Yamaha G20A Owner'S/Operator'S Manual Download Page 1

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OWNER’S/
OPERATOR’S
MANUAL

MULTI-
PASSENGER
VEHICLE

LIT-19626-20-00

YAMAHA MOTOR

MANUFACTURING CORP.

OF AMERICA

JR8-F8199-00

Printed in U.S.A.

G20A

Yamaha Motor Corp., USA

Cypress, California

made in

10/31/00

LIT196262000

USA

*LIT196262000*

1PC - G20A O/M

G20a O_M Cover

11/2/00, 10:04 PM

KCC

Summary of Contents for G20A

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Page 3: ...our new Yamaha If you have any questions about the operation or maintenance of your vehicle please consult a Yamaha dealer TECHNICAL SERVICE DEPT GOLF CAR SALES GROUP YAMAHA MOTOR MANUFACTURING CORP of AMERICA G20A OWNER S OPERATOR S MANUAL 2000 by Yamaha Motor Manufacturing Corporation of America 1st edition All rights reserved Any reprinting or unauthorized use without the written permission of ...

Page 4: ...r vehicle and should remain with the car when resold Read and understand this manual completely before operating your vehicle WARNING NOTE Particularly important information is distinguished in this manual by the fol lowing notations The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instruc tions could result in severe injury or death to the vehicle...

Page 5: ...i MULTI PASSENGER 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 OCCUPANT SAFETY 3 10 ...

Page 6: ...ed in transporting a Multi Passenger Vehicle to and from an authorized Yamaha Golf Car Dealer for service or in performing field service is also excluded from this warranty THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the Multi Passenger Vehicle as specified in the appropriate Owner s Operator s Manual 2 Give notice to an authorized Yamaha dealer of any and ...

Page 7: ... deny you warranty coverage if your specialty vehicle engine or a part has failed due to abuse neglect improper maintenance or unapproved modifica tions You are responsible for presenting your specialty vehicle engine to a Yamaha dealer as soon as a problem exists The warranty repairs should be completed in a reasonable time not to exceed 30 days If you have any questions regarding your warranty r...

Page 8: ...performance of regular maintenance should be retained in the event ques tions arise concerning maintenance The receipts should be transferred to each subsequent owner of this specialty vehicle engine The emission control systems of your Yamaha spe cialty vehicle engine were designed built tested and certified as being in conformity with California emission control regulations using genuine Yamaha ...

Page 9: ...the following labels carefully before oper ating your multi passenger vehicle and promptly replace any labels which become damaged or removed WARNING Y 191B 4 Y 500 1 1 4 3 2 Vehicle capacity 2 occupants per seat 4 persons total V e h i c l e c a p a c i t y 2 o c c u p a n t s p e r s e a t 4 p e r s o n s t o t a l ...

Page 10: ...IAL NUMBER The vehicle 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 record of these numbers for reference when ordering parts from a Yamaha dealer NOTE Y 851 5 5 Y 852 ...

Page 11: ...rized people should drive the vehicle from the driver s side only and only in designated areas It is recommended that only people who possess a valid motor vehicle driver s license be allowed to oper ate the vehicle Do not operate the vehicle on public streets roads or highways Such use is prohibited by law and dan gerous Operation on public roads can result in collision with other vehicles Do not...

Page 12: ...e the vehicle remain seated and hold on when the car is in motion Do not run the engine indoors Exhaust gas is poisonous Do not start the vehicle until all occupants are seated and holding on with their entire bodies inside the vehicle Use extra care in congested areas or when backing up Always back up slowly and watch carefully Do not use rear seat for cargo or luggage storage Rear seat is to be ...

Page 13: ...ration and service manuals as well as the following safe ty procedures Properly immobilize vehicle before beginning any maintenance Properly block chassis before work ing underneath vehicle Before disconnecting any part of the fuel system drain the applicable part of the system to prevent fuel leaks Avoid fire hazards and have appro priate fire protection equipment available Maintain all safety de...

Page 14: ...n 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 Periodically inspect fueling and charging facilities and procedures to be certain that applicable safety codes regulations and procedures are being followed 1 2 3 4 5 6 7 8 9 10 11 4 2 MULTI PASSENGER ...

Page 15: ...2 14 13 8 11 12 3 17 4 FEATURES 1 Steering wheel 2 Front seat 3 Rear seat 4 Battery 5 Brake pedal 6 Parking brake pedal 7 Accelerator pedal 8 Drive selector lever 9 Main switch a Oil warning light b Choke knob c Front cowl d Front tire e Front bumper f Rear cowl g Rear tire h Fuel cap ...

Page 16: ...OFF Ignition circuit is switched off The key can be removed only in this position ON Electrical circuits are switched on The vehicle can be driven OIL WARNING LIGHT When the engine oil level falls below an acceptable level this light comes on If the light comes on stop the engine check the engine oil level and add oil as necessary See page 6 3 å Oil warning light ...

