Yamaha Golf Cart

Yamaha Golf Cart
RIC
@VAMAHA EPS,
PURCHASE O
a JA O, Clio
GOLF CAR G22A
LIT-19626-16-05 JUQO-F8199-13
The engine exhaust from this product
contains chemicals known to the
State of California to cause cancer, birth
defects or other reproductive harm.
YAMAHA LIT-CALIF-65-01
G22A
INTRODUCTION
Congratulations on your purchase of a
Yamaha golf car. This manual contains
information you will need for proper
operation, maintenance, and care of your
golf car. A thorough understanding of
these simple instructions will help you to
obtain maximum enjoyment from your
new Yamaha.
If you have any questions about the
operation or maintenance of your golf car,
please consult a Yamaha dealer.
YAMAHA GOLF-CAR COMPANY
G22A OWNER'S/OPERATOR'S
MANUAL
© 2006 by Yamaha Golf-Car Company
1st Edition
All rights reserved. Any reprinting
or unauthorized use without the
written permission of
Yamaha Golf-Car Company
is expressly prohibited.
Printed in U.S.A.
LIT-19626-16-05
IMPORTANT MANUAL
INFORMATION
Particularly important information is
distinguished in this manual by the
following notations:
The Safety Alert Symbol means
ATTENTION! BE ALERT! YOUR
SAFETY IS INVOLVED!
LA WARNING,
Failure to follow WARNING instruc-
tions could result in severe injury
or death to the golf car
occupants, a bystander, or a
person inspecting or repairing
the golf car.
NOTE:
e Yamaha continually seeks ad-
vancements in product design and
quality; therefore, while this manual
contains the most current product
information available at the time of
printing, there may be minor
discrepancies between your golf
car and this manual. If you
have any questions concerning this
manual, please consult your
Yamaha dealer.
e This manual should be considered
a permanent part of your golf car
and should remain with the car
when resold.
AUTIO!
This message describes special
precautions that must be taken to
avoid damage to the golf car.
NOTE:
This message provides additional key
information.
4 WARNING,
Read and understand this manual
completely before operating your
golf car.
G22A
CONTENTS|
WARRANTY
IMPORTANT LABELS
OPERATOR SAFETY
MAINTENANCE SAFETY PROGRAM
CONTROLS
PRE-OPERATION CHECKS
OPERATION
MAINTENANCE
STORAGE
—.
SPECIFICATIONS 0
WIRING
G22A ii
| WARRANTY
Lo
YAMAHA GOLF-CAR COMPANY
LIMITED 3-YEAR
GOLF CAR WARRANTY
Yamaha Golf-Car Company hereby warrants that
any new G22A gas or G22E electric Yamaha golf
car purchased from an authorized Yamaha golf car
dealer in the United States will be free from defects
in material and workmanship for THREE years from
date of purchase, subject to the stated limitations.
DURING THE PERIOD OF WARRANTY any
authorized Yamaha golf car dealer will, free of
charge, repair or replace, at Yamaha's option, any
part adjudged defective by Yamaha due to faulty
workmanship or material from the factory. Parts
used in warranty repairs will be warranted for the
balance of the machine's warranty period. All parts
replaced under warranty become property of
Yamaha Golf-Car Company.
GENERAL EXCLUSIONS from this warranty shall
include any failures caused by:
a. Abnormal strain, neglect, or abuse, including
lack of proper maintenance, and use contrary
to the Owner's/Operator's Manual instructions.
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 other than use as a two-person, golf
course vehicle.
Damage due to improper transportation.
g. Acts of God, i.e. lightning, hail damage,
flooding, fire, etc.
5
™h
SPECIFIC EXCLUSIONS: The first year of warranty
shall cover the entire car except for the specific
exclusions below. Parts excluded from the second
year of warranty include the body parts, seats,
mats, bumper assembly, bag carrier, scorecard
holder, and the trim. Parts excluded from the third
year of warranty include the second year exclusions
and the electrical system (except electronic speed
controller and electric motor), and control cables.
Other specific exclusions from this warranty shall
include any parts replaced due to normal wear or
routine maintenance, including oil and air filter
elements, tires, brake shoes, spark plugs, starter
and clutch drive belts. Any charges incurred in
transporting a golf car or charger to and from an
authorized Yamaha golf car dealer for service or in
performing field service is also excluded from this
warranty.
1-1
THE CUSTOMER'S RESPONSIBILITY under this
warranty shall be to:
1. Operate and maintain the golf and charger as
specified in the appropriate Owner's/Operator's
Manual;
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 machine or
charger available at that time for inspection and
repairs by the dealer's authorized representative.
