4 STROKE GOLF CAR - · PDF fileLI T -19626-11-09 JW1-F8199-12 YAMAHA GOLF-CAR COMPANY 1000 HWY 34 East Newnan, GA 30265 770-254-4000 Printed in U .S. A 2009-KCC 4 STROKE GOLF CAR

LI T -19626-11-09 JW1-F8199-12YAMAHA GOLF-CAR

COMPANY 1000 HWY 34 East Newnan, GA 30265

770-254-4000

Printed in U .S. A 2009-KCC

4 STROKE GOLF CAR YDRA

!

OWNER’S / OPERATOR’SMANUAL

READ THIS MANUAL CAREFULLY!It contains important safety information.

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IMPORTANT MANUAL INFORMATION

TIPYamaha continually seeks advancements in product designand quality; therefore, while thismanual contains the most currentproduct information available at thetime of printing, there may be minordiscrepancies between your golf carand this manual. If you have any questions concerning thismanual, please consult yourYamaha dealer.

Read and understand this manualcompletely before operating yourgolf car. This manual should beconsidered a permanent part ofyour golf car and should remainwith the car when resold.

Particularly important information isdistinguished in this manual by the following notations:

This is the safety alert symbol. It isused to alert you to potential person-al injury hazards. Obey all safetymessages that follow this symbol toavoid possible injury or death.

A WARNING indicates a hazardoussituation which, if not avoided,could result in death or seriousinjury.

A NOTICE indicates special pre-cautions that must be taken toavoid damage to the vehicle orother property.

TIPA TIP provides key information tomake procedures easier or clearer.

NOTICE

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INTRODUCTIONCongratulations on your purchase of aYamaha golf car. This manual containsinformation you will need for proper operation, maintenance, and care of yourgolf car. A thorough understanding ofthese simple instructions will help you toobtain maximum enjoyment from yournew Yamaha.

If you have any questions about the operation or maintenance of your golfcar, please consult a Yamaha dealer.

YAMAHA GOLF-CAR COMPANY

YDRA OWNER’S/OPERATOR’SMANUAL

© 2009 by Yamaha Golf-Car Company3rd Edition

All rights reserved. Any reprintingor unauthorized use without the

written permission ofYamaha Golf-Car Company

is expressly prohibited.Printed in U.S.A.LIT-19626-11-09

iJW1


ii JW1

IMPORTANT MANUAL INFORMATION

TIPYamaha continually seeks advancements in product designand quality; therefore, while thismanual contains the most currentproduct information available at thetime of printing, there may be minordiscrepancies between your golf carand this manual. If you have any questions concerning thismanual, please consult yourYamaha dealer.

Read and understand this manualcompletely before operating yourgolf car. This manual should beconsidered a permanent part ofyour golf car and should remainwith the car when resold.

Particularly important information isdistinguished in this manual by the following notations:

This is the safety alert symbol. It isused to alert you to potential person-al injury hazards. Obey all safetymessages that follow this symbol toavoid possible injury or death.

A WARNING indicates a hazardoussituation which, if not avoided,could result in death or seriousinjury.

A NOTICE indicates special pre-cautions that must be taken toavoid damage to the vehicle orother property.

TIPA TIP provides key information tomake procedures easier or clearer.

NOTICE


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NOTES


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WARRANTY

CONTENTS

IMPORTANT LABELS

SAFETY CONSIDERATIONS

MAINTENANCE

STORAGE

SPECIFICATIONS

WIRING

OPERATION

PRE-OPERATION CHECKS

CONTROLS

OPERATOR SAFETY

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WARRANTY

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Yamaha Golf-Car Company hereby warrants that anynew YDRA gas or YDRE electric Yamaha golf carpurchased from an authorized Yamaha golf car deal-er in the United States will be free from defects inmaterial and workmanship for FOUR years from dateof purchase, subject to the stated limitations.

DURING THE PERIOD OF WARRANTY any autho-rized Yamaha golf car dealer will, free of charge,repair or replace, at Yamaha’s option, any partadjudged defective by Yamaha due to faulty work-manship or material from the factory. Parts used inwarranty repairs will be warranted for the balance ofthe vehicle’s warranty period. All parts replacedunder warranty become property of Yamaha Golf-CarCompany.

GENERAL EXCLUSIONS from this warranty shallinclude any failures caused by:

a. Abnormal strain, neglect, or abuse, includinglack of proper maintenance, and use contraryto the Owner’s/Operator’s Manual instructions.

b. Accident or collision damage.c. Installation of parts or accessories that are not

original equipment.d. Fading, rust, or deterioration due to exposure

or ordinary wear and tear.e. Modifications or alterations that affect the car’s

condition, operation, performance, or durability,or which makes the car serve a purpose otherthan use as a two-person, golf course vehicle.

f. Damage due to improper transportation.g. Acts of God, i.e. lightning, hail damage,

flooding, fire, etc.

WARRANTY COVERAGE:Year 1: The first year of warranty shall cover the entire

vehicle except for the Specific Exclusionsbelow.

Year 2: The second year exclusions are the YDRAbattery, body parts, seats, mats, bumperassembly, bag carrier, scorecard holder, trim,and the Specific Exclusions below.

Year 3: The third year exclusions include the secondyear exclusions, plus the control cables andelectrical system (except electronic speedcontroller, battery charger, and electric motor),and the Specific Exclusions below.

Year 4: The fourth year of the warranty covers onlythe electric motor, speed controller, batterycharger, and transaxle on the YDRE and theengine, clutch system (except drive belt), andtransaxle on the YDRA.

SPECIFIC EXCLUSIONS: Specific exclusions fromthis warranty shall include the following:

• Any parts replaced due to normal wear or routine maintenance, including oil and air filterelements, tire wear, spark plugs, starter andclutch drive belts.

• Any charges incurred in transporting a golf caror charger to and from an authorized Yamahagolf car dealer for service or in performing fieldservice are also excluded from this warranty.

• Gasoline powered golf car starting batteries on vehicles equipped with a golf course GPSdevice, or any other device with a high parasitic current draw, unless the vehicle isequipped with an optional factory installeddeep cycle starting battery.

THE CUSTOMER’S RESPONSIBILITY under thiswarranty shall be to:1. Operate and maintain the golf car and charger as

specified in the appropriate Owner’s/Operator’sManual;

2. Give notice to an authorized Yamaha golf car dealer of any and all apparent defects within ten(10) days after discovery, and make the vehicle orcharger available at that time for inspection andrepairs by the dealer’s authorized representative.

WARRANTY TRANSFER: Any transfer of warrantymust take place within the first three years of theoriginal in-service date of the vehicle. The vehiclemust be re-registered by an authorized Yamaha Golf-Car Dealer within 30 days of transfer. A fee may becharged for the transfer of the warranty.

YAMAHA GOLF-CAR COMPANY MAKES NOOTHER WARRANTY OF ANY KIND, EXPRESSEDOR IMPLIED. ALL IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE WHICH EXCEED THEOBLIGATIONS AND TIME LIMITS STATED IN THISWARRANTY ARE HEREBY DISCLAIMED BYYAMAHA GOLF-CAR COMPANY AND EXCLUDEDFROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG IMPLIED WARRANTY LASTS, SOTHE ABOVE LIMITATION MAY NOT APPLY TOYOU. ALSO EXCLUDED FROM THIS WARRANTYIS ANY INCIDENTAL OR CONSEQUENTIAL DAM-AGES INCLUDING LOSS OF USE. SOME STATESDO NOT ALLOW THE EXCLUSION OR LIMITA-TION OF INCIDENTAL OR CONSEQUENTIALDAMAGES, SO THE ABOVE EXCLUSION MAYNOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGALRIGHTS, AND YOU MAY ALSO HAVE OTHERRIGHTS, WHICH VARY, FROM STATE TO STATE.

Yamaha Golf-Car Company, NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 6/1/09 LIT-13710-01-10

LIMITED 4-YEAR GOLF CAR LIMITED WARRANTY


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WIRING

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YDRA WIRING DIAGRAM

LIM

IT S

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SPECIFICATIONS

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BATTERIESItems YDRA

Battery: BCI group 24,RC: minimum 75 minCCA: minimum 400A

CHASSISItems YDRA

Steering system:Type Rack and PinionSteering angle (L.H.) 1.85 turnSteering angle (R.H.) 1.85 turn

Brakes:Brake system MechanicalType of brake Maintenance-Free internal transaxle disc brakeBrake pedal free play linkageadjustment 45-50 mm

(1.77-1.96 in.)(Brake cable end play) 0.1-0.5 mm (0.004-0.02 in.)Parking brake:

Type Foot type; parking brake with automaticrelease.

Release timing(With pedal segment in secondnotch)(Bolt heads round parallel to arm) 0.0 ~ 0.3 mm (0.000 ~ 0.001 in.)Wheel:

Tire size:Front 18 x 8.50–8.00/4 PRRear 18 x 8.50–8.00/4 PRRim size: 7.00–I–8.00Tire pressure: 110 kPa, 1.1 kgf/cm2 (16 psi)


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1-2JW1

WARRANTY

The California Air Resources Board and YamahaGolf-Car Company are pleased to explain the emis-sions control system warranty on your 2008 small off-road engine (SORE) vehicle. In California, newSORE vehicles must be designed, built and equippedto meet the State’s stringent anti-smog standards.Yamaha Golf-Car Company must warrant the EECSon your SORE vehicle for the period of time listedbelow provided there has been no abuse, neglect orimproper maintenance of your SORE vehicle.

Your EECS may include parts such as the carburetor,fuel-injection system, the ignition system, catalyticconverter, fuel tanks, fuel lines, fuel caps, valves,canisters, filters, vapor hoses, clamps, connectors,and other associated emission-related components.

Where a warrantable condition exists, Yamaha Golf-Car Company will repair your SORE vehicle at nocost to you including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE:This emissions control system is warranted for twoyears. If any emission-related part on your equip-ment is defective, the part will be repaired orreplaced by Yamaha Golf-Car Company.

OWNER’S WARRANTY RESPONSIBILITIES:As the SORE vehicle owner, you are responsible forperformance of the required maintenance listed in yourowner’s manual. Yamaha Golf-Car Company recom-mends that you retain all receipts covering mainte-nance on your SORE vehicle, but Yamaha Golf-CarCompany cannot deny warranty solely for the lack ofreceipts.

As the SORE vehicle owner, you should however beaware that Yamaha Golf-Car Company may deny youwarranty coverage if your SORE vehicle or a part hasfailed due to abuse, neglect, or improper maintenanceor unapproved modifications.

You are responsible for presenting your SORE vehicleto Yamaha Golf-Car Company’s distribution center orservice center as soon as the problem exists. The war-ranty repairs should be completed in a reasonableamount of time, not to exceed 30 days. If you have aquestion regarding your warranty coverage, you shouldcontact YGC Service at 1-866-747-4027.

GENERAL EMISSIONS WARRANTY COVERAGE:Yamaha Golf-Car Company warrants to the ultimatepurchaser and each subsequent purchaser that theSORE vehicle is:

Designed, built and equipped so as to conform with allapplicable regulations; and

Free from defects in materials and workmanship thatcause the failure of a warranted part to be identical inall material respects to that part as described inYamaha Golf-Car Company’s application for certifica-tion.

The warranty period begins on the date the SOREvehicle is delivered to an ultimate purchaser or firstplaced into service. The warranty period is two years.

Subject to certain conditions and exclusions as statedbelow, the warranty on emission-related parts is as fol-lows:

1. Any warranted part that is not scheduled forreplacement as required maintenance in the writ-ten instructions supplied, is warranted for the war-ranty period stated above. If the part fails duringthe period of warranty coverage, the part will berepaired or replaced by Yamaha Golf-CarCompany according to subsection (4) below. Anysuch part repaired or replaced under warranty willbe warranted for the remainder of the period.

2. Any warranted part that is scheduled only for regu-lar inspection in the written instructions supplied iswarranted for the warranty period stated above.Any such part repaired or replaced under warrantywill be warranted for the remaining warranty period.

3. Any warranted part that is scheduled for replace-ment as required maintenance in the writteninstructions supplied is warranted for the period oftime before the first scheduled replacement datefor that part. If the part fails before the first sched-uled replacement, the part will be repaired orreplaced by Yamaha Golf-Car Company accordingto subsection (4) below. Any such part repaired orreplaced under warranty will be warranted for theremainder of the period prior to the first scheduledreplacement point for the part.

4. Repair or replacement of any warranted part underthe warranty provisions herein must be performedat a warranty station at no charge to the owner.

5. Notwithstanding the provisions herein, warrantyservices or repairs will be provided at all of our dis-tribution centers that are franchised to service thesubject engines or equipment.

6. The SORE vehicle owner will not be charged fordiagnostic labor that is directly associated withdiagnosis of a defective, emission-related warrant-ed part, provided that such diagnostic work is per-formed at a warranty station.

