Yamaha G-Max G22A Owner'S And Operator'S Manual Download

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GOLF CAR

OWNER'S / OPERATOR’S
MANUAL

LIT-19626-16-04

JU0-F8199-1

YAMAHA MOTOR

MANUFACTURING CORP.

OF AMERICA

1000 HWY 34 East
Newnan, GA 30265

770-254-4000

Printed in U.S.A

2004-KCC

LIT_19626_16_03 cover.qxd 5/26/04 9:40 AM Page 1

To Order Parts Call 1-888-702-5326 - https://monsterfloorequipmentparts.com

Summary of Contents for G-Max G22A

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Page 3: ...ation or maintenance of your golf car please consult a Yamaha dealer YAMAHA MOTOR MANUFACTURING CORP OF AMERICA G22A OWNER S OPERATOR S MANUAL 2004 by Yamaha Motor Manufacturing Corporation of America 1st edition All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Manufacturing Corporation of America is expressly prohibited Printed in U S A P N LIT...

Page 4: ... understand this manual completely before operating your golf car WARNING NOTE Particularly important information is distinguished in this manual by the following 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 golf car occupants a bystander or a person inspecting or repairing t...

Page 5: ...INTENANCE SAFETY PROGRAM 4 MAINTENANCE 8 STORAGE SPECIFICATIONS 9 WIRING 11 OPERATION 7 PRE OPERATION CHECKS 6 CONTROLS 5 OPERATOR SAFETY 3 10 r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m o n s t e r f l o o r e q u i p m e n t p a r t s c ...

Page 6: ...wear or routine maintenance including oil air filter elements brake shoes spark plugs starter and clutch drive belts Any charges incurred in transporting a golf car to and from an authorized Yamaha Golf Car Dealer for service or in performing field service are also excluded from this warranty THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the golf car as spec...

Page 7: ...ot tamper with governor to increase speed Operation at higher speeds can cause loss of control that can result in severe injury or death Ne pas toucher au régulateur afin d augmenter la vitesse Un fonctionnement à des vitesses supérieures au réglage initial peut causer une perte de contrôle qui peut mener à une blessure grave voire fatale YAMAHA JN3 K8299 10 1 2 3 4 r d e r P a r t s C a l l 1 8 8...

Page 8: ...n 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 The engine serial number 2 is affixed in the location shown NOTE Y 852A 3 Engine Information Y 102a J U 0 1 2 3 II II II I II II II I I I I I I I SM 03 399 r d e r P a r t s C a l l 1 8...

Page 9: ...wo people to ride in the golf car This golf car is restricted to two occupants Do not operate the golf car while under the influence of alcohol or drugs their affect on vision and judgment make operating a golf car dangerous Do not operate the golf car on pub lic streets roads or highways Such use is prohibited by law and dan gerous Operation on public roads can result in collision with other vehi...

Page 10: ...course Avoid turning the steering wheel too sharply at higher speeds Always drive slowly straight up or straight down slopes never at an angle Do not run the engine indoors Exhaust gas is poisonous Do not make any modification or addition which affects capacity or safe operation or make any changes not in accordance with the owner s operator s manual OPERATOR SAFETY Y 10 Y 9 Y 69 r d e r P a r t s...

Page 11: ...s Place operation and safety instruc tions recommended by the golf car manufacturer along with the golf course safety rules in a conspicuous place near the golf car rental area or golf car pick up area It is also rec ommended that the following warning be posted in a conspicuous location Do Not Operate Golf Cars When Under The Influence Of Alcohol Or Drugs GOLF COURSE SAFETY SURVEY Perform safety ...

Page 12: ... of golf car operators Preventative Maintenance Per form all scheduled maintenance in accordance with manufacturer s recommendations to provide the golfing patron with a safe properly operating golf car Personnel Allow only qualified trained and authorized personnel to inspect adjust and maintain golf cars Parts and Materials Use only replacement parts and materials recommended by the manufacturer...

