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Yamaha U-MAX G23A, Owner'S/Operator'S Manual, Page: 54 / 84

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Yamaha U-MAX G23A Owner'S/Operator'S Manual Download Page 54

8-4

EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS

The above items and the corresponding acronyms are provided in accordance with U.S. EPA
REGULATIONS FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULATIONS
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.

Item

Acronym

●

CARB. ASSY., LH., JT., CARBURETOR
2 & JT., CARBURETOR 1

CARB (Carburetor)

●

T.C.I. MAGNETO ASSY. & PLUG, SPARK

El (Electronic Ignition)

●

CRANKCASE 1 & HEAD, CYLINDER 1

PCV (Positive Crankcase Ventilation)

●

AIR FILTER ASSY.

ACL (Air Cleaner)

●

MUFF., 2

UJU510.book  Page 4  Tuesday, May 18, 2004  11:28 AM

Summary of Contents for U-MAX G23A

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Page 3: ...ons 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 TECHNICAL SERVICE DEPT YAMAHA GOLF CAR COMPANY G23A OWNER S OPERATOR S MANUAL 2004 by Yamaha Golf Car Company 2nd edition All rights reserved Any reprinting or unauthorized use without the written permission of UJU51...

Page 4: ...and this manual If you have any questions concerning this manual please consult your Yamaha dealer The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the utility vehicle occupants a bystander or a person inspecting or repairing the utility vehicle CAUTION This message describes special pr...

Page 5: ...y charges incurred in transporting a Utility 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 Operate and maintain the Utility Vehicle as specified in the appropriate Owner s Operator s Manual Give notice to an authorized Yamaha dealer of any and all ...

Page 6: ...m exists The warranty repairs should be completed in a reasonable time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Yamaha Customer Relations Department at 770 254 4164 Yamaha Golf Car Company warrants to the ultimate purchaser and each subsequent purchaser thereafter that each new 1996 and later model year specialty veh...

Page 7: ...h California emission control regulations using genuine Yamaha parts Accordingly it is recommended that any replacement part s used for maintenance replacement or repair of emission control systems be Yamaha parts The owner may elect to have maintenance replacement or repair of the emission EXCLUSIONS No warranty coverage will be allowed if the part s failure was caused by owner operator abuse neg...

Page 8: ... Main switch 4 1 Oil level warning light 4 2 Fuel tank cap 4 2 Drive select lever 4 3 1 2 3 4 Auxiliary DC jack 4 6 Cargo bed 4 8 Trailer hitch bracket 4 12 PRE OPERATION CHECKS 5 1 Pre operation check list 5 2 Brakes 5 3 Fuel 5 4 Engine oil 5 5 Transmission oil 5 5 Accelerator pedal 5 6 Steering 5 6 Fittings and fasteners 5 6 Lights 5 6 Switches 5 6 Tires 5 7 OPERATION 6 1 5 6 UJU510 book Page 1 ...

Page 9: ...nance lubrication 8 2 Exhaust emission control system and components 8 4 Seat 8 5 Battery 8 14 Fuse replacement 8 15 Transmission oil 8 16 Wheel removal 8 17 Wheel installation 8 18 Brake adjustment 8 19 Brake pedal free play adjustment 8 19 Replacing a headlight bulb 8 21 Adjusting a headlight beam 8 22 Replacing a taillight bulb 8 23 CLEANING AND STORAGE 9 1 Draining the fuel 9 1 Engine preparat...

Page 10: ...1 LOCATION OF THE WARNING AND SPECIFICATION LABELS 7 UJU510 book Page 1 Tuesday May 18 2004 11 28 AM ...

Page 11: ...ines OFF O N YAMAHA JU5 K7761 00 WARNING ON LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ATTENTION OIL WARNING Vehicle capacity 1 operator and 1 passenger Remain seated and hold on while in motion This vehicle is recommended only for operators 16 and older with a valid motor vehicle license Adults must supervise use by minors Check state laws for minimum age requirements Dri...

Page 12: ...centered and as low and far forward as possible Top heavy loads increase the risk of overturn WARNING YAMAHA 5UG K7764 00 Keep hands body other persons away when closing bed Do not operate the vehicle with bed up JU7 K7767 00 YAMAHA Do not fill portable fuel container gas can in cargo bed Static electricity sparks can ignite fuel vapor causing fire or explosion Set fuel container on the ground and...