Page 17: ...desired position Lever Position Car Movement F FORWARD R REVERSE The back up buzzer will beep when the drive select lever is turned to R ACCELERATOR PEDAL The accelerator pedal controls the vehicle s speed Action Car Speed Depress pedal Increase Release pedal Decrease å Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the vehicle Brake pedal NOTE CONTROLS Y 191F Y 18 Y 21 B ...

Page 18: ...king brake pedal whenever parking the vehicle 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 after the engine starts å Choke knob NOTE CONTROLS Y 22 A Y 23 A CHOKE ...

Page 19: ...ond nature Be sure the main switch key is removed before performing the pre operation checks to prevent accidental starting and apply the parking brake to keep the car from moving PRE OPERATION CHECKLIST Before each use check the following Fuel system Engine oil level Air cooling duct Battery Tire condition Steering system Back up buzzer Pedal operation Body and chassis SEAT Open the rear seat for...

Page 20: ...ke care not to spill gasoline If gasoline spills wipe it up imme diately with dry rags Always dis pose of gasoline soaked rags properly Tighten the filler cap securely after refueling If you swallow gasoline inhale a lot of gasoline vapor or get gaso line in your eyes get immediate medical attention If any gasoline gets on your skin immediately wash with soap and water Change clothing if gaso line...

Page 21: ...l if the level is above the MIN mark 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 Use care not to get oil on the starter belt The distance between the dipstick marks represents approx 1 2 US qt 1 2 L of oil Recommended engine oil classifica tion API Service SE SF or SG Engine oils labeled Energy Conserv ing II are recommen...

Page 22: ...the battery Check the battery terminals for corrosion TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the vehicle Tire pressure For G20 A 20 23 psi 140 160 kPa 1 4 1 6 kgf cm2 Tire Wear Limit Check the tire surface for damage cracks or embedded objects When tire tread wears down to 0 04 in 1 mm replace the tire å Wear limit A Y 191L Engine Cooling Inlet Duct Check the...

Page 23: ...play or hear rattling sounds which may indicate loose steering components consult a Yamaha dealer BACK UP BUZZER Check the back up buzzer by moving the drive select lever to R for reverse The buzzer should sound PEDAL OPERATION Check the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha deal er Brake Pedal Make sure the brake pedal feels firm when pre...

Page 24: ... click and releases when the accelerator pedal is pressed å Parking brake pedal Release the parking brake by depressing the accelerator pedal Accelerator Pedal Before checking operation of the accelerator pedal be sure the main switch is in the OFF position Make sure the accelerator pedal oper ates smoothly Accelerator pedal BODY AND CHASSIS Before each use visually inspect the vehicle body and ch...

Page 25: ...accelerator pedal when turning on the main switch or the vehicle may suddenly start moving 3 Pull the choke knob out and hold it while starting Release the choke knob after the engine starts å Choke knob The choke is not required when the engine is warm 4 Check that your path is clear in the direction you plan to go and slow ly depress the accelerator pedal The vehicle will start to move Accelerat...

Page 26: ...NG To stop the vehicle 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 Parking brake pedal Do not hold the vehicle on an incline with the accelerator use the brake CAUTION ...

Page 27: ...ke pedal freeplay C CA CA CA CA CA 8 12 and adjust if necessary Check steering operation C C C C C 6 5 Check tire pressure tread C CA CA CA CA CA 6 5 depth tire surface for damage Check body and chassis for C C C C C C 6 6 damage Check tightness of all bolts C C C C C C nuts and screws Check reverse buzzer C C C C C C 6 5 operation EVERY Check fuel filter for clogging C C C C C MONTH Check wear of...

Page 28: ...and insulation Check shoe lining thickness C C C and rear axle bearing play Check kingpin play seal and CA CA CA cap Adjust wheel alignment Check wheel nut tightness C C C front wheel bearing play Check gear box oil level C C C 8 10 and leakage Check operation and adjust CA CA CA pedal stop if necessary EVERY Check brushes for wear and C S 2 YEARS commutator for dirt EVERY Replace fuel filter and ...

Page 29: ...d ing acronyms are provided in accor dance with U S EPA REGULATIONS FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULA TIONS 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 ...

Page 30: ...ark plug gap with a feeler gauge Standard spark plug BPR2ES Spark plug gap 0 028 0 031 in 0 7 0 8 mm å Gap 3 Clean the gasket and plug sur faces and install the spark plug fin ger tight before tightening to the following torque Spark plug torque 14 5 ft lb 20 Nm 2 0 m kg When removing or installing the spark plug be careful not to dam age the insulator A damaged insu lator could allow external spa...

Page 31: ... an oil collection station 4 Install the drain plug along with a new drain plug gasket finger tight before tightening to the following torque Drain plug torque 23 ft lb 31 Nm 3 1 m kg 5 Add the correct quantity of oil through the oil filler hole Recommended engine oil classifica tion API Service SE SF or SG Engine oils labeled Energy Conserv ing II are recommended NOTE NOTE WARNING Recommended oil...

Page 32: ...e 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 å Air filter cover clips Air filter cover 2 Lift the air filter and pre filter out of the air filter case å Air filter Pre filter Be careful not to drop anything into the air inlet CAUTION CAUTION MAINTENANCE 1 2 3 4 5 6 7 8 9 10 11 8 6 MULT...