WARRANTY TRANSFER: To transfer any
remaining warranty from the original purchaser to
any subsequent purchaser, it is imperative that the
machine be inspected and registered for warranty
by an authorized Yamaha golf car dealer. In order
for this warranty to remain in effect, this inspection
and registration must take place within ten (10) days
after transfer. An inspection and registration fee will
be charged for this servico.
YAMAHA GOLF-CAR COMPANY MAKES NO
OTHER WARRANTY OF ANY KIND, EXPRESSED
OR IMPLIED. ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE WHICH EXCEED THE
OBLIGATIONS AND TIME LIMITS STATED IN
THIS WARRANTY ARE HEREBY DISCLAIMED
BY YAMAHA GOLF-CAR COMPANY AND
EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS
ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION MAY NOT
APPLY TO YOU. ALSO EXCLUDED FROM THIS
WARRANTY ARE ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES INCLUDING LOSS
OF USE. SOME STATES DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL
OR CONSEQUENTIAL DAMAGES, SO THE
ABOVE EXCLUSION MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER
RIGHTS, WHICH VARY, FROM STATE TO
STATE.
Yamaha Golf-Car Company,
NEWNAN, GEORGIA 30265-1320
EFFECTIVE DATE: 01/01/06
LIT-13710-03-06
G22A
IMPORTANT LABELS |
/N SAFETY AND
INSTRUCTION |
LABELS
! €
Please read the following
labels carefully before
operating your golf car,
and promptly replace any
labels which become dam-
aged or removed.
TY
OPERATING INSTRUCTIONS
M Read the warning fobel on the bevercge holder pone! before operating, WARNING
TE A lie iy
Mer 0 AVERTISSEMENT
start. nd, (26 parking Brake
= Toa polenta clima! sega rater fecajerator но р Menor au
edal ond press the brake peda Do not tamper d'ou = a +
» Never travel el as > EN for the terroin, visibitity with governor augmenter la
conditions, or your e vitesse. Un
w Drive with extra caution *in n ¿mperted orecs, when operating in to increase fonctionnement
Ы operas, ow e ma [pees OM A late à surfaces. spoed. Operation à des vitesses
m Press the parking broke pedal until it locks, and turn the moin at higher speeds supérieures au
switch + ; leaving the vehicie. can cause loss р
w Recd the Omer 's/Operator‘s Manval for mors information, of control that réglage initial
m This vehicle was not manufactured for use on public streets ond can result in Porto de contróle
does not comply with Teo mat vehicle "safety standards severe injury or P i t
cpplicable En passenger c death. qui paut mener
(YAMAHA JUO-K7762-00 § Uo blassure
Y
Y-500 A YAMAHA tale. ry,
A WARNING
DEATH OR SEVERE PERSONAL INJURY CAN RESULT EQOM FAILURE TO FOLLOW THESE INSTRUCTIONS.
= Head Operating Instructions on steenng wheel 8 Operate from driver's se only,
bafore operation, # Do not allow more thar twa occupants per seah
= SA ite only wne OF La Bo not start venicie until all LA AL pe eated.
crizett and o La] main Seated n La E.
a e rer cad de = rie He) pr body imside A ic Hk
m Drive slowly in tur
uw Drive slowly Straight up and down slope
E Set parking brake before leaving TN
® Turn main switch to OFF and remove key a not in us
er CT TNA influence ot al cohol Ku E
Y-656
f 9
® USE REGULAR — UTILISER
WARNING/AVERTISSEMENT | смелое UNIQUEMENT
GASOLINE DE L'ESSENCE
a @anolins is 5 ueno = aù - ONLY SANS PLOMB
extrema extrimaman eemable, я
flammable. 2 Qarder átincallas, Nammas Motor if Pour l'huitæ du
» Keep heat, sparks ot chaleur loin du ; Raguirements: moieur, II faul;
yo NETO réé@rvoir coeur a
h away fr m fuel das tuyaux à carburant. > Use only SAE be rp
tank and Fuel nes. ne pas ajouter d'essence Murat SE SAE 1OW-30
À 4 = Do nat add {ual esidant que la moteur SE, ar amvico SE:
while engine is est an ri S ou quand le » Maintain ой = Garder le niveau :
winning os hot. moteur ent ©
a Do noi mod fuel = Ne pas me modifier le lu système dipstick "MIN" ire er Je
system, я " Е
should be performed révision Di dire faite oe AMADO mes. MAKE Snes
by dasiar ar chez le fournisseur ou ue ME \
qualifiad pacsonnel. — par de pérsoneel qualifié. eau hulle.
YAMAHA IMNENSEIT-10 /
Y-767
G22A 2. 1
| IMPORTANT LABELS |
ВМ-03-399
te]
GOLF CAR SERIAL
NUMBER
The golf car serial number (D is
stamped in the location shown.