7. Yamaha Golf-Car Company is liable for damagesto other engine or equipment components proxi-mately caused by a failure under warranty of anywarranted part.

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS


WARRANTY

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8. Throughout the SORE vehicle warranty periodstated above, Yamaha Golf-Car Company willmaintain a supply of warranted parts sufficient tomeet the expected demand for such parts.

9. Any replacement part may be used in the perfor-mance of any warranty maintenance or repairs andmust be provided without charge to the owner.Such use will not reduce the warranty obligationsof Yamaha Golf-Car Company.

10. Add-on or modified parts that are not exempted bythe Air Resources Board may not be used. Theuse of any non-exempted add-on or modified partsby the ultimate purchaser will be grounds for disal-lowing a warranty claims. Yamaha Golf-CarCompany will not be liable to warrant failures ofwarranted parts caused by the use of a non-exempted add-on or modified part.

WARRANTED PARTS:The repair or replacement of any warranted part other-wise eligible for warranty coverage may be excludedfrom such warranty coverage if Yamaha Golf-CarCompany demonstrates that the SORE vehicle hasbeen abused, neglected, or improperly maintained, andthat such abuse, neglect, or improper maintenance wasthe direct cause of the need for repair or replacementof the part. That notwithstanding, any adjustment of acomponent that has a factory installed, and properlyoperating, adjustment limiting device is still eligible forwarranty coverage. The following emission warrantyparts are covered:

1. Fuel Tank2. Fuel Cap3. Fuel Line4. Fuel Line Fittings5. Clamps6. Control Valves7. Control Solenoids8. Electronic Controls9. Control Cables10. Control Linkages


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SPECIFICATIONS

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ENGINEItems YDRA

Description:Engine type 4-stroke, Gasoline, 60˚ incline OHVNumber of cylinders SingleDisplacement 357 cm3

Bore x stroke 85 x 63 mm (3.30 x 2.48 in.)Compression ratio 8.1:1Rated output 8.5 kw (11.4 hp)/3500 rpmCooling system Forced air-cooledStarting system StarterIgnition system TCI MagnetoSpark plug type BPR2ESSpark plug gap 0.7-0.8 mm (0.028-0.031 in.)Lubrication system Splash-style positive oil lubricationEngine oil type YAMALUBE 10W40 4-cycle oilEngine oil capacity 1.0 L, 1000 cc (1.0 US qt)Oil change quantity 1.0 L, 1000 cc (1.0 US qt)

TRANSMISSIONItems YDRA

Transmission:Type V-belt automatic centrifugal engagementV-belt width and outer line length 29.5 x 1010 mm (1.16 x 39.76 in.)V-belt wear limit 27.7 mm (1.09 in.)

Governor:Type Oil bath flyweightFactory speed setting 19 km/h (12 mph)

Differential/reduction gear:Differential type Bevel gearLubricant/capacity Yamalube Shaft Drive Gear Oil/

1750 mL, 1750 cc (1.85 US quarts)


SPECIFICATIONS

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10-1 JW1

GENERAL SPECIFICATIONSItems YDRA

Dimensions:Overall length 2395 mm (94.3 in.)Overall width 1200 mm (47.2 in.)Overall height (steering height) 1190 mm (46.9 in.)Height of floor 310 mm (12.2 in.)Wheelbase 1640 mm (64.6 in.)Tread:

Front 870 mm (34.3 in.)Rear 980 mm (38.6 in.)

Minimum ground clearance 110 mm (4.3 in.)

Weight:Dry weight (without battery) 255 kg (562 lb)

Vibration Level:Vibration on seat (EN 1032,ISO5008) for Europe Will not exceed 0.5 m/s2

Vibration on steering wheel(EN1032, ISO5008) (for Europe) Will not exceed 2.5 m/s2

Performance:Factory speed setting 19 km/h (12 mph)Maximum speed 24 km/h (15 mph)Minimum turning radius 2.8 m (9.2 ft)Seating capacity Two occupants per seat,

four occupants maximum

Fuel Tank Capacity 25.0 L (6.6 U.S. Gallons)

PAINT CODESOEM Code Name Ditzler NumberSPU60185 Glacier 918519W44145 Emerald 48748W49874 Garnet 701739AH2039 Onyx Metallic 918520AH5068 Cobalt Metallic 918521AH5080 Anthracite Metallic 918522AH9064 Sandstone Metallic 918523


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IMPORTANT LABELS

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Y-924

4 3

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SAFETY AND INSTRUCTION LABELS

Read the following labels carefully before operating your golf car, andpromptly replace any labels which become damaged or removed. Death orserious personal injury can result from failing to read and comply withthe safety labels in this manual.

Y-500a

1


IMPORTANT LABELS

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GASO

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STORAGE

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ENGINE PREPARATION With the key removed and the sparkplug lead disconnected, turn theclutch by hand until compression isfelt. This puts the valves in theclosed position.

CHASSIS PREPARATION1. Verify the tire pressure is set to

110 kPa, 1.1 kgf/cm2 (16 psi).

2. Clean exterior of the golf car andapply a rust inhibitor.

3. Cover the golf car with a breathable cover and store it in adry, well-ventilated area.

BATTERY PREPARATION1. Remove the battery from the golf

car and store it in a cool, dryplace that stays between 0°C(32°F) and 30°C (90°F).

2. Have the battery rechargedevery 60-90 days to keep it fullycharged. The battery must bekept fully charged to avoid damage.

3. Batteries like the one suppliedwith your car normally do notrequire you to check the waterlevel inside the battery for theone-year warranty period provid-ed by the manufacturer.

Do not allow cleaning solution toenter battery cells. Serious bat-tery damage can result.

4. Clean the top of the battery witha solution of baking soda andwater, as necessary, to removecorrosion.

NOTICE


STORAGE

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1. Fill the fuel tank with fresh fueland add the specified amount ofYamaha Fuel Stabilizer andConditioner or equivalentproduct. Operate the vehicle for at least five minutes to distributetreated fuel through the fuel system.

å Float bowl drain screw

2. Turn the fuel shutoff valve to the“CLOSED” position.

3. Drain the carburetor floatchamber into a clean container byloosening the drain bolt; this willhelp prevent fuel deposits frombuilding up. Pour the drained fuelinto the fuel tank.

Specified amount:

7.5 cc of stabilizer for each liter offuel (1 oz. of stabilizer for each gallon of fuel)

TIPUse of fuel stabilizer and conditionereliminates the need to drain the fuelsystem. Consult a Yamaha dealer ifthe fuel system needs to be drainedinstead.

Y-521

A

Perform the following preparationswhen storing your golf car forextended periods of time:

TIPTurn main switch key to “OFF”position, remove key, and store keyin a safe place.

DRAINING FUEL

Gasoline and its vapors are highlyflammable and explosive. Deathor serious personal injury canresult from failing to comply withthe safety instructions in thismanual.l Do not smoke when draining

fuel and keep away from sparks,flames, or other sources ofignition.

l Stop engine and allow it to coolfor several minutes beforedraining fuel.

l Drain fuel in a well-ventilatedarea.

l Take care not to spill gasoline. If gasoline spills, wipe it upimmediately with dry rags.Always dispose of gasoline-soaked rags properly.

l Tighten the filler cap securelyafter checking fuel level toavoid leaking.

l If you inhale a lot of gasolinevapor, or get gasoline in youreyes, get immediate medicalattention.

l If any gasoline gets on yourskin, immediately wash withsoap and water. Changeclothing if gasoline spills on itto avoid potential fire hazard.


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IMPORTANT LABELS

2-3JW1

WARNINGAVERTISSEMENT

Do not tamperwith governorto increasespeed. Operationat higher speedscan cause lossof control thatcan result insevere injury ordeath.

Ne pas toucher aurégulateur afind’augmenter lavitesse. Unfonctionnementà des vitessessupérieures auréglage initialpeut causer uneperte de contrôlequi peut menerà une blessuregrave, voirefatale.

YAMAHA JN3-K8299-10

Y-764a

4

Important Emissions InformationYamaha Golf-Car Company

THIS EQUIPMENT CONFORMS TO 2008 CALIFORNIA EVP REGULATIONS FOR SMALL OFF-ROAD ENGINES UNDER 13CCR SECTION 2766(D). THIS ENGINE MEETS 2008 CALIFORNIAEXH EMISSION REGULATIONS AND CONFORMS TO PHASE 2 U.S. EPA REGULATIONS FORSMALL OFF-ROAD ENGINES. EMISSIONS COMPLIANCE PERIOD: CATEGORY A (EPA)EF: SYMXS 3572EBDCM: Jan 2008THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE

DISPLACMENT: 357ccEMISSION CONTROL SYSTEM: EMEVAPORATIVE CODE: COYMX34A

MAINTENANCE SPECIFICATIONS ENGINE OIL: SAE 10W40IGNITION TIMING: 27 BTDC SPARK PLUG GAP: .028-031NO OTHER ADJUSTMENTS NEEDED

The air index of this engine is 3

0 2 4 6 8 10Most Clean Least CleanNote: The lower the Air Index, the less PollutionThis engine is certified to be emissions compliant for the following use:

[ ] Moderate (125 hours) [ ] Intermediate (250 hours) [ X ] Extended (1000 hours) Check owner’s manual for further details.

Y-1599

5


IMPORTANT LABELS

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2-4 JW1

Y-851B

GOLF CAR SERIALNUMBERThe golf car serial number 1 isidentified in the location shown.

TIPThe first three digits of the serialnumber are for model identification;the remaining digits are the unit production number. Keep a record of these numbers for reference when ordering parts from a YamahaGolf-Car Company dealer.

The engine serial number 2 isaffixed in the location shown.

Y-852A

3 Engine Information

Y-1539

JWX

-000

000

1

2

3

II IIIII

IIIIIII

IIIIII

SM-03-399


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MAINTENANCE

8-12JW1

Brake Pedal Free PlayAdjustment

Before adjusting brake pedal freeplay, pump the brake pedal severaltimes to self-adjust the brakes.

To adjust the brake pedal free play:

1. Remove the floor mat and service lid from the floor of thegolf car.

2. Check the brake pedal free playby pressing against the pedalwith two fingers (using lightforce) and measuring the distance the pedal travels beforeresistance is felt.

Brake pedal free play Å:45-50 mm (1.77-1.96 in.)

3. If the free play distance needsadjusting, loosen the lock nut åand turn the adjusting nut ∫ in or out until the free play specification is met. Then tightenthe lock nut in place.

Do not over-tighten the brakecables. Over-tightening willincrease brake wear and affectoverall performance of car.Premature brake wear can result.

NOTICE

NOTICE

Y-61c

Y-909A

A B

Y-62b

7

1817

1615

1413

1211

1098

a


MAINTENANCE

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8-11 JW1

Y-57

TIPFor transaxle oil replacement, con-sult a Yamaha dealer or other quali-fied mechanic.

Before performing wheel or brakemaintenance, verify that the mainswitch is in the “OFF” position.Serious transaxle damage can result.

Wheel ReplacementTo remove and install a wheel onyour golf car:

1. With the wheels blocked to prevent the golf car from moving,loosen the wheel nuts.

2. Elevate the golf car with a jackand remove the wheel nuts andthe wheel.

3. Reverse the removal steps wheninstalling the wheel.

Wheel nut tightening torque:80 Nm, 8.0 m.kg (58 ft.lb)

Brake Adjustment The brakes on your golf car are self-adjusting.

Before you operate the car, pressdown on the brake pedal severaltimes to make sure the brakes arefunctioning properly.

Consult your Yamaha dealer beforeusing your golf car if you suspectbrake problems. Death or seriouspersonal injury can result from fail-ing to comply with the safetyinstructions in this manual.

NOTICE


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3-1JW1

Y-928

Y-68

Yamaha golf cars are designed to besimple to operate. However, be sureto observe the following to reducethe risk of serious injury or death dueto loss of control and other hazards:

BEFORE OPERATINGTHE GOLF CARl Read this Owner’s/Operator’s

manual and all safety and instructionlabels on the golf car before operating.

l Perform the pre-operation checksfound in Section 6 of this manual.

l Only authorized people shoulddrive the golf car, from the driver’sside only, and only in designatedareas.

l Do not allow more than two occupants per seat. This golf car isrestricted to two occupants unlessequipped with a rear seat.

l Do not operate the golf car whileunder the influence of alcohol ordrugs; their effect on vision andjudgment make operating a golfcar dangerous.

l Do not operate the golf car on public streets, roads or highwaysunless allowed by law or local regulating authority.

WHILE OPERATING THEGOLF CARl Keep your entire body inside the

golf car, remain seated and holdon when the car is in motion.

l Do not start the golf car until alloccupants are seated.

l Keep your hands on the steeringwheel and your eyes on the pathahead.

OPERATOR SAFETY!


