Yamaha U-MAX G27A Owner'S/Operator'S Manual Download

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It contains important safety information.

OWNER’S/OPERATOR’S MANUAL

JU7-F8199-10

LIT-19626-01-08

YAMAHA MOTOR CO., LTD.

PRINTED IN USA

2004.06-0.3

2 CR

(E)

G27A

G28A

Summary of Contents for U-MAX G27A

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Page 3: ...ns 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 G27A G28A OWNER S OPERATOR S MANUAL 2003 by Yamaha Golf Car Company 2nd edition All rights reserved Any reprinting or unauthorized use without the written permission of E...

Page 4: ...e 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 ...

Page 5: ...Any 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 al...

Page 6: ...lem 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 v...

Page 7: ...th 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 ne...

Page 8: ...1 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 EE book Page 1 Thu...

Page 9: ...Periodic maintenance lubrication 8 3 Exhaust emission control system and components 8 5 Drive belt 8 14 Battery 8 15 Fuse replacement 8 16 Transmission oil 8 17 Wheel removal 8 18 Wheel installation 8 19 Brake adjustment 8 20 Brake pedal free play adjustment 8 20 Replacing a headlight bulb 8 22 Adjusting a headlight beam 8 23 Replacing a taillight bulb 8 24 CLEANING AND STORAGE 9 1 Draining the fu...

Page 10: ...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 EE book Page 1 Thursday June 24 2004 9 43 AM ...

Page 11: ...1 2 3 4 5 6 7 8 9 10 11 12 13 9 EE book Page 2 Thursday June 24 2004 9 43 AM ...

Page 12: ... extremely flammable Keep heat sparks and open flame away from fuel tank and fuel lines Do not add fuel while engine is running or hot Do not modify fuel system Service should be performed by dealer or qualified personnel L essence est exstrêmement inflammable Garder étincelles flammes et chaleur loin du réservoir à essence et des tuyaux à carburant Ne pas ajouter d essence pendant que le moteur e...

Page 13: ...operly loading a trailer and failure to use extra care when pulling trailer can cause an accident or injury Never load more than 68 kg 150 lbs tongue weight on the towing bracket Do not tow more than 227 kg 500 lbs rolling weight trailer plus cargo Allow for increased braking distance and use extreme caution when operating on inclines Read carefully the loading information and trailer hitch sectio...

Page 14: ...G28A 7 EE book Page 5 Thursday June 24 2004 9 43 AM ...

Page 15: ... s a p p l i c a b l e t o p a s s e n g e r c a r s Severe INJURY or DEATH can result if you ignore the following Maximum Load in Cargo Bed 500 lb 227 kg Never carry passengers in cargo bed Cargo can affect handling and stability Read Owner s Manual before loading or towing When loading with cargo or towing a trailer Reduce speed and allow more room to stop Avoid hills and rough terrain Be sure c...

Page 16: ...6 7 8 ENGINE AIR INDEX California only EE book Page 7 Thursday June 24 2004 9 43 AM ...

Page 17: ...ATURES 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 Parking brake pedal 15 Horn button EE book Page 1 Thursday June 24 2004 9 43 AM ...

Page 18: ... 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 EE book Page 2 Thursday June 24 2004 9 43 AM ...

Page 19: ...hold 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 oper...

Page 20: ... far enough ahead of you Never go over the top of a slope at speed if you cannot see Always check for obstacles before operat ing in a new area Never operate the vehicle in fast flowing water or water deeper than 15 cm 6 in Remember that wet brakes may have re duced stopping ability Test your brakes af ter leaving water If necessary apply them several times to let friction dry out the lin ings Alw...

Page 21: ...ible 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 Allow greater distance for braking EE book Page 3 Thursday June 24 2004 9 43 AM ...

Page 22: ...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 EE book Page 1 Thursday June 24 2004 9 43 AM ...

Page 23: ...w If the light comes on stop the engine check the engine oil level and add oil as necessary See page 8 9 8 10 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 EE book Page 2 Thursday June 24 2004 9 43 AM ...

Page 24: ...cle 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 EE book Page 3 Thursday June 24 2004 9 43 AM ...

Page 25: ...rator pedal Brake pedal Press the brake pedal down to slow or stop the utility vehicle 1 Brake pedal NOTE The engine stops when the utility vehicle comes to a complete stop Action Vehicle speed Depress pedal Increase Release pedal Decrease 1 1 EE book Page 4 Thursday June 24 2004 9 43 AM ...

Page 26: ...vehicle 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 EE book Page 5 Thursday June 24 2004 9 43 AM ...

Page 27: ...iliary 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 EE book Page 6 Thursday June 24 2004 9 43 AM ...

Page 28: ...uit 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 get hot because the jack can be damaged Maximum rated capacity for the auxiliary DC ...

Page 29: ...d Opening and closing the tailgate For G28A 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 EE book Page 8 Thursday June 24 2004 9 43 AM ...

Page 30: ...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 slowly to its original position Make sure that the latch for the cargo bed is properly en gaged Maximum load limit 113 kg 250 lb G27A 227 kg 500 lb G28A EE book Page 9 Thursday June 24 2004 9 43 AM ...

Page 31: ...rgo 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 EE book Page 10 Thursday June 24...

Page 32: ...rgo 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 be...

Page 33: ...quipped 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 EE book Page 12 Thursday June 24 2004 9 43 AM ...

Page 34: ...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 Manual EE book P...

Page 35: ...el Fill with fuel if necessary 5 4 5 5 Engine oil Check oil level Fill with oil if necessary 5 5 8 9 8 10 Transmission oil Check for leakage 5 5 8 17 8 18 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 22 8 24 Wheels and tires ...