NOTE: —
The first three digits of the serial num-
ber are for model identification; the
remaining digits are the unit produc-
tion number. Keep a record of these
numbers for reference when ordering
parts from a Yamaha Golf-Car
Company dealer.
The engine serial number (2) 15
affixed in the location shown.
@ Engine Information
r M
IMPORTANT ENGINE INFORMATION
M nt y man YAMAHA
PEER плату АМ
DISPLACEMENT, HH | ELSA ie HE ER Е НН
JEMITION TING & DLE MOTOR MOHTENEN ALJUSTMENTS NEEDED.
DIE SPEER na mn ATO LON}
ENGINE OL: EAE WW me 8
THIS ENGINE MEETS =~ EMISSION REGULATIONS FOR OFF-ROAD ENGINES.
Tia ENGINE ENDL TO - Pins EPA REGULATIONS FOR BIMALL NONFIOAD ENGINES
ul YAMAHA MOTOR COLTD. J
Y-851
G22A
/\OPERATOR SAFETY |
Y-8
Y-68
Yamaha golf cars are designed to be
simple to operate. However, be sure
to observe the following:
BEFORE OPERATING
THE GOLF CAR
e Read this Owner's/Operator's man-
ual and all safety and instruction
labels on the golf car before operat-
ing.
e Perform the pre-operation checks
found in Section 6 of this manual.
e Only authorized people should
drive the golf car, from the driver's
side only, and oniy in designated
areas.
e Do not allow more than two people
to ride in the golf car. This golf car is
restricted to two occupants.
e Do not operate the golf car while
under the influence of alcohol or
drugs; their affect on vision and
judgment make operating a golf car
dangerous.
e Do not operate the golf car on pub-
lic streets, roads or highways. Such
use is prohibited by law, and dan-
gerous. Operation on public roads
can result in collision with other
vehicles.
WHILE OPERATING THE
GOLF CAR
e Keep your entire body inside the
golf car, remain seated, and hold on
when the car is in motion.
e Do not start the golf car until all
occupants are seated.
3-1
[| A OPERATOR SAFETY
— |
e Keep your hands on the steering
wheel and your eyes on the path
ahead.
e Use extra care in congested areas
or when backing up. Always back
up slowly, and watch carefully.
e Avoid starting or stopping abruptly.
e Vary the speed of the golf car to
match the terrain of the course.
e Avoid turning the steering wheel too
sharply at higher speeds.
e Always drive slowly straight up or
straight down slopes — never at an
angle.
e Do not run the engine indoors.
Exhaust gas is poisonous.
e Do not make any modification or
addition which affecis capacity or
safe operation, or make any
changes not in accordance with the
owner's/operator's manual.
| AN GOLF COURSE SAFETY PROGRAM |
Like all machines, golf cars can
cause injury if improperly used or
maintained. This section contains
broad safety practices required for
safe golf car operation. Before golf
cars are operated, golf course per-
sonnel should establish any addition-
al safety practices that may be
required for safe operation.
Experience has shown that golf cars
are safe when operated in accor-
dance with the safety warnings
affixed to every golf car. This safe
operation is enhanced when golf cars
are used according to the safety rules
and practices established to meet the
terrain and conditions of the course
they are used on.
The information contained here is
intended for golf course personnel
responsible for golf car safety. If you
are responsible for the operation and
maintenance of this golf car, we
encourage you to implement this golf
car safety program.
DRIVER
QUALIFICATIONS
Allow only authorized people to oper-
ate golf cars. It is recommended that
only people who possess a valid
motor vehicle drivers license be
allowed to operate golf cars.
Place operation and safety instruc-
tions recommended by the golf car
manufacturer, along with the golf
course safety rules, in a conspicuous
place near the golf car rental area or
golf car pick-up area. lt is also rec-
ommended that the following warning
be posted in a conspicuous location:
G22A
Do Not Operate Golf Cars When
Under The Influence Of Alcohol Or
Drugs
GOLF COURSE SAFETY
SURVEY
Perform safety surveys regularly to
identify hazardous areas where golf
cars should net be operated.
GOLF COURSE HAZARD
PREVENTION
The following golf course hazards
must be made safe:
eo Steep Grades. Where steep
grades exist, restrict golf cars to
designated golf car pathways
where possible. In addition, identify
steep grades with a suitable warn-
ing like:
Warning: Steep Grade, Descend
Slowly With Foot On Brake
e Sharp Turns, Blind Corners,
Bridge Approaches. Chain or
rope off these potentially haz-
ardous areas or identify them with
a suitable warning describing the
nature of the hazard and the prop-
er precautions to be taken to avoid
the hazard.
e Wet Areas. Wet grass may cause a
golf car to lose traction and may
affect stability. Chain or rope off wet
areas or identify wet areas with a
suitable warning.
