 UTILITY...

  • Page 46: Wiring

    WIRING G11A WIRING DIAGRAM 11-1 UTILITY...
  • Page 48 01/10/01 1PC - G11A O/M LIT196261197 *LIT196261197* Yamaha Motor Corp., USA Cypress, California made in YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA Printed in U.S.A.