Page 36: ...make sure they are working properly If the brakes do not provide proper braking per formance inspect the brake system See pages 8 20 8 22 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...

Page 37: ...g 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 because it may cause ...

Page 38: ...AZARD 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...

Page 39: ...ck 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 t...

Page 40: ...with improper or uneven 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 acci dent 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...

Page 41: ...pecified could cause the tire to dislodge from the rim under severe riding conditions The following are Manufacturer Size Front DURO 22 11 10 6 PLY Rear DURO 22 11 10 6 PLY 4 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 Fa...

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 EE book Page 9 Thursday June 24 2004 9 43 AM ...

Page 43: ...ed 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 EE book Page 1 Thursday June 24 2004 9 43 AM ...

Page 44: ... 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 EE book Page 2 Thursday June 24 2004 9 43 AM ...

Page 45: ...be used Press the accelerator pedal slightly 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 EE book Page 3 Thursday June 24 2004 9 43 AM ...

Page 46: ...ity or suitability of them Choose 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 ...

Page 47: ...eight Adjust the load in the trailer if necessary to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo in the cargo bed as close to the center of the vehicle 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 MAXIMUM...

Page 48: ...g sharp turns unless at very slow speeds Avoid hills and rough terrain Choose ter rain carefully Added weight affects the sta bility and handling of the vehicle 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...

Page 49: ...controls Pay particular attention to the safety information on pages 3 1 3 3 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 T...

Page 50: ...load limit 318 kg 700 lb G27A 454 kg 1000 lb G28A 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 o...

Page 51: ...celerator 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...

Page 52: ...opes 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 o...

Page 53: ...es 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 over...

Page 54: ...rough water deeper than 15 cm 6 in or fast flowing water Wet brakes may have reduced effectiveness After leaving the water test your brakes If necessary apply the brakes several times to let friction dry out the linings WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Loss of control which could result in an accident including overturn HOW TO AVOID...

Page 55: ...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 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 slow...

Page 56: ... 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 it is running ...

Page 57: ...anges 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 EE book Page 2 Thursday June 24 2004 9 4...

Page 58: ...onth 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 f...

Page 59: ...ck 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 0...

Page 60: ...test 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 C...

Page 61: ...A the seat must be lifted 1 Seat 2 Prop rod G28A Cargo bed Lift the cargo bed to service the engine for the G28A 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 EE book Page 6 Thursday June 24 2004 9 43 AM ...

Page 62: ... operate 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 EE book Page 7 Thursday June 24 2004 9 43 AM ...

Page 63: ...or 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 EE book Page 8 Thursday June 24 2004 9 43 AM ...

Page 64: ... 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 seat G27A or cargo bed G28A See page 8 6 8 7 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 EE book Pa...

Page 65: ...m 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 EE book Page 10 Thursday June 24 2004 9 43 AM ...

Page 66: ... 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 q...

Page 67: ...filter 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 EE book Page 12 Thursday June 24 2004 9 43 AM ...

Page 68: ...UTION 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 EE book Page 13 Thursday June 24 2004 9 43 AM ...

Page 69: ...ondary 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 EE book Page 14 Thursday June 24 2004 9 4...

Page 70: ...ilk 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 EE book...

Page 71: ...ure to use the specified fuse Using 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 EE book Pa...

Page 72: ...heck 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 EE book Page 17 Thursday June 24 2004 9 43 AM ...

Page 73: ...eplacement 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 EE book Page 18 Thursday June 24 2004 9 43 AM ...

Page 74: ... 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 80 Nm 8 0 m kgf 58 ft lbf Rear 80 Nm 8 0 m kgf 58 ft lbf EE book Page 19 Thursday June 24 2004 9 43 AM ...

Page 75: ...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 EE book Page 20 Thursday June...

Page 76: ...f 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 1 2 G27A EE book Page 21 Thursday June 24 2004 9 43 AM ...

Page 77: ...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 Tightening torque 17 N m 1 7 m kgf 12 ft lbf G28A EE book Page 22 Thursday June 24 2004 9 43 AM ...

Page 78: ...tabs 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 EE book Page 23 Thursday June 24 2004 9 43 AM ...

Page 79: ...Replacing a taillight bulb If a taillight bulb burns out have a Yamaha dealer replace it EE book Page 24 Thursday June 24 2004 9 43 AM ...

Page 80: ... carburetor 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 po...

Page 81: ...on 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 war...

Page 82: ...9 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 Wheelbase 1637 mm 64 4 in G27A 1939 mm 76 3 in G28A Tread Front 940 mm 37 0 in G27A 1029 mm 40 5 in G28A Rear 980 mm 38 6 in G27A 1029 mm 40 5 in G28A EE book Page 1 Thursday June 24 2004 9 43 AM ...

Page 83: ...ating capacity 2 persons Engine Engine 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 Model G27A G28A EE book Page 2 Thursday June 24 200...

Page 84: ...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 Rack and pinion G27A Worm and pin G28A Model G27A G28A EE book Page 3 Thursday June 24 2004 9 43 AM ...

Page 85: ...ng shoes self adjusting Brake pedal freeplay linkage adjustment 20 25 mm 0 79 0 98 in Parking brake Type Foot type with automatic release Wheel Tire size Front 20 x 10 8 4 PLY G27A 22 x 11 10 6 PLY G28A Rear 20 x 10 8 4 PLY G27A 22 x 11 10 6 PLY G28A Tire pressure Front 70 84 kPa 0 70 0 84 kgf cm2 10 12 psi Rear 70 84 kPa 0 70 0 84 kgf cm2 10 12 psi Model G27A G28A EE book Page 4 Thursday June 24 ...

Page 86: ...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 G27A G28A EE book Page 5 Thursday June 24 2004 9 43 AM ...

Page 87: ... a 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 EE bo...

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