4-1
[AN GOLF COURSE SAFETY PROGRAM |
e Loose Terrain. Loose terrain may
cause a golf car to lose traction and
may affect stability. Repair loose ter-
rain, chain or rope off these areas,
or identify loose terrain with a suit-
able warning.
e Golf Car and Pedestrian Interfer-
ence. Reroute golf car traffic or
pedestrian traffic in congested
areas wherever possible to prevent
accidents. If it is impractical to
reroute traffic, erect warning signs
to warn pedestrians of golf car traf-
fic, and to warn golf car operators to
drive slowly, use caution, and watch
for pedestrians.
MAINTENANCE
REQUIRED FOR GOLF
CAR SAFETY
Practice the following to help ensure
the safety of golf car operators:
e Preventative Maintenance. Per-
form all scheduled maintenance in
accordance with manufacturer's
recommendations to provide the
golfing patron with a safe, properly
operating golf car.
e Personnel. Allow only qualified,
trained, and authorized personnel
to inspect, adjust, and maintain golf
cars.
4-2
e Parts and Materials. Use only
replacement parts and materials
recommended by the manufacturer.
e Ventilation. Properly ventilate all
maintenance and storage areas in
accordance with applicable fire
codes and ordinances to avoid fire
hazards. Ventilation is required to
remove flammable vapors and
fumes from gasoline powered car
storage areas. Ventilation is also
required to remove hydrogen gas
from the car storage areas during
the battery charging process.
G22A
| A GOLF COURSE SAFETY PROGRAM |
SAFETY PRECAUTIONS
DURING MAINTENANCE
When performing maintenance, follow
all safety instructions contained in the
manufacturer's operation and service
manuals, as well as the following
safety procedures:
e Properly immobilize golf car before
beginning any maintenance.
e Properly block chassis before
working underneath golf car.
e Before disconnecting any part of the
fuel system, drain the applicable
part of the system to prevent fuel
leaks.
¢ Avoid fire hazards, and have
appropriate fire protection
equipment available.
e Before working on an electric golf
car, disable the car's electrical
system in accordance with the
manufacturer's instructions.
e Use only properly insulated tools
when working on electrically
powered golf cars or around
batteries.
o Maintain all safety devices including
brakes, steering mechanisms,
warning devices, and governors, in
a safe operating condition. Do not
modify these safety devices as
supplied by the manufacturer.
e After each maintenance or repair,
the car must be driven by a
qualified, trained, and authorized
person — in an area free of
pedestrian traffic — to ensure proper
operation and adjustment.
G22A
e Record all maintenance performed
in a maintenance record log by
date, name of person performing
maintenance, and type of
maintenance. Periodically inspect
maintenance log to ensure
accurate and complete entries.
e Provide operator comment cards
to assist in identifying non-periodic
maintenance needs for specific
golf cars.
¢ Maintain in a legible condition all
nameplates, warnings, and
instructions provided by the
manufacturer.
e If new nameplates, warnings, or
instructions are needed, contact
your Yamaha Golf-Car Company
dealer.
FUEL HANDLING/
STORAGE AND
BATTERY CHARGING
Take the following precautions to
ensure maintenance worker safety:
e Supervise the storage and
handling of liquid fuels in
accordance with applicable fire
and safety requirements.
e Only use battery charging facilities
and procedures that are in
accordance with applicable
ordinances and regulations.
e Periodically inspect fueling to be
certain that applicable safety
codes, regulations, and
procedures are being followed.
4-3
| CONTROLS
NSD
12
Y-13
5-1
FEATURES
(1) Brake pedal
(2) Parking brake pedal
(3) Accelerator pedal
(4) Steering wheel
6) Oil warning light
(6) Main switch
(7) Choke knob
Drive selector switch
(9) Seat
Front cowl
(1) Front tire
(2) Front bumper
(3) Battery
Rear cowl
(5) Fuel shutoff valve
Fuel cap
(7 Rear Tire
Rear bumper
G22A
G22A
CONTROLS |
MAIN SWITCH
The main switch controls the follow-
ing items:
OFF
Ignition circuit is switched off.
The key can be removed only in this
position.
ON
Electrical circuits are switched on. |
The golf car can be driven.
OIL WARNING LIGHT
When the engine oil level falls below
an acceptable level, this light comes
on. If the light comes on, stop the
engine, check the engine oil level,
and add oil as necessary. (See
page 6-3).
(A) Oil warning light
5-2
[CONTROLS
DRIVE SELECT LEVER
The drive select lever is used to shift
the golf car into forward or reverse.