Page 13: ...ES 1 Steering wheel 2 Seat 3 Battery 4 Taillight 5 Rear tire 6 Fuel tank 7 Starter choke 8 Drive select lever 9 Front tire 10 Headlight 11 Accelerator pedal 12 Brake pedal 13 Parking brake pedal 14 Horn button 15 Auxiliary DC jack UJU510 book Page 1 Tuesday May 18 2004 11 28 AM ...

Page 14: ...the remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha dealer Key identification number The key identification number is stamped on the key as shown in the following illustration This number can be used for ordering a new key 1 Key identification number UJU510 book Page 2 Tuesday May 18 2004 11 28 AM ...

Page 15: ...old on to the grab rail at all times while the vehicle is in motion Never operate this vehicle on any public Never operate at speeds too fast for your skills or the conditions Always go at a speed that is proper for the terrain visibility and operating conditions and your experi ence Never attempt jumps or other stunts Always inspect your vehicle each time you use it to be sure it is in safe opera...

Page 16: ...errain carefully before going down slopes Go as slowly as possible Always check for obstacles before operat ing in a new area Always be sure there are no obstacles or people behind you when you operate in re verse When it is safe to proceed in re verse go slowly Do not brake abruptly when carrying loads in the cargo bed Always use the size and type of tires spec ified in this manual Always maintai...

Page 17: ...ched off The key can be removed in this position only ON All electrical circuits except for the headlights and taillights are switched on The utility vehicle can be operated ON All electrical circuits are switched on The headlights and taillights come on The utility vehicle can be operated UJU510 book Page 1 Tuesday May 18 2004 11 28 AM ...

Page 18: ...omes on stop the engine check the engine oil level and add oil as necessary See page 8 8 8 9 1 Oil level warning light CAUTION Always make sure there is enough engine Fuel tank cap Remove the fuel tank cap by turning it coun terclockwise 1 Fuel tank cap UJU510 book Page 2 Tuesday May 18 2004 11 28 AM ...

Page 19: ...e either forward or in reverse After coming to a complete stop shift the lever to the desired position NOTE The back up buzzer will sound when the drive select lever is shifted to R Lever position Vehicle movement F FORWARD R REVERSE UJU510 book Page 3 Tuesday May 18 2004 11 28 AM ...

Page 20: ...al Press the brake pedal down to slow or stop the utility vehicle 1 Brake pedal NOTE The engine stops when the accelerator pedal is released and the utility vehicle comes to a complete stop Action Vehicle speed Depress pedal Increase Release pedal Decrease 1 1 UJU510 book Page 4 Tuesday May 18 2004 11 28 AM ...

Page 21: ...hicle 1 Parking brake pedal NOTE Release the parking brake by depressing the accelerator pedal Starter choke Pull the starter choke knob out and hold it when starting a cold engine Release it after the engine starts 1 Starter choke knob 1 1 UJU510 book Page 5 Tuesday May 18 2004 11 28 AM ...

Page 22: ...iary 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 1 Auxiliary DC jack cap UJU510 book Page 6 Tuesday May 18 2004 11 28 AM ...

Page 23: ...t and cause the fuse to blow If accessories are used for extended periods when the utility vehicle is not being operated or with the main switch set to ON the battery will lose its charge and starting the engine may become difficult Do not use an automotive cigarette lighter or other accessories with a plug that gets hot because the jack can be damaged Maximum rated capacity for the auxiliary DC j...

Page 24: ...g and closing the tailgate 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 UJU510 book Page 8 Tuesday May 18 2004 11 28 AM ...

Page 25: ...rop 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 slowly to its original position Make sure that the latch for the cargo bed is properly en gaged CAUTION Do not lift the cargo bed by the release le ver Damage to the lever may occur Maximum load limit 363 kg 800 lb UJU510 book Page 9 Tuesday May 18 2004 11 28 A...

Page 26: ...go bed Cargo should be properly distributed Reduce speed when carrying cargo Al low greater distance for braking WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall be thrown out or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never carry a passenger This cargo bed is designed to carry cargo only UJU510 book Page 10 Tuesday May 1...

Page 27: ...o bed and seat backs WARNING POTENTIAL HAZARD Fire or explosion while filling a portable fuel container WHAT CAN HAPPEN Static electricity sparks can ignite fuel vapors The plastic bed is not grounded increasing the risk of static electricity build up HOW TO AVOID THE HAZARD Do not refill fuel containers in the plastic bed Set fuel container on the ground and touch the nozzle to the container befo...