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3-2 JW1

l Use extra care in congested areasor when backing up. Always backup slowly, and watch carefully.

l Avoid starting or stopping abruptly.

l Vary the speed of the golf car tomatch the terrain of the course.

l Avoid turning the steering wheeltoo sharply at higher speeds toavoid tipping or rolling the golf car.

l Always drive slowly straight up orstraight down slopes – never at anangle to avoid tipping or rolling thegolf car.

l Do not run the engine indoors.Exhaust gas is poisonous andcould result in carbon monoxidepoisoning.

l Do not make any modification oraddition which affects capacity orsafe operation, or make anychanges not in accordance withthe owner’s/operator’s manual.

Y-921

Y-922

Y-923

OPERATOR SAFETY!


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MAINTENANCE

8-10JW1

Transaxle OilTo check transaxle oil level:1. Place the golf car on a flat, level

surface.

2. Remove seven plastic rivets 1and two bolts 2, and remove thebag holder insert.

3. Place an oil pan under thetransaxle case.

4. Clean area around servicing plug 4.

5. Using an 8 mm hex wrench,remove transaxle oil servicingplug located on the rear of thetransaxle case.

6. Transaxle oil should be at the topof the oil servicing hole or justbeginning to run out of hole.

Do not allow foreign material toenter transaxle. Serious transaxledamage can result.

7. If needed, add Yamalube ShaftDrive Gear Oil until it is at the topof the plug hole or just beginningto run out of servicing hole.

TIPThe YDRA Golf Car is equipped withan internal wet brake. Use of oil otherthan Yamalube Shaft Drive Gear Oilwill cause brake noise.

8. Install the transaxle servicingplug and tighten to 14-19 Nm,1.4-1.9 m•kg (120-168 in•lb).

9. Install the bag holder insert 3and secure with two bolts 2 andseven plastic rivets 1.

NOTICE

Y-1215

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Y-1213


MAINTENANCE

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8-9 JW1

Y-523aAB

Fuse Replacement

Be sure to use the specified fuse.Using a wrong fuse can causeelectrical system damage and create a fire hazard. Death or serious personal injury can resultfrom failing to comply with thesafety instructions in thismanual.

When replacing a fuse, be sure the main switch is turned off toprevent accidental short-circuitingand electrical system damage.

1. Locate the in-line fuse holder onthe main wire harness adjacent tothe battery.

2. Pull fuse holder cover off.

3. Pull fuse out, inspect and replaceif necessary.

å Fuse holder∫ Fuse

Fuse Type:10 Amp, Blade Style

NOTICE


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4-1JW1

Like all machines, golf cars cancause injury if improperly used ormaintained. This section containsbroad safety practices required forsafe golf car operation. Before golfcars are operated, golf course personnel should establish any additional safety practices that maybe required for safe operation.

Experience has shown that golf cars are safe when operated inaccordance with the safety warningsaffixed to every golf car. This safeoperation is enhanced when golfcars are used according to the safetyrules and practices established tomeet the terrain and conditions ofthe course they are used on.

The information contained here isintended for golf course personnelresponsible for golf car safety. If youare responsible for the operationand maintenance of this golf car, weencourage you to implement thisgolf car safety program.

DRIVER QUALIFICATIONSAllow only authorized people tooperate golf cars. It is recommendedthat only people who possess avalid motor vehicle driver’s licensebe allowed to operate golf cars.

Place operation and safety instructions recommended by thegolf car manufacturer, along with the golf course safety rules, in aconspicuous place near the golf carrental area or golf car pick-up area.It is also recommended that the following warning be posted in aconspicuous location:

Do not operate golf cars whenunder the influence of alcohol ordrugs. Death or serious personalinjury can result from failing tocomply with the safety instruc-tions in this manual.

GOLF COURSE SAFETYSURVEYPerform safety surveys regularly toidentify hazardous areas where golfcars should not be operated.

GOLF COURSE HAZARDPREVENTIONThe following golf course hazardsmust be made safe:

l Steep Grades. Where steepgrades exist, restrict golf cars todesignated golf car pathwayswhere possible. In addition, identify steep grades with a suitable warning like:

Descend steep grades slowly withfoot on brake. Death or seriouspersonal injury can result fromfailing to comply with the safetyinstructions in this manual.

l Sharp Turns, Blind Corners,Bridge Approaches. Chain orrope off these potentially hazardous areas or identify themwith a suitable warning describingthe nature of the hazard and theproper precautions to be taken toavoid the hazard.

SAFETY CONSIDERATIONS!


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l Wet Areas. Wet grass may causea golf car to lose traction and mayaffect stability. Golf car operatorsshould reduce speed in wet areasor during periods of inclementweather.

l Loose Terrain. Loose terrain maycause a golf car to lose tractionand may affect stability. Repairloose terrain, chain or rope offthese areas, or identify loose terrain with a suitable warning.

l Golf Car and Pedestrian Interference. Reroute golf car traffic or pedestrian traffic in congested areas wherever possibleto prevent accidents. If it is impractical to reroute traffic, erectwarning signs to warn pedestriansof golf car traffic, and to warn golfcar operators to drive slowly, usecaution and watch for pedestrians.

MAINTENANCE REQUIRED FOR GOLFCAR SAFETYPractice the following to help ensurethe safety of golf car operators:

l Preventative Maintenance. Perform all scheduled maintenance in accordance withmanufacturer’s recommendationsto provide the golfing patron with asafe, properly operating golf car.

l Personnel. Allow only qualified,trained, and authorized personnelto inspect, adjust and maintain golfcars.

l Parts and Materials. Use onlyreplacement parts and materialsrecommended by the manufacturer.

l Ventilation. Properly ventilate allmaintenance and storage areas inaccordance with applicable firecodes and ordinances to avoid firehazards. Ventilation is required toremove flammable vapors andfumes from gasoline powered carstorage areas. Ventilation is alsorequired to remove hydrogen gasfrom the car storage areas duringthe battery charging process.



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MAINTENANCE

8-8JW1

Y-45

++

––

B

A

Y-44

Inspection:To inspect the drive belt, check forfrayed edges or tears, and measuredrive belt against the following specification. If the belt showsexcessive wear or damage, replacethe belt with a new one.å New: 29.5 mm (1.16 in.)∫ Replace when belt reaches:

27.7 mm (1.09 in.)5. To install the drive belt, reverse

the above steps, rolling the beltback over the secondary sheave.

BatteryThe 12-volt battery that providesstarting power to your gas car normally does not require the addition of water. If the battery losesits charge, have an experiencedmechanic charge it.

Battery electrolyte is poisonous anddangerous, causing severe burns,etc. It contains sulfuric acid. Avoidcontact with skin, eyes, or clothing.Antidote:EXTERNAL: Flush with water. INTERNAL: Drink large quantities ofwater or milk. Follow with milk ofmagnesia, beaten egg, or vegetable oil. Call physician imme-diately.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 inenclosed space. Always shield eyeswhen working near batteries.KEEP OUT OF REACH OF CHILDREN.


MAINTENANCE

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8-7 JW1

Y-60

BA

Y-508

Inspection and cleaning:

3. Wash the foam pre-filter in soapand water. Allow it to dry.

å Soap and water∫ Foam element

4. Check the filter element. If damaged or dirty, replace it.

Do not wring out the foam pre-filter, this could cause it totear.

5. To replace the elements,reverse the above steps.

The pre-filter has a notch on oneside. It will only fit in the case oneway. Serious engine damage canresult from an improperly posi-tioned filter.

Drive BeltTo remove the drive belt:

1. Set the drive select lever halfwaybetween forward and reverse.

2. Pull up on the drive belt andpush it outward over the edge ofthe secondary sheave.

3. Turn the secondary sheaveclockwise and the drive belt willroll off the sheave.

4. Remove the drive belt from theprimary sheave.

NOTICE

NOTICE


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4-3JW1

SAFETY PRECAUTIONSDURING MAINTENANCEWhen performing maintenance, followall safety instructions contained in themanufacturer’s operation and servicemanuals, as well as the followingsafety procedures:l Properly immobilize golf car before

beginning any maintenance to avoidany unexpected vehicle movement.

l Properly block chassis before working underneath golf car to avoidany unexpected vehicle movement.

l Before disconnecting any part of thefuel system, drain the applicable partof the system to prevent fuel leaks.

l When working on the fuel system orthe battery, do not smoke, or allowany sparks or open flames near the vehicle, to avoid any fires orexplosions.

l Before performing any maintenance,disable the car’s electrical system inaccordance with the manufacturer’sinstructions.

l Use only properly insulated toolswhen working on electricallypowered golf cars or aroundbatteries to avoid electrical shock ordamage to the electrical system.

l Maintain all safety devices, includ-ing brakes, steering mechanisms,warning devices and governors, in asafe operating condition. Do notmodify these safety devices assupplied by the manufacturer.

l After each maintenance or repair,the car must be driven by aqualified, trained and authorizedperson – in an area free ofpedestrian traffic – to ensure properoperation and adjustment.

l Record all maintenance performedin a maintenance record log bydate, name of person performingmaintenance and type ofmaintenance. Periodically inspectmaintenance log to ensureaccurate and complete entries.

l Provide operator comment cardsto assist in identifying non-periodicmaintenance needs for specificgolf cars.

l Maintain in a legible condition allnameplates, warnings, andinstructions provided by the manufacturer.

l If new nameplates, warnings orinstructions are needed, contactyour Yamaha Golf-Car Companydealer.

FUEL HANDLING/STORAGE AND BATTERY CHARGINGTake the following precautions toensure maintenance worker safety:l Supervise the storage and

handling of liquid fuels in accordance with applicable fireand safety requirements to avoidany fires or explosions.

l Only use battery charging facilitiesand procedures that are in accordance with applicable ordinances and regulations toavoid explosions, electrical shockor damage to the electrical system.

l Periodically inspect fueling to becertain that applicable safetycodes, regulations and procedures are being followed toavoid any fires or explosions.



CONTROLS

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5-1 JW1

Y-91612

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Y-919

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Y-918ab12 11

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7

FEATURES1 Brake pedal2 Parking brake pedal3 Accelerator pedal4 Steering wheel5 Oil warning light6 Main switch7 Drive select lever8 Choke knob9 Seata Front bodyb Front tirec Front bumperd Batterye Rear bodyf Fuel shutoff valveg Fuel cap h Rear tirei Rear bumper


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MAINTENANCE

8-6JW1

Y-515

A

Y-518

A

A

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B

Y-519a

C

D

å Oil filler hole

Use care not to fill past the MAXdipstick mark, and be sure no foreign material enters the crankcase. Serious engine damage can result.

After replacing engine oil, check foroil leaks around the drain plug. If oilleaks are found, consult a Yamahadealer.

Air FilterTo remove the air filter elements:

1. Unlatch the air filter cover clipsand remove cover.

å Air filter cover clips∫ Air filter cover

2. Lift the air filter and pre-filter outof the air filter case.

ç Air filter∂ Pre-filter

Be careful not to drop anythinginto the air inlet. Serious enginedamage can result.

NOTICE

NOTICE


MAINTENANCE

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8-5 JW1

Engine Oil Replacement1. Warm up the engine for several

minutes, place the golf car on alevel surface, then stop the engine.

Use caution not to touch hotengine oil or hot engine parts,during the following procedure.Death or serious personal injurycan result from failing to complywith the safety instructions in thismanual.

2. Place an oil pan under theengine drain plug.

3. Remove the oil drain plug and letthe oil drain completely.

TIPDispose of used oil in an environmentally safe way, such astaking oil to 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:31 Nm, 3.1 m.kg(23 ft.lb)

5. Add the correct quantity of oilthrough the oil filler hole.

TIPRecommended engine oil classification: API Service SE, SF, orSG. Engine oils labeled “EnergyConserving II” are recommended.

Recommended oil:YAMALUBE 10W40

Engine oil capacity:1.0 L, 1000 cc(1.0 US qt)

Oil change quantity:1.0 L, 1000 cc(1.0 US qt)

Y-624


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CONTROLS

5-2JW1

OFFON

Y-912b

OFFON

Y-913b

OFFON

Y-914

A

MAIN SWITCHThe main switch controls the following items:

OFFAll electrical circuits are switched off.The key can be removed only in thisposition.

ONElectrical circuits are switched on.The golf car can be driven.

OIL WARNING LIGHT When the engine oil level falls belowan acceptable level, this light comeson.

If the light comes on, stop theengine, check the engine oil leveland add oil as necessary. Enginedamage can result from lowengine oil levels. (See page 6-3).

å Oil warning light

NOTICE


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5-3 JW1

DRIVE SELECT LEVERThe drive select lever is used to shiftthe golf car into forward or reverse.After coming to a complete stop,move the lever to the desired position.

Lever Position Car Movement

F FORWARDR REVERSE

TIPThe back-up buzzer will beep whenthe drive select lever is turned to “R.”

ACCELERATOR PEDALThe accelerator pedal controls thegolf car’s speed.