Page 13: ... by a quali fied trained and authorized per son in an area free of pedestrian traffic to ensure proper operation and adjustment Record all maintenance performed in a maintenance record log by date name of person performing maintenance and type of mainte nance Periodically inspect mainte nance log to ensure accurate and complete entries Provide operator comment cards to assist in identifying non pe...

Page 14: ...at 3 Fuel cap 4 Brake pedal 5 Parking brake pedal 6 Accelerator pedal 7 Drive selector lever 8 Main switch 9 Oil warning light a Choke knob b Front cowl c Front tire d Front bumper e Rear cowl f Rear bumper g Rear tire h Battery r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m o n s t e r f l o o r e q u i p m e n t p a r t s c ...

Page 15: ...ly in this position ON Electrical circuits are switched on The golf car 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 r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m o n s t e r f l o o r e q u i p m e...

Page 16: ...The back up buzzer will beep when the drive select lever is turned to R ACCELERATOR PEDAL The accelerator pedal controls the golf car 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 golf car Brake pedal NOTE CONTROLS Y 19 Y 20A A Y 18 Y 21a B r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m ...

Page 17: ...atically release when the accelerator pedal is depressed If the main switch is in the ON position depressing the accelerator may suddenly cause the golf car to move CHOKE KNOB Pull and hold out choke knob when starting a cold engine Release the knob after the engine starts å Choke knob WARNING NOTE CONTROLS Y 22a C Y 23 A r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m o n s t e r f l ...

Page 18: ...efore 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 Battery Tire condition Steering system Back up buzzer Pedal operation Body and chassis SEAT Open the seat for checking and ser vicing WARNING r d e r P a r t s C a l l 1 8 8 8 7 0 2 ...

Page 19: ...soline 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 gasoline in your eyes get imme diate medical attention If any gasoline gets on your skin immediately wash with soap and water Change clothing if gaso line spills on it Avoid usi...

Page 20: ...to fill past the MAX dipstick mark and be sure no foreign material enters the crankcase 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 Con serving II are recommended NOTE NOTE CAUTION PRE OPERATION CHECKS Recommended oil YAMALUBE 4 ...

Page 21: ...revent battery acid from spilling from the battery Check the battery terminals for corrosion TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the golf car Tire pressure For G22A 16 psi 110 kPa 1 1 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 PRE OPERATION CH...

Page 22: ...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 dealer Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its orig inal position when r...

Page 23: ...he accelerator pedal Accelerator Pedal Before checking operation of the accelerator pedal be sure the main switch is in the OFF posi tion Make sure the accelerator pedal operates smoothly å Accelerator pedal BODY AND CHASSIS Before each use visually inspect the golf car body and chassis for damage and or missing parts WARNING NOTE Y 22a C Y 20A A r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t...

Page 24: ...may sudden ly 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 slowly depress the accelerator pedal The golf car will start to move å Accelerator pedal The parking brake automatically releases when the acc...

Page 25: ...NG If the vehicle s engine won t start use the following chart Cause Remedy Fuel System No fuel in tank Fill fuel tank Clogged fuel Clean fuel line line Consult Yamaha dealer Foreign matter Clean fuel in fuel filter fiter Consult Yamaha dealer Clogged Clean carburetor carburetor Consult Yamaha dealer Electrical System Spark plug dirty Clean carbon with carbon or or wipe spark wet plug dry Faulty i...

Page 26: ... for looseness and corrosion of battery C C C C C C 6 4 terminals and hold downs Check brake 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 4 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 ...

Page 27: ...k wiring connections C C C and insulation Check shoe lining thickness C C C and rear axle bearing play Check steering knuckle bushing freeplay Adjust wheel alignment CA CA CA 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 2 YEARS Check brushes for wear and C S commutator for ...

Page 28: ...vided 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 serviced by a Yamaha d...

Page 29: ...e spark 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 finger 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 ...

Page 30: ... 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 Con serving II are recommended NOTE NOTE WARNING Recommended oil YA...

Page 31: ...n 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 r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h ...

Page 32: ...bove steps The pre filter has a notch on one side It will only fit in the case one way 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 4 Remove the drive belt from the primary sh...