Page 28: ...ipped 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 UJU510 book Page 12 Tuesday May 18 2004 11 28 AM ...

Page 29: ...Failure to inspect the vehicle before op erating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your vehicle each time you use it to make sure the vehicle is in safe operating condition Always follow the inspection and maintenance proce dures and schedules described in the Owner s Operator...

Page 30: ...l if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 5 8 8 8 9 Transmission oil Check for leakage 5 5 8 16 8 17 Accelerator pedal Check for proper accelerator pedal operation 5 6 Steering Check for proper operation 5 6 Fittings and fasteners Check all fittings and fasteners 5 6 Lights and switches Check for proper operation 5 6 8 21 8 23 Wheels and tires Check tire pressu...

Page 31: ...ke sure they are working properly If the brakes do not provide proper braking per formance inspect the brake system See pages 8 19 8 21 WARNING POTENTIAL HAZARD Driving with improperly operating brakes WHAT CAN HAPPEN You could lose braking ability which could lead to an accident HOW TO AVOID THE HAZARD Always check the brakes at the start of every ride Do not operate the vehicle if you find any p...

Page 32: ...knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost Gasohol There are two types of gasohol gasohol con taining ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gaso hol containing methanol is not recommended by Yamaha bec...

Page 33: ...ARD Improper care when refueling WHAT CAN HAPPEN Fuel can spill which can cause a fire and severe injury Fuel expands when it heats up If the fuel tank is overfilled fuel could spill out due to heat from the engine or the sun HOW TO AVOID THE HAZARD Do not overfill the fuel tank Be careful not to spill fuel especially on the engine or exhaust pipe Wipe up any spilled fuel immediately Be sure the f...

Page 34: ... the 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 sure they are in working condition Repair as necessary for proper operation WARNING POTENTIAL HAZARD Checking operation of the...

Page 35: ...n tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of control increasing your risk of accident HOW TO AVOID THE HAZARD 1 The tires listed below have been ap proved by Yamaha Motor Manufac turing Corporation of America for this model Other tire combinations are not recommended Use the same brand of ...

Page 36: ...a 2 11 kgf cm2 30 psi Check and adjust tire pressures when the tires are cold Tire pressures must be equal on both sides 3 Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi Higher pressures may cause the tire to burst Inflate the tires very slowly and carefully Fast inflation could cause the tire to burst UJU510 bo...

Page 37: ... shift the drive select lever to F for forward or R for reverse CAUTION 2 Turn the main switch to ON or ON WARNING POTENTIAL HAZARD Depressing accelerator pedal while turning on the main switch WHAT COULD HAPPEN The utility vehicle could start moving UJU510 book Page 1 Tuesday May 18 2004 11 28 AM ...

Page 38: ...knob NOTE The choke is not required when the engine is warm 4 Check that your path is clear in the direc tion you plan to go and slowly depress the accelerator pedal The engine will start and the utility vehicle will start to move 1 Accelerator pedal NOTE The parking brake automatically releases 1 1 UJU510 book Page 2 Tuesday May 18 2004 11 28 AM ...

Page 39: ...choke should not be used Stopping To stop the utility vehicle gradually press down on the brake pedal When the utility vehicle has come to a stop apply the parking brake pedal and turn the main switch to OFF 1 Brake pedal 2 Parking brake pedal CAUTION 2 1 UJU510 book Page 3 Tuesday May 18 2004 11 28 AM ...

Page 40: ...ose a genuine Yamaha accessory or one that is equiva lent in design and quality Accessories should be rigidly and securely mounted An accessory which can shift po sition or come off while you are operating could affect your ability to control the vehi cle Do not mount an accessory where it could interfere with your ability to control the vehi cle Examples include but are not limited to an object t...

Page 41: ...of this vehicle may cause changes in handling which in some situ ations could lead to an accident HOW TO AVOID THE HAZARD 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 MAXIMUM LOAD...

Page 42: ... as possible Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an acci dent Make sure the load does not interfere with controls or your ability to see where you are going Drive more slowly than you would without a load The more weight you carry the slow er you should go Allow more braking distance A heavier ve hicle takes longer to s...

Page 43: ...in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking UJU510 book Page 7 Tuesday May 18 2004 11 28 AM ...