Action Car SpeedDepress pedal IncreaseRelease pedal Decrease

å Accelerator pedal

BRAKE PEDALPress down on the brake pedal tostop the golf car.

∫ Brake pedal

Y-920

BEEP

Y-20A

A

Y-18

Y-21a

B


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8-4JW1

Spark Plug InspectionYou should periodically remove andinspect the spark plug. Dirty or worn spark plugs can cause poorperformance.

When removing or installing thespark plug, be careful not to damage the insulator. A damagedinsulator could allow externalsparks, which could lead toexplosion or fire. Death or seriouspersonal injury can result fromfailing to comply with the safetyinstructions in this manual.

å Spark plug∫ Spark plug cap1. Check for discoloration and

remove carbon deposits with aspark plug cleaner or wirebrush. The normal electrodecolor will be tan.

2. Check the spark plug type, andcheck the spark plug gap with afeeler gauge.

Standard spark plug: BPR2ES

Spark plug gap:0.7 ˜ 0.8 mm (0.028 ˜ 0.031 in.)

å Gap3. Clean the gasket and plug

surfaces and install the sparkplug finger-tight before tighteningto the following torque:

Spark plug torque:20 Nm, 2.0 m.kg(14.5 ft.lb)

Y-516A

B

A

Y-37


MAINTENANCE

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8-3 JW1

EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS

Item Acronym• CARB. ASSY., LH., JT., CARB (Carburetor)

CARBURETOR 2 & JT.,CARBURETOR 1

• T.C.I. MAGNETO ASSY. & El (Electronic Ignition)PLUG, SPARK

• CRANKCASE 1 & HEAD, PCV (Positive Crankcase CYLINDER 1 Ventilation)

• AIR FILTER ASSY. ACL (Air Cleaner)• MUFF., 2

The above items and the corresponding acronyms are provided in accordance with U.S.EPA REGULATIONS FOR SMALLNONROAD ENGINES and the CALIFORNIA REGULATIONS FORNEW 1995 AND LATER OFF-HIGHWAY RECREATIONAL VEHICLES AND ENGINES.

The acronyms conform to the latestversion of the SAE’s recommendedpractice document J1930,“Diagnostic Acronyms, Terms, andDefinitions For Electrical/ElectronicSystem”.

It is recommended that these itemsbe serviced by a Yamaha dealer orother qualified mechanic.

TROUBLESHOOTINGIf the vehicle’s engine won’t start,use the following chart:

Cause RemedyFuel System

No fuel in tank Fill fuel tankFuel shutoff valve Open fuel shutoffclosed valveClogged fuel Clean fuel line –line Consult Yamaha

dealerForeign matter Clean fuel filter –in fuel filter Consult Yamaha

dealerClogged Clean carburetor –carburetor Consult Yamaha

dealerElectrical System

Spark plug dirty Clean carbon orwith carbon, or wipe spark plugwet dryFaulty ignition Consult Yamahasystem dealer


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CONTROLS

5-4JW1

PARKING BRAKEPEDALPress down on the parking brakepedal whenever parking the golf car.

ç Parking brake pedal

TIPRelease the parking brake bydepressing the accelerator pedal.

The parking brake will automaticallyrelease when the accelerator pedalis depressed. If the main switch isin the “ON” position, depressingthe accelerator may suddenlycause the golf car to move. Deathor serious personal injury canresult from failing to comply withthe safety instructions in this manual.

CHOKE KNOBPull and hold out choke knob whenstarting a cold engine. Release theknob after the engine starts.

å Choke knob

FUEL SHUTOFF VALVEEnsure the fuel shutoff valve is in the “OPEN” position for normal operation.

å Fuel shutoff valve

Y-22a

C

Y-903

A

Counterclockwise/open

Clockwise/closed

A

Y-1572



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Y-905

Pre-operation checks should bemade each time you use your golfcar. Get in the habit of performingthe following checks in the sameway so that they become secondnature.

To keep car from moving whileperforming pre-operation checks:

l Remove main switch key. l Apply parking brake.

Death or serious personal injurycan result from failing to complywith the safety instructions in thismanual.

PRE-OPERATIONCHECKLISTBefore each use check the following:

4 Fuel system4 Engine oil level4 Battery4 Tire condition4 Steering system4 Back-up buzzer4 Pedal operation4 Body and chassis

SEATOpen the seat for checking and servicing.


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CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE

Remarks

Page

EVERY Replace engine oil R R R 8-5

YEAR Adjust throttle cables,**choke cable, check carburetor CA CA CA *throttle shaft for wear**Check starter V-belt for

CS CS CS

CS CS CS

CS CS CS

CS CS CS

CS CS CS

CS CS CS

CS CS

CS

CS

*damage and tensionCheck drive belt for slippage,

8-7wear or scratchesCheck operation of speed limiter *

Apply battery terminal protectant S S S –

Check wiring connections–and insulation

Check rear axle bearing playfor roughness or freeplay *

Check steering knucklebushing free play / Adjustwheel alignment

CA CA CA *

Check wheel nut tightness,*front wheel bearing play

Check transaxle oil level andinspect for leakage 8-10

Check operation and adjustCA CA CA *pedal stop if necessary

EVERY2 YEARS

Check brushes for wear andS *commutator for dirt

EVERY4 YEARS

Replace fuel filter andR *fuel hoses

Check tightness of cylinder CA *head / Adjust valves

CS R *

Inspect internal wet brake andreplace pads if necessary *

* Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does not contain these procedures. They are contained in the Service Manual.

**Related to emission control system.

40 Rounds 250 rds 500 rds 1000 rds 2000 rds20 hours 125 hrs 250 hrs 500 hrs 1000 hrs100 miles 600 mls 1200 mls 2500 mls 5000mls160 kms 1000 kms 2000 kms 4000 kms 8000 kms(Every (Every 6 (Every (Every (Everymonth) months) year) 2 years) 4 years)

DailyPre-

Opera-tion

CS R

Replace transaxle oil


MAINTENANCE

8-1 JW1

PERIODIC MAINTENANCE CHARTSRegular maintenance is required for the best performance and safe operation ofyour golf car.

Be sure to turn off the main switch and apply the parking brake when you per-form maintenance, unless otherwise specified. If the owner is not familiar withservicing the machine, death or serious personal injury can result. When indoubt the work should be done by a Yamaha dealer or other qualified mechanic.


40 Rounds 250 rds 500 rds 1000 rds 2000 rds20 hours 125 hrs 250 hrs 500 hrs 1000 hrs

Remarks 100 miles 600 mls 1200 mls 2500 mls 5000mls160 kms 1000 kms 2000 kms 4000 kms 8000 kms(Every (Every 6 (Every (Every (Everymonth) months) year) 2 years) 4 years) Page

PRE-OP Check engine oil CS CS CS 6-3

Check air cooling duct CS CS CS CS CS CS

CS CS CS CS CS CS

CS CS CS CS CS CS

CS

CS

CS CS CS CS

CS

CS

CS CS CS CS

CS

CS CS CS CS CS CS

CS CS CS CS CS CS

CS CS CS CS CS CS

CS CS CS CS CS

CS CS CS CS CS

CS CS CS CS CS

CS CS CS

CS CS CS

CS

*

Check fuel lines for leakage 6-2

Check fuel level 6-2

Check for loosenessand corrosion of battery 6-4terminals and hold downsCheck brake pedal free play

CA CA CA CA CA 8-13and adjust if necessaryCheck steering operation 6-5

Check tire pressure, treadCA CA CA CA CA 6-4depth, tire surface for damage

Check body and chassis for6-6damage

Check tightness of all bolts,*nuts, screws and rivets

Check back-up buzzer 6-5operation

EVERY Check fuel filter for clogging *

MONTH Check wear of drive belt 8-7/8-8

Check operation of7-1Forward / Reverse shifting

Clean / Lube pedal control area CL –

EVERY 6 Wash pre-filter, check airS S S S

8-6/8-7MONTHS cleaner element

Check spark plug and plug cap8-4condition** / Check compression

Check shock absorbers for oil*leaks and damaged springs



DailyPre-

Opera-tion

1

2

3

4

5

6

7

8

9

10

11


1

2

3

4

5

6

7

8

9

10

11


6-2JW1

Y-514a

B

A

CFUEL SYSTEMMake sure there is sufficient fuel inthe tank and that the fuel shutoffvalve is open. Also check fuel lineand connections for leakage.å Fuel tank∫ Fuel capç Fuel shutoff valve

Gasoline and its vapors are highlyflammable and explosive. To avoidfires and explosions and to reducethe risk of injury when refueling,follow these instructions.

1. Stop engine and allow it tocool for several minutesbefore refueling.Do not smoke when refuelingand keep away from sparks,flames or other sources ofignition.Refuel in a well-ventilated area.

2. Take care not to spill gasoline.If gasoline spills, wipe it upimmediately with dry rags.Always dispose of gasoline-soaked rags properly.

3. Tighten the filler cap securelyafter refueling.

Gasoline is poisonous and cancause injury or death. If you swallow gasoline, inhale a lot ofgasoline vapor or get gasoline inyour eyes, get immediate medicalattention.If any gasoline gets on your skin,immediately wash with soap andwater. Change clothing if gasolinespills on it.

Recommended fuel:Unleaded gasoline

Fuel tank capacity:25.0 L(6.6 US gal)



1

2

3

4

5

6

7

8

9

10

11

6-3 JW1

Avoid using gasoline blended withmethyl alcohol which can damagefuel system parts.

ENGINE OILWith the golf car parked on levelground, remove the dipstick andmake sure the engine oil is betweenthe MIN and MAX marks (the crosshatched area on the end of thedipstick).

å Oil level dipstick∫ Maximum oil levelç Safe operating range

If the oil level is below the MIN markon the dipstick, add oil through theoil filler hole until the oil level isbetween the MIN and MAX marks.

å Oil filler hole

Engine damage can result.l Use care not to fill past the MAX

dipstick mark, and be sure no foreign material enters the crankcase.

l Use care not to get oil on thestarter belt.

TIPThe distance between the dipstickmarks represents approx. 1/2 L (1/2 US qt) of oil.


NOTICE




Y-514

MIN MAX

Y-28

A

B

C

Y-515

A NOTICE


1

2

3

4

5

6

7

8

9

10

11

OPERATION

7-2JW1

STOPPINGTo stop the golf car, gradually pressdown on the brake pedal.

å Brake pedal

When the car has come to a stop,apply the parking brake pedal andturn the main switch to “OFF.”

∫ Parking brake pedal

Do not hold the golf car on anincline with the accelerator – usethe brake. Transmission damagecan result.

NOTICEY-65c

A

B


OPERATION

1

2

3

4

5

6

7

8

9

10

11

JW1

OFFON

Y-911a

Y-18

Y-903

A

Y-20B

B

STARTING1. With the parking brake applied,

turn the drive select lever to “FWD”for forward, or “REV” for reverse.

Do not shift from “FWD” forwardto “REV” reverse while the golfcar is moving. Transmission dam-age can result.

2. Turn the main switch to “ON.”

Do not depress the acceleratorpedal when turning on the mainswitch or the golf car may startmoving unexpectedly. Death orserious personal injury can resultfrom failing to comply with the safety instructions in this manual.

3. Pull the choke knob out and hold itwhile starting. Release the chokeknob after the engine starts.

å Choke knob

TIPThe choke is not required when theengine is warm.

4. Check that your path is clear in thedirection you plan to go, and slow-ly depress the accelerator pedal.The golf car will start to move.

∫ Accelerator pedal

TIPThe parking brake automaticallyreleases when the accelerator pedalis depressed.

NOTICE

7-1


1

2

3

4

5

6

7

8

9

10

11


6-4JW1

Engine Cooling Inlet DuctCheck the engine cooling inlet ductfor debris. Remove any debris present.

å Engine cooling inlet duct

BATTERYCheck that the battery is held securelyin place to prevent the battery frombeing damaged from vibration or jarring. Also check that no battery capsare missing to prevent battery acidfrom spilling from the battery. Checkthe battery terminals for corrosion.

Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuricacid. Avoid contact with skin, eyesor clothing. Ventilate when charg-ing or using in enclosed space.Always shield eyes when workingnear batteries. KEEP OUT OFREACH OF CHILDREN.

TIRE CONDITIONTire Air PressureCheck the tire air pressure beforeoperating the golf car.

Tire pressure:For JW1: 110 kPa, 1.1 kgf/cm2

(16 psi)

Tire Wear LimitCheck the tire surface for damage,cracks or embedded objects. Whentire tread wears down to 1 mm (0.04 in.), replace the tire.

å Wear limit

Y-30

Y-1347

A

A

Y-31



1

2

3

4

5

6

7

8

9

10

11

6-5 JW1

Y-20A

A

Y-932

Y-33

STEERING SYSTEMCheck the steering system forexcessive free play by:

l moving the steering wheel up and down, and back and forth.

l turning the steering wheel slightly to the right and left.