Page 33: ...d 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 veg etable oil Call physician immedi ately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame ciga...

Page 34: ...rong fuse can cause elec trical system damage and create a fire hazard When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting 1 Remove cap screw on cover Pull fuse case cover forward å Cap screw Fuse case cover You do not have to remove the cover 2 Pull cap off fuse Pull fuse out and replace if necessary ç Fuse cap Fuse Replacement Fuse 10 Amp Blade Styl...

Page 35: ...oil little by little until oil flows from the level plug hole 5 Allow excess gear oil to flow out until it stops Do not allow foreign material to enter the gear box 6 Reinstall the oil level plug For gear oil replacement consult a Yamaha dealer or other qualified mechanic NOTE CAUTION Y 48 Y 520 A B Recommended oil SAE 90 gear oil Gearcase capacity G22A 0 44 US qt 415 mL 415 cc r d e r P a r t s C...

Page 36: ... wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 58 ft lb 80 Nm 8 0 m kg Brake Adjustment The brakes on your golf car are self adjusting Before you operate the car press down on the brake pedal several times to make sure the brakes are functioning properly Consult your Yamaha dealer before using your golf car if you suspect brake problems Brake failure could...

Page 37: ...easuring the distance the pedal travels before resistance is felt Brake pedal free play Å 20 25 mm 0 79 0 98 in 3 If the free play distance needs adjusting loosen the lock nut and turn the adjusting nut in or out 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 reducing braking performance WA...

Page 38: ...gasoline spills wipe it up imme diately 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 gaso line spills on it 1 Fill the fuel tank å Floa...

Page 39: ...from the golf car 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 dam age Batteries like the one supplied with your car normally do not require you to check the water level inside the battery for the one year warranty period provided by the manufacturer ...

Page 40: ...n 870 mm Rear 38 6 in 980 mm Min ground clearance 3 8 in 97 mm Weight Dry weight without battery 670 lb 304 kg Performance Factory speed setting 12 mph 19 km h Maximum speed 15 mph 24 km h Minimum turning radius 114 2 in 2 9 m Seating capacity 2 persons Hill climbing ability 27 50 grade on pavement 1 2 3 4 5 6 7 8 9 10 11 10 1 G22A r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m o n s ...

Page 41: ...cle oil or SAE 10W30 Engine oil capacity 1 16 US qt 1 1 L 1100 cc Oil change quantity 1 0 US qt 0 9 L 900 cc TRANSMISSION Items G22A 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 G22A Differenti...

Page 42: ...ing Brake pedal freeplay linkage adjustment 20 25 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 With pedal segment in second notch Bolt heads round parallel to arm 0 000 0 001 in 0 0 0 3 mm Wheel Tire size Front 18 x 8 50 8 00 4 PR Rear 18 x 8 50 8 00 4 PR Rim size 7 00 I 8 00 Tire pressure For G16A 16 psi 110 kPa ...

Page 43: ...A Voltage Regulator Starter generator Relay Battery Pilot lamp 12V 3 4W Main switch Accelerator stop switch Back switch Buzzer Body ground 1 Engine stop relay 9 Relay 2 Engine ground a Battery 3 Pickup b Pilot lamp 12V 3 4W 4 Rotor c Main switch 5 Oil level gauge d Accelerator stop switch 6 Blade fuse 10A e Back switch 7 Voltage regulator f Buzzer 8 Starter generator g Body ground COLOR CODE B Bla...

Page 44: ...1 2 3 4 5 6 7 8 9 10 11 G22A NOTES r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m o n s t e r f l o o r e q u i p m e n t p a r t s c ...

Page 45: ...1 2 3 4 5 6 7 8 9 10 11 NOTES G22A r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m o n s t e r f l o o r e q u i p m e n t p a r t s c ...

Page 46: ...NOTES 1 2 3 4 5 6 7 8 9 10 11 G22A r d e r P a r t s C a l l 1 8 8 8 7 0 2 5 3 2 6 h t t p s m o n s t e r f l o o r e q u i p m e n t p a r t s c ...

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