Page 44: ...icular attention to the safety information on pages 3 1 3 2 Please also read all caution and warning labels on your vehicle This vehicle is designed for the operator and one passenger Never carry passengers in the cargo bed WARNING POTENTIAL HAZARD Carrying a passenger in the cargo bed WHAT CAN HAPPEN The passenger could fall or be struck by objects in the cargo bed HOW TO AVOID THE HAZARD Never c...

Page 45: ...t inside the Maximum load limit 590 kg 1300 lb WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle han dling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or p...

Page 46: ... pedal slowly and smoothly The centrifugal clutch will engage and you will start to accelerate Avoid higher speeds until you are thoroughly familiar with When slowing down or stopping take your foot off the accelerator pedal and smoothly press the brake pedal Improper use of the brakes can cause the tires to lose traction re ducing control and increasing the possibility of an accident The engine s...

Page 47: ...es you attempt to drive on Avoid slopes with slippery surfaces or ones where you will not be able to see far enough ahead of you Slow down when you reach the crest of the hill if you cannot clearly see what is on the other side there could be another person an ob WARNING POTENTIAL HAZARD Operating on steep slopes WHAT CAN HAPPEN The utility vehicle can overturn more easily on steep slopes than on ...

Page 48: ...s that may appear If you must turn to avoid an ob stacle do not turn at a sharp angle that could allow the vehicle to pitch or roll over Go as slowly as possible If you are starting to go too fast apply the brakes gently Avoid sudden application of the brakes which could WARNING POTENTIAL HAZARD Going down a slope improperly WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overt...

Page 49: ... rough terrain Look for obstacles that could cause damage to the ve hicle or could lead to a rollover or accident Avoid jumping the vehicle as injury loss of control and damage to the vehicle could oc cur WARNING POTENTIAL HAZARD Operating in rough terrain WHAT CAN HAPPEN The vehicle can overturn or go out of control HOW TO AVOID THE HAZARD Always be alert to changing terrain Go slowly and be extr...

Page 50: ...trees watch carefully on both sides and above the vehicle for obstacles such as branches that the vehicle might hit causing an accident or for brush that might enter the vehicle as you pass and strike the driver or passenger UJU510 book Page 7 Tuesday May 18 2004 11 28 AM ...

Page 51: ...p it with the vehicle The service information included in this man ual is intended to provide you the owner with the necessary information for completing your own preventive maintenance and minor re pairs NOTE _ If you do not have a torque wrench available during a service operation requiring one take your vehicle to a Yamaha dealer to check the WARNING POTENTIAL HAZARD Servicing an engine while i...

Page 52: ...nth 1 6 6 12 km mi 160 100 1 000 600 1 000 600 2 000 1 200 hours 20 125 125 250 Valves Check valve clearance Adjust if necessary Spark plug Check condition Adjust gap and clean Replace if necessary Air filter element and pre air filter element Clean Replace if necessary Every 20 40 hours More often in wet or dusty areas Carburetor Check starter operation Adjust if necessary Exhaust system Check fo...

Page 53: ... operation and for leakage Correct if necessary Steering system Check operation and for looseness Replace if damaged Check toe in Adjust if necessary Engine mounts Check for cracks or damage Check bolt tightness Fittings and fasteners Check all chassis fittings and fasteners Correct if necessary ITEM ROUTINE Whichever comes first INITIAL EVERY month 1 6 6 12 km mi 160 100 1 000 600 1 000 600 2 000...

Page 54: ...st 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 Item Acronym CARB ASSY LH JT CARBURETOR 2 JT CARBURETOR 1 CARB Carburetor T C I MAGNETO ASSY PLUG SPARK El Electronic Ignition CRANKCASE 1 HEAD CYLINDER 1 PCV Positive Cra...

Page 55: ...ine 1 Pull the cargo bed release lever towards the rear 3 Lift the cargo bed up until the end of the prop rod hooks onto the prop rod guide to support the cargo bed 1 Cargo bed release lever CAUTION Do not lift the cargo bed by the release le ver Damage to the lever may occur UJU510 book Page 5 Tuesday May 18 2004 11 28 AM ...

Page 56: ...perate the utility vehicle with the cargo bed in the up position Inju ry could occur if the cargo bed falls accidentally Before closing the cargo bed be sure others are standing away from the utility vehicle and that no one is sitting on the seat Keep hands and fingers away from the space between the car go bed and seat backs UJU510 book Page 6 Tuesday May 18 2004 11 28 AM ...