If you feel excessive free play, orhear rattling sounds which may indicate loose steering components,consult a Yamaha dealer.

BACK-UP BUZZERCheck the back-up buzzer by moving the drive select lever to “R”for reverse. The buzzer shouldsound.

PEDAL OPERATIONCheck the following pedal controlsfor proper operation. If a pedal doesnot work properly, consult a Yamahadealer.

Accelerator Pedal1. WARNING! Make sure the

main switch is in the “OFF”position.

2. Make sure the accelerator pedaloperates smoothly.



1

2

3

4

5

6

7

8

9

10

11


6-6JW1

Brake PedalMake sure the brake pedal feels firmwhen pressed and returns to its original position when released.

∫ Brake pedal

Parking Brake PedalMake sure the parking brake pedallocks in place with a positive click,and releases when the acceleratorpedal is pressed.



BODY AND CHASSISBefore each use, visually inspect the golf car body and chassis fordamage and/or missing parts.

Y-22a

C

Y-21a

B



1

2

3

4

5

6

7

8

9

10

11

6-5 JW1

Y-20A

A

Y-932

Y-33

STEERING SYSTEMCheck the steering system forexcessive free play by:

l moving the steering wheel up and down, and back and forth.

l turning the steering wheel slightly to the right and left.

If you feel excessive free play, orhear rattling sounds which may indicate loose steering components,consult a Yamaha dealer.

BACK-UP BUZZERCheck the back-up buzzer by moving the drive select lever to “R”for reverse. The buzzer shouldsound.

PEDAL OPERATIONCheck the following pedal controlsfor proper operation. If a pedal doesnot work properly, consult a Yamahadealer.

Accelerator Pedal1. WARNING! Make sure the

main switch is in the “OFF”position.

2. Make sure the accelerator pedaloperates smoothly.



1

2

3

4

5

6

7

8

9

10

11


6-6JW1

Brake PedalMake sure the brake pedal feels firmwhen pressed and returns to its original position when released.

∫ Brake pedal

Parking Brake PedalMake sure the parking brake pedallocks in place with a positive click,and releases when the acceleratorpedal is pressed.



BODY AND CHASSISBefore each use, visually inspect the golf car body and chassis fordamage and/or missing parts.

Y-22a

C

Y-21a

B


OPERATION

1

2

3

4

5

6

7

8

9

10

11

JW1

OFFON

Y-911a

Y-18

Y-903

A

Y-20B

B

STARTING1. With the parking brake applied,

turn the drive select lever to “FWD”for forward, or “REV” for reverse.

Do not shift from “FWD” forwardto “REV” reverse while the golfcar is moving. Transmission dam-age can result.

2. Turn the main switch to “ON.”

Do not depress the acceleratorpedal when turning on the mainswitch or the golf car may startmoving unexpectedly. Death orserious personal injury can resultfrom failing to comply with the safety instructions in this manual.

3. Pull the choke knob out and hold itwhile starting. Release the chokeknob after the engine starts.

å Choke knob

TIPThe choke is not required when theengine is warm.

4. Check that your path is clear in thedirection you plan to go, and slow-ly depress the accelerator pedal.The golf car will start to move.

∫ Accelerator pedal

TIPThe parking brake automaticallyreleases when the accelerator pedalis depressed.

NOTICE

7-1


1

2

3

4

5

6

7

8

9

10

11


6-4JW1

Engine Cooling Inlet DuctCheck the engine cooling inlet ductfor debris. Remove any debris present.

å Engine cooling inlet duct

BATTERYCheck that the battery is held securelyin place to prevent the battery frombeing damaged from vibration or jarring. Also check that no battery capsare missing to prevent battery acidfrom spilling from the battery. Checkthe battery terminals for corrosion.

Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuricacid. Avoid contact with skin, eyesor clothing. Ventilate when charg-ing or using in enclosed space.Always shield eyes when workingnear batteries. KEEP OUT OFREACH OF CHILDREN.

TIRE CONDITIONTire Air PressureCheck the tire air pressure beforeoperating the golf car.

Tire pressure:For JW1: 110 kPa, 1.1 kgf/cm2

(16 psi)

Tire Wear LimitCheck the tire surface for damage,cracks or embedded objects. Whentire tread wears down to 1 mm (0.04 in.), replace the tire.

å Wear limit

Y-30

Y-1347

A

A

Y-31



1

2

3

4

5

6

7

8

9

10

11

6-3 JW1

Avoid using gasoline blended withmethyl alcohol which can damagefuel system parts.

ENGINE OILWith the golf car parked on levelground, remove the dipstick andmake sure the engine oil is betweenthe MIN and MAX marks (the crosshatched area on the end of thedipstick).

å Oil level dipstick∫ Maximum oil levelç Safe operating range

If the oil level is below the MIN markon the dipstick, add oil through theoil filler hole until the oil level isbetween the MIN and MAX marks.

å Oil filler hole

Engine damage can result.l Use care not to fill past the MAX

dipstick mark, and be sure no foreign material enters the crankcase.

l Use care not to get oil on thestarter belt.

TIPThe distance between the dipstickmarks represents approx. 1/2 L (1/2 US qt) of oil.


NOTICE




Y-514

MIN MAX

Y-28

A

B

C

Y-515

A NOTICE


1

2

3

4

5

6

7

8

9

10

11

OPERATION

7-2JW1

STOPPINGTo stop the golf car, gradually pressdown on the brake pedal.

å Brake pedal

When the car has come to a stop,apply the parking brake pedal andturn the main switch to “OFF.”

∫ Parking brake pedal

Do not hold the golf car on anincline with the accelerator – usethe brake. Transmission damagecan result.

NOTICEY-65c

A

B


MAINTENANCE

8-1 JW1

PERIODIC MAINTENANCE CHARTSRegular maintenance is required for the best performance and safe operation ofyour golf car.

Be sure to turn off the main switch and apply the parking brake when you per-form maintenance, unless otherwise specified. If the owner is not familiar withservicing the machine, death or serious personal injury can result. When indoubt the work should be done by a Yamaha dealer or other qualified mechanic.


40 Rounds 250 rds 500 rds 1000 rds 2000 rds20 hours 125 hrs 250 hrs 500 hrs 1000 hrs

Remarks 100 miles 600 mls 1200 mls 2500 mls 5000mls160 kms 1000 kms 2000 kms 4000 kms 8000 kms(Every (Every 6 (Every (Every (Everymonth) months) year) 2 years) 4 years) Page

PRE-OP Check engine oil CS CS CS 6-3

Check air cooling duct CS CS CS CS CS CS

CS CS CS CS CS CS

CS CS CS CS CS CS

CS

CS

CS CS CS CS

CS

CS

CS CS CS CS

CS

CS CS CS CS CS CS

CS CS CS CS CS CS

CS CS CS CS CS CS

CS CS CS CS CS

CS CS CS CS CS

CS CS CS CS CS

CS CS CS

CS CS CS

CS

*

Check fuel lines for leakage 6-2

Check fuel level 6-2

Check for loosenessand corrosion of battery 6-4terminals and hold downsCheck brake pedal free play

CA CA CA CA CA 8-13and adjust if necessaryCheck steering operation 6-5

Check tire pressure, treadCA CA CA CA CA 6-4depth, tire surface for damage

Check body and chassis for6-6damage

Check tightness of all bolts,*nuts, screws and rivets

Check back-up buzzer 6-5operation

EVERY Check fuel filter for clogging *

MONTH Check wear of drive belt 8-7/8-8

Check operation of7-1Forward / Reverse shifting

Clean / Lube pedal control area CL –

EVERY 6 Wash pre-filter, check airS S S S

8-6/8-7MONTHS cleaner element

Check spark plug and plug cap8-4condition** / Check compression

Check shock absorbers for oil*leaks and damaged springs



DailyPre-

Opera-tion

1

2

3

4

5

6

7

8

9

10

11


1

2

3

4

5

6

7

8

9

10

11


6-2JW1

Y-514a

B

A

CFUEL SYSTEMMake sure there is sufficient fuel inthe tank and that the fuel shutoffvalve is open. Also check fuel lineand connections for leakage.å Fuel tank∫ Fuel capç Fuel shutoff valve

Gasoline and its vapors are highlyflammable and explosive. To avoidfires and explosions and to reducethe risk of injury when refueling,follow these instructions.

1. Stop engine and allow it tocool for several minutesbefore refueling.Do not smoke when refuelingand keep away from sparks,flames or other sources ofignition.Refuel in a well-ventilated area.

2. Take care not to spill gasoline.If gasoline spills, wipe it upimmediately with dry rags.Always dispose of gasoline-soaked rags properly.

3. Tighten the filler cap securelyafter refueling.

Gasoline is poisonous and cancause injury or death. If you swallow gasoline, inhale a lot ofgasoline vapor or get gasoline inyour eyes, get immediate medicalattention.If any gasoline gets on your skin,immediately wash with soap andwater. Change clothing if gasolinespills on it.

Recommended fuel:Unleaded gasoline

Fuel tank capacity:25.0 L(6.6 US gal)



1

2

3

4

5

6

7

8

9

10

11

6-1 JW1

Y-905

Pre-operation checks should bemade each time you use your golfcar. Get in the habit of performingthe following checks in the sameway so that they become secondnature.

To keep car from moving whileperforming pre-operation checks:

l Remove main switch key. l Apply parking brake.

Death or serious personal injurycan result from failing to complywith the safety instructions in thismanual.

PRE-OPERATIONCHECKLISTBefore each use check the following:

4 Fuel system4 Engine oil level4 Battery4 Tire condition4 Steering system4 Back-up buzzer4 Pedal operation4 Body and chassis

SEATOpen the seat for checking and servicing.


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2

3

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5

6

7

8

9

10

11

MAINTENANCE

8-2JW1


Remarks

Page

EVERY Replace engine oil R R R 8-5

YEAR Adjust throttle cables,**choke cable, check carburetor CA CA CA *throttle shaft for wear**Check starter V-belt for

CS CS CS

CS CS CS

CS CS CS

CS CS CS

CS CS CS

CS CS CS

CS CS

CS

CS

*damage and tensionCheck drive belt for slippage,

8-7wear or scratchesCheck operation of speed limiter *

Apply battery terminal protectant S S S –

Check wiring connections–and insulation

Check rear axle bearing playfor roughness or freeplay *

Check steering knucklebushing free play / Adjustwheel alignment

CA CA CA *

Check wheel nut tightness,*front wheel bearing play

Check transaxle oil level andinspect for leakage 8-10

Check operation and adjustCA CA CA *pedal stop if necessary

EVERY2 YEARS

Check brushes for wear andS *commutator for dirt

EVERY4 YEARS

Replace fuel filter andR *fuel hoses

Check tightness of cylinder CA *head / Adjust valves

CS R *

Inspect internal wet brake andreplace pads if necessary *



40 Rounds 250 rds 500 rds 1000 rds 2000 rds20 hours 125 hrs 250 hrs 500 hrs 1000 hrs100 miles 600 mls 1200 mls 2500 mls 5000mls160 kms 1000 kms 2000 kms 4000 kms 8000 kms(Every (Every 6 (Every (Every (Everymonth) months) year) 2 years) 4 years)

DailyPre-

Opera-tion

CS R

Replace transaxle oil


MAINTENANCE

1

2

3

4

5

6

7

8

9

10

11

8-3 JW1

EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS

Item Acronym• CARB. ASSY., LH., JT., CARB (Carburetor)

CARBURETOR 2 & JT.,CARBURETOR 1

• T.C.I. MAGNETO ASSY. & El (Electronic Ignition)PLUG, SPARK

• CRANKCASE 1 & HEAD, PCV (Positive Crankcase CYLINDER 1 Ventilation)

• AIR FILTER ASSY. ACL (Air Cleaner)• MUFF., 2

The above items and the corresponding acronyms are provided in accordance with U.S.EPA REGULATIONS FOR SMALLNONROAD ENGINES and the CALIFORNIA REGULATIONS FORNEW 1995 AND LATER OFF-HIGHWAY RECREATIONAL VEHICLES AND ENGINES.

The acronyms conform to the latestversion of the SAE’s recommendedpractice document J1930,“Diagnostic Acronyms, Terms, andDefinitions For Electrical/ElectronicSystem”.

It is recommended that these itemsbe serviced by a Yamaha dealer orother qualified mechanic.

TROUBLESHOOTINGIf the vehicle’s engine won’t start,use the following chart:

Cause RemedyFuel System

No fuel in tank Fill fuel tankFuel shutoff valve Open fuel shutoffclosed valveClogged fuel Clean fuel line –line Consult Yamaha

dealerForeign matter Clean fuel filter –in fuel filter Consult Yamaha

dealerClogged Clean carburetor –carburetor Consult Yamaha

dealerElectrical System

Spark plug dirty Clean carbon orwith carbon, or wipe spark plugwet dryFaulty ignition Consult Yamahasystem dealer


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2

3

4

5

6

7

8

9

10

11

CONTROLS

5-4JW1

PARKING BRAKEPEDALPress down on the parking brakepedal whenever parking the golf car.