After coming to a complete stop,
move the lever to the desired posi-
tion.
Lever Position Car Movement
F FORWARD
R REVERSE
Y-20A
Y-21a
5-3
NOTE:
The back-up buzzer will beep when
the drive select lever is turned to “R.”
ACCELERATOR PEDAL
The accelerator pedal controls the
golf car's speed.
Action Car Speed
Depress pedal Increase
Release pedal Decrease
(A) Accelerator pedal
BRAKE PEDAL
Press down on the brake pedal to
stop the golf car.
Brake pedal
G22A
Y-22a
ee
«a Y-23
Clockwise/ciosed
=
Counterclockwise/open
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pe
.
y Ba =
SENN TE
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3 == ‘ож
|
G22A
CONTROLS |
PARKING BRAKE
PEDAL
Press down on the parking brake
pedal whenever parking the golf car.
O Parking brake pedal
NOTE:
Release the parking brake by
depressing the accelerator pedal.
4h WARNIN
The parking brake will automatically
release when the accelerator pedal
is depressed. If the main switch is in
the “ON” position, depressing the
accelerator may suddenly cause the
golf car to move.
CHOKE KNOB
Pull and hold out choke knob when
starting a cold engine. Release the
knob after the engine starts.
A) Choke knob
FUEL SHUTOFF VALVE
Ensure the fuel shutoff valve is in the
“OPEN” position for normal operation.
A) Fuel shutoff valve
| PRE-OPERATION CHECKS и
Pre-operation checks should be
made each time you use your golf
car. Get in the habit of performing the
following checks in the same way so
that they become second nature.
e Be sure the main switch key is
removed before performing the
pre-operation checks to prevent
accidental starting, and apply
the parking brake to keep the car
from moving.
| PRE-OPERATION
CHECKLIST
Before each use check the following:
V Fuel system
v Engine oil level
Y Battery
« Tire condition
v Steering system
v Back-up buzzer
v Pedal operation
v Body and chassis
SEAT
Open the seat for checking and ser-
vicing.
PRE-OPERATION CHECKS |
Y-514a
FUEL SYSTEM
Make sure there is sufficient fuel in
the tank and that the fuel shutoff valve
is open. Also check fuel line and
connections for leakage.
(A) Fuel tank
Fuel cap
© Fuel shutoff valve
Gasoline and its vapors are highly
flammable and explosive.
e Do not smoke when refueling
and keep away from sparks,
flames, or other sources of igni-
tion.
e Stop engine and allow it to cool
for several minutes before refuel-
ing.
e Refuel in a well-ventilated area.
e Take care not to spill gasoline. If
gasoline spills, wipe it up imme-
diately with dry rags. Always dis-
pose of gasoline-soaked rags
properly.
e Tighten the filler cap securely
after refueling.
e If you swallow gasoline, inhale a
lot of gasoline vapor, or get
gasoline in your eyes, get imme-
diate medical attention.
e If any gasoline gets on your skin,
immediately wash with soap and
water. Change clothing if gaso-
line spills on it.
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
6.3 US gal
(24.0 L)
methyl alcohol which can damage
fuel system parts.
G22A
6-2
| PRE-OPERATION CHECKS |
ENGINE OIL
With the golf car parked on level
ground, remove the dipstick and
make sure the engine oil is between
the MIN and MAX marks (the cross-
hatched area on the end of the dip-
stick).
@ Qil level dipstick
Maximum oil level
© Safe operating range
If the oil level is below the MIN mark
on the dipstick, add oil through the oil
filler hole until the oil level is between
the MIN and MAX marks.
(A) Oil filler hole
SAUTION -
e Use care not to fill past the MAX
dipstick mark, and be sure no
foreign material enters the
crankcase.
e Use care not to get oil on the
starter belt.
Recommended oil:
YAMALUBE 4-cycle oil or
SAE 10W-30
Engine oil capacity:
1.16 US at
(1.1 L, 1100 cc)
Oil change quantity:
1.0 US at
(0.9 L, 900 cc)
6-3
NOTE:
The distance between the dipstick
marks represents approx. 1/2 US at
(1/2 L) of oil.
NOTE:
Recommended engine oil classifica-
tion: API Service SE, SF, or SG.
Engine oils labeled “Energy Con-
serving Il” are recommended.
G22A
| PRE-OPERATION CHECKS |
7 Y-30
Engine Cooling Inlet Duct
Check the engine cooling inlet duct for
debris. Remove any debris present.
(A) Engine cooling inlet duct
BATTERY
Check that the battery is held secure-
ly in place to prevent the battery from
being damaged from vibration or jar-
ring. Also check that no battery caps
are missing to prevent battery acid
from spilling from the battery. Check
the battery terminals for corrosion.