Page 57: ...r engine performance 1 Spark plug 2 Spark plug cap 1 Check for discoloration and heavy car bon deposits The normal electrode color will be tan If it is not replace it a Spark plug gap 1 2 Specified spark plug BPR2ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in a UJU510 book Page 7 Tuesday May 18 2004 11 28 AM ...

Page 58: ...allow ex ternal sparks which could lead to explosion or fire Engine oil Checking the engine oil level 1 Place the utility vehicle on a level sur face 2 Lift the cargo bed See page 8 5 8 6 for lifting and lowering procedures 3 Remove the dipstick wipe it off with a clean rag and then insert the dipstick back into the dipstick hole Spark plug torque 20 Nm 2 0 m kgf 14 5 ft lbf 1 UJU510 book Page 8 T...

Page 59: ... level mark 5 The oil level should be between the max CAUTION Be sure no foreign material enters the crankcase Replacing the engine oil 1 Place the utility vehicle on a level sur face 2 Place a container under the engine 3 Remove the engine oil filler cap and en gine oil drain bolt to drain the oil MIN MAX 1 2 3 1 UJU510 book Page 9 Tuesday May 18 2004 11 28 AM ...

Page 60: ...to an oil collection station 4 Install the drain bolt along with a new drain bolt gasket and then tighten it to the specified torque 5 Add the specified amount of engine oil and then install the oil filler cap CAUTION Be sure no foreign material enters the crankcase Tightening torque Drain bolt 30 Nm 3 0 m kgf 22 ft lbf Recommended oil See page 10 3 Oil change quantity 0 9 L 0 79 Imp qt 0 95 US qt...

Page 61: ...ilter element cleaning To remove the air filter elements 1 Unlatch the air filter cover holders and re move cover 2 Lift the air filter element and pre air filter element out of the air filter case 1 Air filter element 2 Pre air filter element CAUTION Be careful not to drop anything into the air inlet 1 1 1 2 1 2 UJU510 book Page 11 Tuesday May 18 2004 11 28 AM ...

Page 62: ...ION Do not wring out the pre air filter element this could cause it to tear CAUTION Do not attempt to clean the air filter ele ment with compressed air It could be damaged 5 To replace the elements reverse the above steps CAUTION The UP mark on the pre air filter element should face up 1 2 UJU510 book Page 12 Tuesday May 18 2004 11 28 AM ...

Page 63: ...ndary sheave clockwise and the drive belt will roll off the sheave Inspection To inspect the drive belt check for frayed edges or tears and measure the drive belt as shown If the belt shows excessive wear or damage or if it reaches the wear limit of 27 9 mm 1 10 in replace the belt with a new one a Wear limit 5 To install the drive belt reverse the Y 60 a UJU510 book Page 13 Tuesday May 18 2004 11...

Page 64: ...lk Follow with milk of magnesia beaten egg or vegetable oil Call physi cian immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in en The battery doesn t require the addition of wa ter If the battery loses its charge have an ex perienced mechanic charge it UJU510 b...

Page 65: ...sing a wrong fuse can cause electrical system damage and create a fire hazard CAUTION When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting 1 Main fuse 2 Auxiliary DC jack fuse 3 Headlight signaling system fuse Replacement Fuse Main fuse 20 A Headlight signaling system fuse 10 A Auxiliary DC jack fuse 10 A 1 2 3 UJU510 book Page 15 Tuesday May 18 2004 1...

Page 66: ...eck the oil level It should be up to the brim of the filler hole If the level is low add sufficient oil of the recommend 1 Transmission oil plug CAUTION Be sure no foreign material enters the transmission case 3 Install the transmission oil filler plug Recommended oil SAE 90 gear oil 1 UJU510 book Page 16 Tuesday May 18 2004 11 28 AM ...

Page 67: ...lacement consult a Yamaha dealer Wheel removal To remove and install a wheel on your utility vehicle 1 Nut 4 1 With the wheels blocked to prevent the utility vehicle from moving loosen the wheel nuts 2 Elevate the utility vehicle with a jack and 1 1 UJU510 book Page 17 Tuesday May 18 2004 11 28 AM ...

Page 68: ...wheels Install the nut with its tapered side towards the wheel _ 1 Tapered nut 2 Lower the vehicle so that the wheel is on the ground 3 Tighten the wheel nuts to the specified torque Wheel nut torque Front 88 Nm 8 8 m kgf 64 ft lbf Rear 88 Nm 8 8 m kgf 64 ft lbf UJU510 book Page 18 Tuesday May 18 2004 11 28 AM ...