The parking brake will automaticallyrelease when the accelerator pedalis depressed. If the main switch isin the “ON” position, depressingthe accelerator may suddenlycause the golf car to move. Deathor serious personal injury canresult from failing to comply withthe safety instructions in this manual.

CHOKE KNOBPull and hold out choke knob whenstarting a cold engine. Release theknob after the engine starts.

å Choke knob

FUEL SHUTOFF VALVEEnsure the fuel shutoff valve is in the “OPEN” position for normal operation.

å Fuel shutoff valve

Y-22a

C

Y-903

A

Counterclockwise/open

Clockwise/closed

A

Y-1572


CONTROLS

1

2

3

4

5

6

7

8

9

10

11

5-3 JW1

DRIVE SELECT LEVERThe drive select lever is used to shiftthe golf car into forward or reverse.After coming to a complete stop,move the lever to the desired position.

Lever Position Car Movement

F FORWARDR REVERSE

TIPThe back-up buzzer will beep whenthe drive select lever is turned to “R.”

ACCELERATOR PEDALThe accelerator pedal controls thegolf car’s speed.

Action Car SpeedDepress pedal IncreaseRelease pedal Decrease


BRAKE PEDALPress down on the brake pedal tostop the golf car.

∫ Brake pedal

Y-920

BEEP

Y-20A

A

Y-18

Y-21a

B


1

2

3

4

5

6

7

8

9

10

11

MAINTENANCE

8-4JW1

Spark Plug InspectionYou should periodically remove andinspect the spark plug. Dirty or worn spark plugs can cause poorperformance.

When removing or installing thespark plug, be careful not to damage the insulator. A damagedinsulator could allow externalsparks, which could lead toexplosion or fire. Death or seriouspersonal injury can result fromfailing to comply with the safetyinstructions in this manual.

å Spark plug∫ Spark plug cap1. Check for discoloration and

remove carbon deposits with aspark plug cleaner or wirebrush. The normal electrodecolor will be tan.

2. Check the spark plug type, andcheck the spark plug gap with afeeler gauge.

Standard spark plug: BPR2ES

Spark plug gap:0.7 ˜ 0.8 mm (0.028 ˜ 0.031 in.)

å Gap3. Clean the gasket and plug

surfaces and install the sparkplug finger-tight before tighteningto the following torque:

Spark plug torque:20 Nm, 2.0 m.kg(14.5 ft.lb)

Y-516A

B

A

Y-37


MAINTENANCE

1

2

3

4

5

6

7

8

9

10

11

8-5 JW1

Engine Oil Replacement1. Warm up the engine for several

minutes, place the golf car on alevel surface, then stop the engine.

Use caution not to touch hotengine oil or hot engine parts,during the following procedure.Death or serious personal injurycan result from failing to complywith the safety instructions in thismanual.

2. Place an oil pan under theengine drain plug.

3. Remove the oil drain plug and letthe oil drain completely.

TIPDispose of used oil in an environmentally safe way, such astaking oil to 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:31 Nm, 3.1 m.kg(23 ft.lb)

5. Add the correct quantity of oilthrough the oil filler hole.





Y-624


1

2

3

4

5

6

7

8

9

10

11

CONTROLS

5-2JW1

OFFON

Y-912b

OFFON

Y-913b

OFFON

Y-914

A

MAIN SWITCHThe main switch controls the following items:

OFFAll electrical circuits are switched off.The key can be removed only in thisposition.

ONElectrical circuits are switched on.The golf car can be driven.

OIL WARNING LIGHT When the engine oil level falls belowan acceptable level, this light comeson.

If the light comes on, stop theengine, check the engine oil leveland add oil as necessary. Enginedamage can result from lowengine oil levels. (See page 6-3).

å Oil warning light

NOTICE


CONTROLS

1

2

3

4

5

6

7

8

9

10

11

5-1 JW1

Y-91612

3

4

5

6

Y-903ab

8

Y-919

13

14

1718

15

16

Y-918ab12 11

10

9

7

FEATURES1 Brake pedal2 Parking brake pedal3 Accelerator pedal4 Steering wheel5 Oil warning light6 Main switch7 Drive select lever8 Choke knob9 Seata Front bodyb Front tirec Front bumperd Batterye Rear bodyf Fuel shutoff valveg Fuel cap h Rear tirei Rear bumper


1

2

3

4

5

6

7

8

9

10

11

MAINTENANCE

8-6JW1

Y-515

A

Y-518

A

A

A

B

Y-519a

C

D

å Oil filler hole

Use care not to fill past the MAXdipstick mark, and be sure no foreign material enters the crankcase. Serious engine damage can result.

After replacing engine oil, check foroil leaks around the drain plug. If oilleaks are found, consult a Yamahadealer.

Air FilterTo remove the air filter elements:

1. Unlatch the air filter cover clipsand remove cover.

å Air filter cover clips∫ Air filter cover

2. Lift the air filter and pre-filter outof the air filter case.

ç Air filter∂ Pre-filter

Be careful not to drop anythinginto the air inlet. Serious enginedamage can result.

NOTICE

NOTICE


MAINTENANCE

1

2

3

4

5

6

7

8

9

10

11

8-7 JW1

Y-60

BA

Y-508

Inspection and cleaning:

3. Wash the foam pre-filter in soapand water. Allow it to dry.

å Soap and water∫ Foam element

4. Check the filter element. If damaged or dirty, replace it.

Do not wring out the foam pre-filter, this could cause it totear.

5. To replace the elements,reverse the above steps.

The pre-filter has a notch on oneside. It will only fit in the case oneway. Serious engine damage canresult from an improperly posi-tioned filter.

Drive BeltTo remove the drive belt:

1. Set the drive select lever halfwaybetween forward and reverse.

2. Pull up on the drive belt andpush it outward over the edge ofthe secondary sheave.

3. Turn the secondary sheaveclockwise and the drive belt willroll off the sheave.

4. Remove the drive belt from theprimary sheave.

NOTICE

NOTICE


1

2

3

4

5

6

7

8

9

10

11

4-3JW1

SAFETY PRECAUTIONSDURING MAINTENANCEWhen performing maintenance, followall safety instructions contained in themanufacturer’s operation and servicemanuals, as well as the followingsafety procedures:l Properly immobilize golf car before

beginning any maintenance to avoidany unexpected vehicle movement.

l Properly block chassis before working underneath golf car to avoidany unexpected vehicle movement.

l Before disconnecting any part of thefuel system, drain the applicable partof the system to prevent fuel leaks.

l When working on the fuel system orthe battery, do not smoke, or allowany sparks or open flames near the vehicle, to avoid any fires orexplosions.

l Before performing any maintenance,disable the car’s electrical system inaccordance with the manufacturer’sinstructions.

l Use only properly insulated toolswhen working on electricallypowered golf cars or aroundbatteries to avoid electrical shock ordamage to the electrical system.

l Maintain all safety devices, includ-ing brakes, steering mechanisms,warning devices and governors, in asafe operating condition. Do notmodify these safety devices assupplied by the manufacturer.

l After each maintenance or repair,the car must be driven by aqualified, trained and authorizedperson – in an area free ofpedestrian traffic – to ensure properoperation and adjustment.

l Record all maintenance performedin a maintenance record log bydate, name of person performingmaintenance and type ofmaintenance. Periodically inspectmaintenance log to ensureaccurate and complete entries.

l Provide operator comment cardsto assist in identifying non-periodicmaintenance needs for specificgolf cars.

l Maintain in a legible condition allnameplates, warnings, andinstructions provided by the manufacturer.

l If new nameplates, warnings orinstructions are needed, contactyour Yamaha Golf-Car Companydealer.

FUEL HANDLING/STORAGE AND BATTERY CHARGINGTake the following precautions toensure maintenance worker safety:l Supervise the storage and

handling of liquid fuels in accordance with applicable fireand safety requirements to avoidany fires or explosions.

l Only use battery charging facilitiesand procedures that are in accordance with applicable ordinances and regulations toavoid explosions, electrical shockor damage to the electrical system.

l Periodically inspect fueling to becertain that applicable safetycodes, regulations and procedures are being followed toavoid any fires or explosions.



1

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3

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5

6

7

8

9

10

11

4-2 JW1

l Wet Areas. Wet grass may causea golf car to lose traction and mayaffect stability. Golf car operatorsshould reduce speed in wet areasor during periods of inclementweather.

l Loose Terrain. Loose terrain maycause a golf car to lose tractionand may affect stability. Repairloose terrain, chain or rope offthese areas, or identify loose terrain with a suitable warning.

l Golf Car and Pedestrian Interference. Reroute golf car traffic or pedestrian traffic in congested areas wherever possibleto prevent accidents. If it is impractical to reroute traffic, erectwarning signs to warn pedestriansof golf car traffic, and to warn golfcar operators to drive slowly, usecaution and watch for pedestrians.

MAINTENANCE REQUIRED FOR GOLFCAR SAFETYPractice the following to help ensurethe safety of golf car operators:

l Preventative Maintenance. Perform all scheduled maintenance in accordance withmanufacturer’s recommendationsto provide the golfing patron with asafe, properly operating golf car.

l Personnel. Allow only qualified,trained, and authorized personnelto inspect, adjust and maintain golfcars.

l Parts and Materials. Use onlyreplacement parts and materialsrecommended by the manufacturer.

l Ventilation. Properly ventilate allmaintenance and storage areas inaccordance with applicable firecodes and ordinances to avoid firehazards. Ventilation is required toremove flammable vapors andfumes from gasoline powered carstorage areas. Ventilation is alsorequired to remove hydrogen gasfrom the car storage areas duringthe battery charging process.



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MAINTENANCE

8-8JW1

Y-45

++

––

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Y-44

Inspection:To inspect the drive belt, check forfrayed edges or tears, and measuredrive belt against the following specification. If the belt showsexcessive wear or damage, replacethe belt with a new one.å New: 29.5 mm (1.16 in.)∫ Replace when belt reaches:

27.7 mm (1.09 in.)5. To install the drive belt, reverse

the above steps, rolling the beltback over the secondary sheave.

BatteryThe 12-volt battery that providesstarting power to your gas car normally does not require the addition of water. If the battery losesits charge, have an experiencedmechanic charge it.

Battery electrolyte is poisonous anddangerous, causing severe burns,etc. It contains sulfuric acid. Avoidcontact with skin, eyes, or clothing.Antidote:EXTERNAL: Flush with water. INTERNAL: Drink large quantities ofwater or milk. Follow with milk ofmagnesia, beaten egg, or vegetable oil. Call physician imme-diately.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 inenclosed space. Always shield eyeswhen working near batteries.KEEP OUT OF REACH OF CHILDREN.


MAINTENANCE

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8-9 JW1

Y-523aAB

Fuse Replacement

Be sure to use the specified fuse.Using a wrong fuse can causeelectrical system damage and create a fire hazard. Death or serious personal injury can resultfrom failing to comply with thesafety instructions in thismanual.

When replacing a fuse, be sure the main switch is turned off toprevent accidental short-circuitingand electrical system damage.

1. Locate the in-line fuse holder onthe main wire harness adjacent tothe battery.

2. Pull fuse holder cover off.

3. Pull fuse out, inspect and replaceif necessary.

å Fuse holder∫ Fuse

Fuse Type:10 Amp, Blade Style

NOTICE


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Like all machines, golf cars cancause injury if improperly used ormaintained. This section containsbroad safety practices required forsafe golf car operation. Before golfcars are operated, golf course personnel should establish any additional safety practices that maybe required for safe operation.

Experience has shown that golf cars are safe when operated inaccordance with the safety warningsaffixed to every golf car. This safeoperation is enhanced when golfcars are used according to the safetyrules and practices established tomeet the terrain and conditions ofthe course they are used on.

The information contained here isintended for golf course personnelresponsible for golf car safety. If youare responsible for the operationand maintenance of this golf car, weencourage you to implement thisgolf car safety program.

DRIVER QUALIFICATIONSAllow only authorized people tooperate golf cars. It is recommendedthat only people who possess avalid motor vehicle driver’s licensebe allowed to operate golf cars.

Place operation and safety instructions recommended by thegolf car manufacturer, along with the golf course safety rules, in aconspicuous place near the golf carrental area or golf car pick-up area.It is also recommended that the following warning be posted in aconspicuous location:

Do not operate golf cars whenunder the influence of alcohol ordrugs. Death or serious personalinjury can result from failing tocomply with the safety instruc-tions in this manual.

GOLF COURSE SAFETYSURVEYPerform safety surveys regularly toidentify hazardous areas where golfcars should not be operated.