TIRE CONDITION
Tire Air Pressure
Check the tire air pressure before
operating the golf car.
Tire pressure:
Рог С22А: 16 psi
(110 kPa, 1.1 kgf/cm?)
Y-31
G22A
Tire Wear Limit
Check the tire surface for damage,
cracks or embedded objects. When
tire tread wears down to 0.04 in. (1
mm), replace the tire.
(A) Wear limit
6-4
| PRE-OPERATION CHECKS |
Y-33
Y-21a
6-5
ed
STEERING SYSTEM
Check the steering system for exces-
sive freeplay by:
e moving the steering wheel up and
down, and back and forth.
e turning the steering wheel slightly
to the right and left.
If you feel excessive freeplay, or hear
rattling sounds which may indicate
loose steering components, consult a
Yamaha dealer.
BACK-UP BUZZER
Check the back up buzzer by moving
the drive select lever to “R” for
reverse. The buzzer should sound.
PEDAL OPERATION
Check the following pedal controls for
proper operation. If a pedal does not
work properly, consult a Yamaha
dealer.
Brake Pedal
Make sure the brake pedal feels firm
when pressed and returns to its orig-
inal position when released.
Brake pedal
G22A
PRE-OPERATION CHECKS |
Y-22a
Parking Brake Pedal
Make sure the parking brake pedal
locks in place with a positive click,
and releases when the accelerator
pedal is pressed.
© Parking brake pedal
NOTE:
Release the parking brake by
depressing the accelerator pedal.
Y-20A
G22A
Accelerator Pedal
LA WARNING,
Before checking operation of the
accelerator pedal, be sure the
main switch is in the “OFF” posi-
tion.
Make sure the accelerator pedal
operates smoothly.
(A) Accelerator pedal
BODY AND CHASSIS
Before each use, visually inspect the
golf car body and chassis for damage
and/or missing parts.
6-6
| OPERATION |
STARTING
1. With the parking brake applied,
turn the drive select lever to “Е”
for forward, or “R” for reverse.
|
Do not shift from “F” forward to
Y-18 “R” reverse while the golf car is
moving.
WE
2. Turn the main switch to “ON.”
NGI _
Do not depress the accelerator
pedal when turning on the main
switch or the golf car may sudden-
ly start moving.
3. Pull the choke knob out and hold
it while starting. Release the
choke knob after the engine
starts.
©
№
A @ Choke knob
NOTE:
ww vo3| The choke is not required when the
engine is warm.
4. Check that your path is clear in
the direction you plan to go, and
slowly depress the accelerator
pedal. The golf car will start to
move.
(A) Accelerator pedal
Y-20A NOTE:
The parking brake automatically
releases when the accelerator pedal
is depressed.
o]
Y-65a
TROUBLESHOOTING
If the vehicle's engine won't start, use
the following chart:
OPERATION |
STOPPING
To stop the golf car, gradually press
down on the brake pedal.
Brake pedal
When the car has come to a stop,
apply the parking brake pedal and
turn the main switch to “OFF”
© Parking brake pedal
Do not hold the golf car on an
incline with the accelerator — use
the brake.
Cause | Remedy
Fuel System
No fuel in tank Fill fuel tank
Fuel shutoff valve | Open fuel shutoff
closed valve
Clogged fuel Clean fuel line —
line Consult Yamaha
dealer
Foreign matter Clean fuel filter —
in fuel filter Consult Yamaha
dealer
Clogged Clean carburetor —
carburetor Consult Yamaha
dealer
Electrical System
Spark plug dirty | Clean carbon or
With carbon, or wipe spark plug
wet dry
Faulty ignition Consult Yamaha
system dealer
G22A
| MAINTENANCE |
PERIODIC MAINTENANCE CHARTS
Regular maintenance is required for the best performance and safe operation of your
golf car.
| AA WARNING
Be sure to turn off the main switch and apply the parking brake when you perform
maintenance unless otherwise specified. If the owner is not familiar with machine ser-
vicing, this work should be done by a Yamaha dealer or other qualified mechanic.