Page 69: ...maha dealer before using your utility vehicle if you suspect brake problems Brake failure could result in a serious accident 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 vehicle Y 61a UJU510 book Page 19 Tuesday M...

Page 70: ...If the free play distance needs adjusting loosen the locknut 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 locknut to the specified torque Brake pedal free play 20 25 mm 0 79 0 98 in 7 18 17 16 15 14 13 12 11 10 9 8 a 2 1 UJU510 book Page 20 Tuesday May 18 2004 11 28 AM ...

Page 71: ...performance Replacing a headlight bulb If a headlight bulb burns out replace it as fol lows 1 Remove the headlight bulb holder by turning it counterclockwise 1 Headlight bulb holder 2 Remove the defective bulb by unhooking the headlight bulb holder tabs UJU510 book Page 21 Tuesday May 18 2004 11 28 AM ...

Page 72: ...bs 4 Install the headlight bulb holder by turn ing it clockwise 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 UJU510 book Page 22 Tuesday May 18 2004 11 28 AM ...

Page 73: ...Replacing a taillight bulb If a taillight bulb burns out have a Yamaha dealer replace it UJU510 book Page 23 Tuesday May 18 2004 11 28 AM ...

Page 74: ...arburetor float chamber into a clean container by loosening the drain NOTE Use of fuel stabilizer and conditioner elimi nates the need to drain the fuel system Con sult a Yamaha dealer if the fuel system needs to be drained instead Engine preparation 1 With the key removed and the spark plug lead disconnected turn the clutch by hand until compression is felt This puts the valves in the closed posi...

Page 75: ... 1 Remove the battery from the utility vehi cle and store it in a cool dry place that stays between 0 C 32 F and 30 C 90 F 2 Have the battery recharged every 60 90 days to keep it fully charged The battery must be kept fully charged to avoid dam age NOTE Batteries like the one supplied with your vehi cle normally do not require you to check the water level inside the battery for the one year warra...

Page 76: ...4 7 in Overall width 1243 mm 48 9 in Overall height steering height 1155 mm 45 5 in Height of floor 300 mm 11 8 in Wheelbase 1900 mm 74 8 in Tread Front 980 mm 38 6 in Rear 980 mm 38 6 in Ground clearance 115 mm 4 5 in UJU510 book Page 1 Tuesday May 18 2004 11 28 AM ...

Page 77: ...e type Air cooled 4 stroke OHV Cylinder arrangement Forward inclined single cylinder Displacement 357 cm3 Bore x stroke 85 x 63 mm 3 30 x 2 48 in Compression ratio 8 0 1 Starting system Electric starter Ignition system TCI Magneto Spark plug type manufacturer BPR2ES NGK Spark plug gap 0 7 0 8 mm 0 028 0 031 in Lubrication system Splash Model G23A UJU510 book Page 2 Tuesday May 18 2004 11 28 AM ...

Page 78: ...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 Transmission oil Type SAE 90 gear oil Quantity 0 42 L 0 37 Imp qt 0 44 US qt Steering system Type Worm and pin Model G23A UJU510 book Page 3 Tuesday May 18 2004 11 28 AM ...

Page 79: ...y linkage adjustment 20 25 mm 0 79 0 98 in Parking brake Type Foot type with automatic release Wheel Tire size Front 18 x 8 5 8 4 PLY Rear 18 x 8 5 8 6 PLY Tire pressure Front 140 160 kPa 1 4 1 6 kgf cm2 20 23 psi Rear 197 217 kPa 2 0 2 2 kgf cm2 29 31 psi Battery BCI group 24 52 AH 20 hr rate RC minimum 75 min CCA minimum 400A Model G23A UJU510 book Page 4 Tuesday May 18 2004 11 28 AM ...

Page 80: ... W 30 W 2 Taillight Sealed beam 2 Indicator light Engine oil level warning light 12 V 3 4 W 1 Specified fuses Main fuse 20 A Headlight signaling system fuse 10 A Auxiliary DC jack fuse 10 A Model G23A UJU510 book Page 5 Tuesday May 18 2004 11 28 AM ...

Page 81: ... re minder to you that the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 160 100 20 6 1 000 600 125 12 2 000 1 200 250 18 3 000 1 800 375 24 4 000 2 400 500 30 5 000 3 000 625 36 6 000 3 600 750 42 7 000 4 200 875 48 8 000 4 800 1 000 54 9 000 5 400 1 125 UJU510 ...

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