GOLF COURSE HAZARDPREVENTIONThe following golf course hazardsmust be made safe:

l Steep Grades. Where steepgrades exist, restrict golf cars todesignated golf car pathwayswhere possible. In addition, identify steep grades with a suitable warning like:

Descend steep grades slowly withfoot on brake. Death or seriouspersonal injury can result fromfailing to comply with the safetyinstructions in this manual.

l Sharp Turns, Blind Corners,Bridge Approaches. Chain orrope off these potentially hazardous areas or identify themwith a suitable warning describingthe nature of the hazard and theproper precautions to be taken toavoid the hazard.



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l Use extra care in congested areasor when backing up. Always backup slowly, and watch carefully.

l Avoid starting or stopping abruptly.

l Vary the speed of the golf car tomatch the terrain of the course.

l Avoid turning the steering wheeltoo sharply at higher speeds toavoid tipping or rolling the golf car.

l Always drive slowly straight up orstraight down slopes – never at anangle to avoid tipping or rolling thegolf car.

l Do not run the engine indoors.Exhaust gas is poisonous andcould result in carbon monoxidepoisoning.

l Do not make any modification oraddition which affects capacity orsafe operation, or make anychanges not in accordance withthe owner’s/operator’s manual.

Y-921

Y-922

Y-923

OPERATOR SAFETY!


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MAINTENANCE

8-10JW1

Transaxle OilTo check transaxle oil level:1. Place the golf car on a flat, level

surface.

2. Remove seven plastic rivets 1and two bolts 2, and remove thebag holder insert.

3. Place an oil pan under thetransaxle case.

4. Clean area around servicing plug 4.

5. Using an 8 mm hex wrench,remove transaxle oil servicingplug located on the rear of thetransaxle case.

6. Transaxle oil should be at the topof the oil servicing hole or justbeginning to run out of hole.

Do not allow foreign material toenter transaxle. Serious transaxledamage can result.

7. If needed, add Yamalube ShaftDrive Gear Oil until it is at the topof the plug hole or just beginningto run out of servicing hole.

TIPThe YDRA Golf Car is equipped withan internal wet brake. Use of oil otherthan Yamalube Shaft Drive Gear Oilwill cause brake noise.

8. Install the transaxle servicingplug and tighten to 14-19 Nm,1.4-1.9 m•kg (120-168 in•lb).

9. Install the bag holder insert 3and secure with two bolts 2 andseven plastic rivets 1.

NOTICE

Y-1215

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MAINTENANCE

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Y-57

TIPFor transaxle oil replacement, con-sult a Yamaha dealer or other quali-fied mechanic.

Before performing wheel or brakemaintenance, verify that the mainswitch is in the “OFF” position.Serious transaxle damage can result.

Wheel ReplacementTo remove and install a wheel onyour golf car:

1. With the wheels blocked to prevent the golf car from moving,loosen the wheel nuts.

2. Elevate the golf car with a jackand remove the wheel nuts andthe wheel.

3. Reverse the removal steps wheninstalling the wheel.

Wheel nut tightening torque:80 Nm, 8.0 m.kg (58 ft.lb)

Brake Adjustment The brakes on your golf car are self-adjusting.

Before you operate the car, pressdown on the brake pedal severaltimes to make sure the brakes arefunctioning properly.

Consult your Yamaha dealer beforeusing your golf car if you suspectbrake problems. Death or seriouspersonal injury can result from fail-ing to comply with the safetyinstructions in this manual.

NOTICE


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Y-928

Y-68

Yamaha golf cars are designed to besimple to operate. However, be sureto observe the following to reducethe risk of serious injury or death dueto loss of control and other hazards:

BEFORE OPERATINGTHE GOLF CARl Read this Owner’s/Operator’s

manual and all safety and instructionlabels on the golf car before operating.

l Perform the pre-operation checksfound in Section 6 of this manual.

l Only authorized people shoulddrive the golf car, from the driver’sside only, and only in designatedareas.

l Do not allow more than two occupants per seat. This golf car isrestricted to two occupants unlessequipped with a rear seat.

l Do not operate the golf car whileunder the influence of alcohol ordrugs; their effect on vision andjudgment make operating a golfcar dangerous.

l Do not operate the golf car on public streets, roads or highwaysunless allowed by law or local regulating authority.

WHILE OPERATING THEGOLF CARl Keep your entire body inside the

golf car, remain seated and holdon when the car is in motion.

l Do not start the golf car until alloccupants are seated.

l Keep your hands on the steeringwheel and your eyes on the pathahead.

OPERATOR SAFETY!


IMPORTANT LABELS

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2-4 JW1

Y-851B

GOLF CAR SERIALNUMBERThe golf car serial number 1 isidentified in the location shown.

TIPThe first three digits of the serialnumber are for model identification;the remaining digits are the unit production number. Keep a record of these numbers for reference when ordering parts from a YamahaGolf-Car Company dealer.

The engine serial number 2 isaffixed in the location shown.

Y-852A

3 Engine Information

Y-1539

JWX

-000

000

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II IIIII

IIIIIII

IIIIII

SM-03-399


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MAINTENANCE

8-12JW1

Brake Pedal Free PlayAdjustment

Before adjusting brake pedal freeplay, pump the brake pedal severaltimes to self-adjust the brakes.

To adjust the brake pedal free play:

1. Remove the floor mat and service lid from the floor of thegolf car.

2. Check the brake pedal free playby pressing against the pedalwith two fingers (using lightforce) and measuring the distance the pedal travels beforeresistance is felt.

Brake pedal free play Å:45-50 mm (1.77-1.96 in.)

3. If the free play distance needsadjusting, loosen the lock nut åand turn the adjusting nut ∫ in or out until the free play specification is met. Then tightenthe lock nut in place.

Do not over-tighten the brakecables. Over-tightening willincrease brake wear and affectoverall performance of car.Premature brake wear can result.

NOTICE

NOTICE

Y-61c

Y-909A

A B

Y-62b

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1615

1413

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STORAGE

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1. Fill the fuel tank with fresh fueland add the specified amount ofYamaha Fuel Stabilizer andConditioner or equivalentproduct. Operate the vehicle for at least five minutes to distributetreated fuel through the fuel system.

å Float bowl drain screw

2. Turn the fuel shutoff valve to the“CLOSED” position.

3. Drain the carburetor floatchamber into a clean container byloosening the drain bolt; this willhelp prevent fuel deposits frombuilding up. Pour the drained fuelinto the fuel tank.

Specified amount:

7.5 cc of stabilizer for each liter offuel (1 oz. of stabilizer for each gallon of fuel)

TIPUse of fuel stabilizer and conditionereliminates the need to drain the fuelsystem. Consult a Yamaha dealer ifthe fuel system needs to be drainedinstead.

Y-521

A

Perform the following preparationswhen storing your golf car forextended periods of time:

TIPTurn main switch key to “OFF”position, remove key, and store keyin a safe place.

DRAINING FUEL

Gasoline and its vapors are highlyflammable and explosive. Deathor serious personal injury canresult from failing to comply withthe safety instructions in thismanual.l Do not smoke when draining

fuel and keep away from sparks,flames, or other sources ofignition.

l Stop engine and allow it to coolfor several minutes beforedraining fuel.

l Drain fuel in a well-ventilatedarea.

l Take care not to spill gasoline. If gasoline spills, wipe it upimmediately with dry rags.Always dispose of gasoline-soaked rags properly.

l Tighten the filler cap securelyafter checking fuel level toavoid leaking.

l If you inhale a lot of gasolinevapor, or get gasoline in youreyes, get immediate medicalattention.

l If any gasoline gets on yourskin, immediately wash withsoap and water. Changeclothing if gasoline spills on itto avoid potential fire hazard.


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IMPORTANT LABELS

2-3JW1

WARNINGAVERTISSEMENT

Do not tamperwith governorto increasespeed. Operationat higher speedscan cause lossof control thatcan result insevere injury ordeath.

Ne pas toucher aurégulateur afind’augmenter lavitesse. Unfonctionnementà des vitessessupérieures auréglage initialpeut causer uneperte de contrôlequi peut menerà une blessuregrave, voirefatale.

YAMAHA JN3-K8299-10

Y-764a

4

Important Emissions InformationYamaha Golf-Car Company

THIS EQUIPMENT CONFORMS TO 2008 CALIFORNIA EVP REGULATIONS FOR SMALL OFF-ROAD ENGINES UNDER 13CCR SECTION 2766(D). THIS ENGINE MEETS 2008 CALIFORNIAEXH EMISSION REGULATIONS AND CONFORMS TO PHASE 2 U.S. EPA REGULATIONS FORSMALL OFF-ROAD ENGINES. EMISSIONS COMPLIANCE PERIOD: CATEGORY A (EPA)EF: SYMXS 3572EBDCM: Jan 2008THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE

DISPLACMENT: 357ccEMISSION CONTROL SYSTEM: EMEVAPORATIVE CODE: COYMX34A

MAINTENANCE SPECIFICATIONS ENGINE OIL: SAE 10W40IGNITION TIMING: 27 BTDC SPARK PLUG GAP: .028-031NO OTHER ADJUSTMENTS NEEDED

The air index of this engine is 3

0 2 4 6 8 10Most Clean Least CleanNote: The lower the Air Index, the less PollutionThis engine is certified to be emissions compliant for the following use:

[ ] Moderate (125 hours) [ ] Intermediate (250 hours) [ X ] Extended (1000 hours) Check owner’s manual for further details.

Y-1599

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IMPORTANT LABELS

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GASO

LINE

IS H

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JW1-

K829

7-01

JW1-

K829

7-01

Y-16

69a

2 3


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9-2JW1

ENGINE PREPARATION With the key removed and the sparkplug lead disconnected, turn theclutch by hand until compression isfelt. This puts the valves in theclosed position.

CHASSIS PREPARATION1. Verify the tire pressure is set to

110 kPa, 1.1 kgf/cm2 (16 psi).

2. Clean exterior of the golf car andapply a rust inhibitor.

3. Cover the golf car with a breathable cover and store it in adry, well-ventilated area.

BATTERY PREPARATION1. Remove the battery from the golf

car and store it in a cool, dryplace that stays between 0°C(32°F) and 30°C (90°F).

2. Have the battery rechargedevery 60-90 days to keep it fullycharged. The battery must bekept fully charged to avoid damage.

3. Batteries like the one suppliedwith your car normally do notrequire you to check the waterlevel inside the battery for theone-year warranty period provid-ed by the manufacturer.

Do not allow cleaning solution toenter battery cells. Serious bat-tery damage can result.

4. Clean the top of the battery witha solution of baking soda andwater, as necessary, to removecorrosion.

NOTICE


SPECIFICATIONS

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GENERAL SPECIFICATIONSItems YDRA

Dimensions:Overall length 2395 mm (94.3 in.)Overall width 1200 mm (47.2 in.)Overall height (steering height) 1190 mm (46.9 in.)Height of floor 310 mm (12.2 in.)Wheelbase 1640 mm (64.6 in.)Tread:

Front 870 mm (34.3 in.)Rear 980 mm (38.6 in.)

Minimum ground clearance 110 mm (4.3 in.)

Weight:Dry weight (without battery) 255 kg (562 lb)

Vibration Level:Vibration on seat (EN 1032,ISO5008) for Europe Will not exceed 0.5 m/s2

Vibration on steering wheel(EN1032, ISO5008) (for Europe) Will not exceed 2.5 m/s2

Performance:Factory speed setting 19 km/h (12 mph)Maximum speed 24 km/h (15 mph)Minimum turning radius 2.8 m (9.2 ft)Seating capacity Two occupants per seat,

four occupants maximum

Fuel Tank Capacity 25.0 L (6.6 U.S. Gallons)

PAINT CODESOEM Code Name Ditzler NumberSPU60185 Glacier 918519W44145 Emerald 48748W49874 Garnet 701739AH2039 Onyx Metallic 918520AH5068 Cobalt Metallic 918521AH5080 Anthracite Metallic 918522AH9064 Sandstone Metallic 918523


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2-1JW1

Y-924

4 3

1

5

2

SAFETY AND INSTRUCTION LABELS

Read the following labels carefully before operating your golf car, andpromptly replace any labels which become damaged or removed. Death orserious personal injury can result from failing to read and comply withthe safety labels in this manual.

Y-500a

1


WARRANTY

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8. Throughout the SORE vehicle warranty periodstated above, Yamaha Golf-Car Company willmaintain a supply of warranted parts sufficient tomeet the expected demand for such parts.

9. Any replacement part may be used in the perfor-mance of any warranty maintenance or repairs andmust be provided without charge to the owner.Such use will not reduce the warranty obligationsof Yamaha Golf-Car Company.

10. Add-on or modified parts that are not exempted bythe Air Resources Board may not be used. Theuse of any non-exempted add-on or modified partsby the ultimate purchaser will be grounds for disal-lowing a warranty claims. Yamaha Golf-CarCompany will not be liable to warrant failures ofwarranted parts caused by the use of a non-exempted add-on or modified part.