FOR G22A
C-CHECK CA-CHECK AND ADJUST R-REPLACE S-SERVICE CL-CLEAN AND LUBRICATE L-LUBRICATE
20 Rounds 125 rds 250 rds | 500rds | 1000 rds
Pre- 20 hours 125 hrs 250 hrs | 500 hrs | 1000 hrs
Remarks Opera- | 100 miles 600 mis | 1200 mis | 2500 mis | 5000mis
tion 160 kms 1000 kms | 2000 kms | 4000 kms | 8000 kms
(Every (Every 6 (Every (Every (Every
month) months) year) 2 years) | 4 years) | Page
PRE- Check engine oil с с C 6-3
OPER- |Check air cooling duct с с с с C с a
ATION — |Check fuel lines for leakage с с Сс Cc с С 6-2
CHECKS | Check fuel level Сс с с с с с 6-2
Check for looseness
and corrosion of battery C с с с C с 6-4
terminals and hold downs
Check brake pedal freeplay
and adjust if necessary с СА СА СА СА СА (8-12
Check steering operation с С с с с 6-5
Check tire pressure, tread
depth, tire surface for damage | © CA CA CA CA CA | 64
Check body and chassis for 6-6
damage y с С С С С C
Check tightness of all bolts,
nuts, and screws С с с C С С *
Check reverse buzzer
operation С с C С C С 6-5
EVERY | Check fuel filter for clogging с С с с с 5
MONTH |Check wear of drive belt С с с с с 8-8
Check operation of
Forward / Reverse shifting с с С С C | 6-5
Clean / Lube pedal control area CL —
EVERY 6| Wash pre-filter, check air
MONTHS | cleaner element S 5 5 5 8-7
Check spark plug and plug cap
condition” / Check compression с © с с 8-4
Check shock absorbers for oil с с С x
leaks and damaged springs
* Items with out 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.
8-1
G22A
L
MAINTENANCE |
FOR G22A
C-CHECK CA-CHECK AND ADJUST R-REPLACE S-SERVICE CL - CLEAN AND LUBRICATE L -LUBRICATE
20 Rounds | 125 газ 250 rds | 500rds | 1000 rds
Pre- | 20 hours 125 hrs 250 hrs | 500 № | 1000 hrs
Remarks Opera- | 100 miles 600 mis | 1200 mis | 2500 mis | 5000mis
tion | 160 kms 1000 kms | 2000 kms | 4000 kms | 8000 kms
(Every (Every 6 (Every (Every (Every
month) months) year) 2 years) | 4 years) | 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 *
damage and tension с с с
Check drive belt for slippage,
wear or scratches с с с 8-8
Check sliding sheave and
ramp shoes; Grease secondary CL CL CL *
sheave bearing
Grease primary sheave L L L В
Check operation of speed limiter с Сс C =
Apply battery terminal protectant 5 $5 5 —
Check wiring connections
and insulation с с с и
Check shoe lining thickness с с с .
and rear axle bearing play
Check steering knuckle
bushing freeplay / Adjust CA CA CA *
wheel alignment
Check wheel nut tightness, с с с A
front wheel bearing play
Check gear box oil level
and leakage С с С | 8-10
Check operation and adjust *
pedal stop if necessary CA CA CA
EVERY | Check brushes for wear and с с *
2 YEARS| commutator for dirt
EVERY |Replace fuel filter and R *
4 YEARS| fuel hoses
Check tightness of cylinder CA .
head / Adjust valves
Replace gear box oil R *
Check for grease leakage; CA a
adjust gearbox if necessary
* tems with out 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.
G22A
| MAINTENANCE
EXHAUST EMISSION CONTROL SYSTEM
AND COMPONENTS
ltem 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 correspond-
ing acronyms are provided in accor-
dance with U.S. EPA REGULATIONS
FOR SMALL NONROAD ENGINES
and the CALIFORNIA REGULA-
TIONS FOR NEW 1995 AND LATER
OFF-HIGHWAY RECREATIONAL
VEHICLES AND ENGINES.
The acronyms conform to the latest
version of the SAE's recommended
practice document J1930, “Diagnostic
Acronyms, Terms, and Definitions For
Electrical/Electronic System”.
lt is recommended that these items
be serviced by a Yamaha dealer or
other qualified mechanic.
G22A
МИН
YYYYYY
Y-37
MAINTENANCE |
Spark Plug Inspection
You should periodically remove and
inspect the spark plug. Dirty or worn
spark plugs can cause poor perfor-
mance.
(A) Spark plug
Spark plug cap
1. Check for discoloration and
remove carbon deposits with a
spark plug cleaner or wire brush.
The normal electrode color will
be tan.
2. Check the spark plug type, and
check the spark plug gap with a
feeler gauge.
Standard spark plug:
BPR2ES
Spark plug gap:
0.028 - 0.031 in (0.7 - 0.8 mm)
@ Gap
3. Clean the gasket and plug sur-
faces and install the spark plug
finger tight before tightening to
the following torque:
Spark plug torque:
14.5 #16
(20 Nm, 2.0 m-kg)
à WARNING
When removing or installing the
spark plug, be careful not to dam-
age the insulator. A damaged
insulator could allow external
sparks, which could lead to explo-
sion or fire.