Page 33: ...t 4 Check the filter element If dam aged or dirty replace it Do not wring out the foam pre fil ter this could cause it to tear 5 To replace the elements reverse the above steps The pre filter has a notch on one side It will only fit in the case one way CAUTION CAUTION 1 2 3 4 5 6 7 8 9 10 11 MAINTENANCE 8 7 MULTI PASSENGER ...

Page 34: ... sheave 4 Remove the drive belt from the pri mary sheave Inspection To inspect the drive belt check for frayed edges or tears and measure drive belt against the following specifi cation If the belt shows excessive wear or damage replace the belt with a new one å New 1 22 in 31 0 mm Replace when belt reaches 1 06 in 27 mm 5 To install the drive belt reverse the above steps rolling the belt back ove...

Page 35: ...s and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHIL DREN The 12 volt battery that provides start ing power to your vehicle normally doesn t require the addition of water during the one year warranty period provided by the...

Page 36: ...cement fuse Gear Box Oil To check gear box oil level 1 Place the vehicle on a level sur face 2 Remove the access panel by removing the screws in the two lower corners of the panel and pulling the panel from the car 3 Remove the oil plug A Recommended oil SAE 90 gear oil Gearcase capacity 0 44 US qt 0 42 L 0 09 Imp gal CAUTION WARNING Replacement Fuse 10 Amp Blade Style Y 35 B A C Y 191J Y 520 A B ...

Page 37: ... oil replacement consult a Yamaha dealer or other qualified mechanic Wheel Replacement To remove and install a wheel on your vehicle 1 With the wheels blocked to prevent the vehicle from moving loosen the wheel nuts 2 Elevate the vehicle with a jack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Brake Adjustment The brakes on your vehicle are self adj...

Page 38: ...pedal travels before resistance is felt Brake pedal free play 25 30 mm 0 98 1 18 in 3 If the free play distance needs adjusting loosen the lock nut and turn the adjusting nut in or out in 180 increments only due to the cam shape of adjuster until the free play specification is met Then tighten the lock nut in place Do not overtighten the brake cables The self adjusters may not operate properly red...

Page 39: ...a Take care not to spill gasoline If gasoline spills wipe it up immedi ately with dry rags Always dis pose of gasoline soaked rags properly Tighten the filler cap securely after checking fuel level If you inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical attention If any gasoline gets on your skin immediately wash with soap and water Change clothing if gasoline spil...

Page 40: ...st inhibitor 3 Cover the vehicle with a breath able cover and store it in a dry well ventilated area BATTERY PREPARATION 1 Remove the battery from the vehi cle and store it in a cool dry place that stays between 32 F 0 C and 90 F 30 C 2 Have the battery recharged every 60 90 days to keep it fully charged The battery must be kept fully charged to avoid damage Batteries like the one supplied with yo...

Page 41: ...Overall height steering height 46 8 in 1190 mm Height of floor 11 8 in 300 mm Wheelbase 97 8 in 2483 mm Tread Front 34 3 in 870 mm Rear 38 6 in 980 mm Min ground clearance 3 8 in 97 mm Weight Dry weight without battery 855 lb 388 kg Performance Maximum speed 12 mph 19 km h Minimum turning radius 167 0 in 4 24 m Seating capacity 4 persons SPECIFICATIONS ...

Page 42: ... or SAE 10W30 Engine oil capacity 1 16 US qt 1 1 L 0 24 Imp gal Oil change quantity 1 0 US qt 0 9 L 0 19 Imp gal TRANSMISSION Items G20A Transmission Type V belt automatic centrifugal engagement V belt width and outer line length 1 22 x 39 76 in 31 x 1010 mm V belt wear limit 1 06 in 27 mm Governor Type Oil bath flyweight Factory speed setting 12 mph 19 km h Differential reduction gear G20A Differ...

Page 43: ...nding shoe Leading trailing shoes self adjusting Brake pedal freeplay linkage adjustment 25 30 mm Brake cable end play 0 004 0 02 in 0 1 0 5 mm Parking brake Type Foot type parking brake with automatic release Release timing 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 G20A 20 23 psi 140 160 ...

Page 44: ...B B B B B B B B Y Y BR 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 BL B B BL G Br B R W R W BL BL BL B B B B B Y 191N G G Br Br B RW R Br R RY Br Br 16 1 2 3 4 5 6 7 8 9 10 14 15 13 12 11 BR G RB B B Br W R B R G B B R R L R L R R F 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 WIRING G20A WIRING DIAGRAM ...

Page 45: ... 4W c Main switch d Accelerator stop switch e Back switch f Buzzer g Body ground h Signal lights i Turn signal lever j Head lights k Tail lights l Head light switch m Flasher unit n Brake light switch o Brake light sensor COLOR CODE B Black BL Blue G Green Y Yellow R Red P Pink Br Brown W White B R Black Red Y B Yellow Black R Y Red Yellow R W Red White 1 2 3 4 5 6 7 8 9 10 11 WIRING ...

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