WARRANTED PARTS:The repair or replacement of any warranted part other-wise eligible for warranty coverage may be excludedfrom such warranty coverage if Yamaha Golf-CarCompany demonstrates that the SORE vehicle hasbeen abused, neglected, or improperly maintained, andthat such abuse, neglect, or improper maintenance wasthe direct cause of the need for repair or replacementof the part. That notwithstanding, any adjustment of acomponent that has a factory installed, and properlyoperating, adjustment limiting device is still eligible forwarranty coverage. The following emission warrantyparts are covered:

1. Fuel Tank2. Fuel Cap3. Fuel Line4. Fuel Line Fittings5. Clamps6. Control Valves7. Control Solenoids8. Electronic Controls9. Control Cables10. Control Linkages


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SPECIFICATIONS

10-2JW1

ENGINEItems YDRA

Description:Engine type 4-stroke, Gasoline, 60˚ incline OHVNumber of cylinders SingleDisplacement 357 cm3

Bore x stroke 85 x 63 mm (3.30 x 2.48 in.)Compression ratio 8.1:1Rated output 8.5 kw (11.4 hp)/3500 rpmCooling system Forced air-cooledStarting system StarterIgnition system TCI MagnetoSpark plug type BPR2ESSpark plug gap 0.7-0.8 mm (0.028-0.031 in.)Lubrication system Splash-style positive oil lubricationEngine oil type YAMALUBE 10W40 4-cycle oilEngine oil capacity 1.0 L, 1000 cc (1.0 US qt)Oil change quantity 1.0 L, 1000 cc (1.0 US qt)

TRANSMISSIONItems YDRA

Transmission:Type V-belt automatic centrifugal engagementV-belt width and outer line length 29.5 x 1010 mm (1.16 x 39.76 in.)V-belt wear limit 27.7 mm (1.09 in.)

Governor:Type Oil bath flyweightFactory speed setting 19 km/h (12 mph)

Differential/reduction gear:Differential type Bevel gearLubricant/capacity Yamalube Shaft Drive Gear Oil/

1750 mL, 1750 cc (1.85 US quarts)


SPECIFICATIONS

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BATTERIESItems YDRA

Battery: BCI group 24,RC: minimum 75 minCCA: minimum 400A

CHASSISItems YDRA

Steering system:Type Rack and PinionSteering angle (L.H.) 1.85 turnSteering angle (R.H.) 1.85 turn

Brakes:Brake system MechanicalType of brake Maintenance-Free internal transaxle disc brakeBrake pedal free play linkageadjustment 45-50 mm

(1.77-1.96 in.)(Brake cable end play) 0.1-0.5 mm (0.004-0.02 in.)Parking brake:

Type Foot type; parking brake with automaticrelease.

Release timing(With pedal segment in secondnotch)(Bolt heads round parallel to arm) 0.0 ~ 0.3 mm (0.000 ~ 0.001 in.)Wheel:

Tire size:Front 18 x 8.50–8.00/4 PRRear 18 x 8.50–8.00/4 PRRim size: 7.00–I–8.00Tire pressure: 110 kPa, 1.1 kgf/cm2 (16 psi)


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1-2JW1

WARRANTY

The California Air Resources Board and YamahaGolf-Car Company are pleased to explain the emis-sions control system warranty on your 2008 small off-road engine (SORE) vehicle. In California, newSORE vehicles must be designed, built and equippedto meet the State’s stringent anti-smog standards.Yamaha Golf-Car Company must warrant the EECSon your SORE vehicle for the period of time listedbelow provided there has been no abuse, neglect orimproper maintenance of your SORE vehicle.

Your EECS may include parts such as the carburetor,fuel-injection system, the ignition system, catalyticconverter, fuel tanks, fuel lines, fuel caps, valves,canisters, filters, vapor hoses, clamps, connectors,and other associated emission-related components.

Where a warrantable condition exists, Yamaha Golf-Car Company will repair your SORE vehicle at nocost to you including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE:This emissions control system is warranted for twoyears. If any emission-related part on your equip-ment is defective, the part will be repaired orreplaced by Yamaha Golf-Car Company.

OWNER’S WARRANTY RESPONSIBILITIES:As the SORE vehicle owner, you are responsible forperformance of the required maintenance listed in yourowner’s manual. Yamaha Golf-Car Company recom-mends that you retain all receipts covering mainte-nance on your SORE vehicle, but Yamaha Golf-CarCompany cannot deny warranty solely for the lack ofreceipts.

As the SORE vehicle owner, you should however beaware that Yamaha Golf-Car Company may deny youwarranty coverage if your SORE vehicle or a part hasfailed due to abuse, neglect, or improper maintenanceor unapproved modifications.

You are responsible for presenting your SORE vehicleto Yamaha Golf-Car Company’s distribution center orservice center as soon as the problem exists. The war-ranty repairs should be completed in a reasonableamount of time, not to exceed 30 days. If you have aquestion regarding your warranty coverage, you shouldcontact YGC Service at 1-866-747-4027.

GENERAL EMISSIONS WARRANTY COVERAGE:Yamaha Golf-Car Company warrants to the ultimatepurchaser and each subsequent purchaser that theSORE vehicle is:

Designed, built and equipped so as to conform with allapplicable regulations; and

Free from defects in materials and workmanship thatcause the failure of a warranted part to be identical inall material respects to that part as described inYamaha Golf-Car Company’s application for certifica-tion.

The warranty period begins on the date the SOREvehicle is delivered to an ultimate purchaser or firstplaced into service. The warranty period is two years.

Subject to certain conditions and exclusions as statedbelow, the warranty on emission-related parts is as fol-lows:

1. Any warranted part that is not scheduled forreplacement as required maintenance in the writ-ten instructions supplied, is warranted for the war-ranty period stated above. If the part fails duringthe period of warranty coverage, the part will berepaired or replaced by Yamaha Golf-CarCompany according to subsection (4) below. Anysuch part repaired or replaced under warranty willbe warranted for the remainder of the period.

2. Any warranted part that is scheduled only for regu-lar inspection in the written instructions supplied iswarranted for the warranty period stated above.Any such part repaired or replaced under warrantywill be warranted for the remaining warranty period.

3. Any warranted part that is scheduled for replace-ment as required maintenance in the writteninstructions supplied is warranted for the period oftime before the first scheduled replacement datefor that part. If the part fails before the first sched-uled replacement, the part will be repaired orreplaced by Yamaha Golf-Car Company accordingto subsection (4) below. Any such part repaired orreplaced under warranty will be warranted for theremainder of the period prior to the first scheduledreplacement point for the part.

4. Repair or replacement of any warranted part underthe warranty provisions herein must be performedat a warranty station at no charge to the owner.

5. Notwithstanding the provisions herein, warrantyservices or repairs will be provided at all of our dis-tribution centers that are franchised to service thesubject engines or equipment.

6. The SORE vehicle owner will not be charged fordiagnostic labor that is directly associated withdiagnosis of a defective, emission-related warrant-ed part, provided that such diagnostic work is per-formed at a warranty station.

7. Yamaha Golf-Car Company is liable for damagesto other engine or equipment components proxi-mately caused by a failure under warranty of anywarranted part.

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS


WARRANTY

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Yamaha Golf-Car Company hereby warrants that anynew YDRA gas or YDRE electric Yamaha golf carpurchased from an authorized Yamaha golf car deal-er in the United States will be free from defects inmaterial and workmanship for FOUR years from dateof purchase, subject to the stated limitations.

DURING THE PERIOD OF WARRANTY any autho-rized Yamaha golf car dealer will, free of charge,repair or replace, at Yamaha’s option, any partadjudged defective by Yamaha due to faulty work-manship or material from the factory. Parts used inwarranty repairs will be warranted for the balance ofthe vehicle’s warranty period. All parts replacedunder warranty become property of Yamaha Golf-CarCompany.

GENERAL EXCLUSIONS from this warranty shallinclude any failures caused by:

a. Abnormal strain, neglect, or abuse, includinglack of proper maintenance, and use contraryto the Owner’s/Operator’s Manual instructions.

b. Accident or collision damage.c. Installation of parts or accessories that are not

original equipment.d. Fading, rust, or deterioration due to exposure

or ordinary wear and tear.e. Modifications or alterations that affect the car’s

condition, operation, performance, or durability,or which makes the car serve a purpose otherthan use as a two-person, golf course vehicle.

f. Damage due to improper transportation.g. Acts of God, i.e. lightning, hail damage,

flooding, fire, etc.

WARRANTY COVERAGE:Year 1: The first year of warranty shall cover the entire

vehicle except for the Specific Exclusionsbelow.

Year 2: The second year exclusions are the YDRAbattery, body parts, seats, mats, bumperassembly, bag carrier, scorecard holder, trim,and the Specific Exclusions below.

Year 3: The third year exclusions include the secondyear exclusions, plus the control cables andelectrical system (except electronic speedcontroller, battery charger, and electric motor),and the Specific Exclusions below.

Year 4: The fourth year of the warranty covers onlythe electric motor, speed controller, batterycharger, and transaxle on the YDRE and theengine, clutch system (except drive belt), andtransaxle on the YDRA.

SPECIFIC EXCLUSIONS: Specific exclusions fromthis warranty shall include the following:

• Any parts replaced due to normal wear or routine maintenance, including oil and air filterelements, tire wear, spark plugs, starter andclutch drive belts.

• Any charges incurred in transporting a golf caror charger to and from an authorized Yamahagolf car dealer for service or in performing fieldservice are also excluded from this warranty.

• Gasoline powered golf car starting batteries on vehicles equipped with a golf course GPSdevice, or any other device with a high parasitic current draw, unless the vehicle isequipped with an optional factory installeddeep cycle starting battery.

THE CUSTOMER’S RESPONSIBILITY under thiswarranty shall be to:1. Operate and maintain the golf car and charger as

specified in the appropriate Owner’s/Operator’sManual;

2. Give notice to an authorized Yamaha golf car dealer of any and all apparent defects within ten(10) days after discovery, and make the vehicle orcharger available at that time for inspection andrepairs by the dealer’s authorized representative.

WARRANTY TRANSFER: Any transfer of warrantymust take place within the first three years of theoriginal in-service date of the vehicle. The vehiclemust be re-registered by an authorized Yamaha Golf-Car Dealer within 30 days of transfer. A fee may becharged for the transfer of the warranty.

YAMAHA GOLF-CAR COMPANY MAKES NOOTHER WARRANTY OF ANY KIND, EXPRESSEDOR IMPLIED. ALL IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE WHICH EXCEED THEOBLIGATIONS AND TIME LIMITS STATED IN THISWARRANTY ARE HEREBY DISCLAIMED BYYAMAHA GOLF-CAR COMPANY AND EXCLUDEDFROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG IMPLIED WARRANTY LASTS, SOTHE ABOVE LIMITATION MAY NOT APPLY TOYOU. ALSO EXCLUDED FROM THIS WARRANTYIS ANY INCIDENTAL OR CONSEQUENTIAL DAM-AGES INCLUDING LOSS OF USE. SOME STATESDO NOT ALLOW THE EXCLUSION OR LIMITA-TION OF INCIDENTAL OR CONSEQUENTIALDAMAGES, SO THE ABOVE EXCLUSION MAYNOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGALRIGHTS, AND YOU MAY ALSO HAVE OTHERRIGHTS, WHICH VARY, FROM STATE TO STATE.

Yamaha Golf-Car Company, NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 6/1/09 LIT-13710-01-10

LIMITED 4-YEAR GOLF CAR LIMITED WARRANTY


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WIRING

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YDRA WIRING DIAGRAM

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NOTES


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WARRANTY

CONTENTS

IMPORTANT LABELS

SAFETY CONSIDERATIONS

MAINTENANCE

STORAGE

SPECIFICATIONS

WIRING

OPERATION


CONTROLS

OPERATOR SAFETY

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INTRODUCTIONCongratulations on your purchase of aYamaha golf car. This manual containsinformation you will need for proper operation, maintenance, and care of yourgolf car. A thorough understanding ofthese simple instructions will help you toobtain maximum enjoyment from yournew Yamaha.

If you have any questions about the operation or maintenance of your golfcar, please consult a Yamaha dealer.

YAMAHA GOLF-CAR COMPANY

YDRA OWNER’S/OPERATOR’SMANUAL

© 2009 by Yamaha Golf-Car Company3rd Edition

All rights reserved. Any reprintingor unauthorized use without the

written permission ofYamaha Golf-Car Company

is expressly prohibited.Printed in U.S.A.LIT-19626-11-09

iJW1


Documents

4 STROKE GOLF CAR - · PDF fileLI T -19626-11-09 JW1-F8199-12 YAMAHA GOLF-CAR COMPANY 1000 HWY 34 East Newnan, GA 30265 770-254-4000 Printed in U .S. A 2009-KCC 4 STROKE GOLF CAR