8-4
| MAINTENANCE
Engine Oil Replacement
1. Warm up the engine for several
minutes, place the golf car on a
level surface, then stop the
engine.
4h WARNING
Use caution not to touch hot
engine oil or hot engine parts, dur-
ing the following procedure.
“=. т == = = = = == = = ”
Y-624
2. Place an oil pan under the engine
drain plug.
3. Remove the oil drain plug and let
the oil drain completely.
NOTE:
Dispose of used oil in an environmen-
tally safe way, such as taking 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:
Recommended oil:
YAMALUBE 4-cycle oil or
SAE 10W-30
Engine oil capacity:
1.16 US at
(1.1 L, 1100 cc)
Oil change quantity:
1.0 US at
(0.9 L, 900 cc)
Drain plug torque:
23 ft-1b
(31 Nm, 3.1 m-kg)
8-5
5. Add the correct quantity of oil
through the oil filler hole.
NOTE:
Recommended engine oil classifica-
tion: API Service SE, SF, or SG.
Engine oils labeled “Energy Con-
serving Il” are recommended.
G22A
MAINTENANCE |
(A) Oil filler hole
Use care not to fill past the MAX
dipstick mark, and be sure no for-
eign material enters the crank-
case. After replacing engine oil,
check for oil leaks around the
drain plug. If oil leaks are found,
consult a Yamaha dealer.
Air Filter
To remove the air filter elements:
1. Unlatch the air filter cover clips
and remove cover.
(A) Air filter cover clips
Air filter cover
2. Lift the air filter and pre-filter out
of the air filter case.
(A) Air filter
Pre-filter
Be careful not to drop anything
into the air inlet.
8-6
| MAINTENANCE
Y-508
Inspection and cleaning:
3. Wash the foam pre-filter in soap
and water. Allow it to dry.
(A) Soap and water
Foam element
4. Check the filter element. If dam-
aged or dirty, replace it.
Do not wring out the foam pre-fil-
ter, this could cause it to tear.
5. To replace the elements, reverse
the above steps.
i Г NH |
PAL 1 LAN
The pre-filter has a notch on one
side. It will only fit in the case one
way.
Drive Belt
To remove the drive belt:
1. Set the drive select lever halfway
between forward and reverse.
2. Pull up on the drive belt and push
it outward over the edge of the
secondary sheave.
3. Turn the secondary sheave clock-
wise and the drive belt will roll off
the sheave.
4. Remove the drive belt from the
primary sheave.
G22A
Y-44
G22A
MAINTENANCE |
Inspection:
To inspect the drive belt, check for
frayed edges or tears, and measure
drive belt against the following speci-
fication. If the belt shows excessive
wear or damage, replace the belt with
a new one.
(A) New: 1.22 in. (31.0 mm)
Replace when belt reaches:
1.06 in. (27 mm)
5. To install the drive belt, reverse
the above steps, rolling the belt
back over the secondary sheave.
Battery
Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin,
eyes, or clothing.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities
of water or milk. Follow with milk
of magnesia, beaten egg, or veg-
etable oil. Call physician immedi-
ately.
EYES: Flush with water for 15
minutes and get prompt medical
attention.
Batteries produce explosive
gases. Keep sparks, flame,
cigarettes, etc., away.
Ventilate when charging or using
in enclosed space. Always shield
eyes when working near batteries.
KEEP OUT OF REACH OF CHIL-
DREN.
8-8
| MAINTENANCE
The 12-volt battery that provides start-
ing power to your gas car normally
doesn't require the addition of water
during the one year period provided by
the battery manufacturer. If the bat-
tery loses its charge, have an experi-
enced mechanic charge it.
Fuse Replacement
TRAIN
Be sure to use the specified fuse.
Using a wrong fuse can cause elec-
trical system damage and create a
fire hazard.
When replacing a fuse be sure the
main switch is turned off to prevent
accidental short circuiting.
1. Remove cap screw on cover. Pull
fuse case cover forward.
(A) Cap screw
Fuse case cover
NOTE:
You do not have to remove the cover.
2. Pull cap off fuse. Pull fuse out and
replace if necessary.
© Fuse cap
D Fuse
Replacement Fuse:
10 Amp, Blade Style
G22A
[
MA ETT E NI!
AHHH LX 1 0 IN
МАТЫ В РТ
Y-48
Recommended oil:
SAE 90 gear oil
Gearcase capacity:
G22A: 0.44 US at
(415 mL, 415 cc)
MAINTENANCE |
Gear Box Oil
To check gear box oil level:
1. Place the golf car on a level sur-
face.
2. Remove the access panel by
removing the screws in the two
lower corners of the panel and
pulling the panel from the car.
3. Remove the oil level plug (A).
4. Add gear oil little by little until oil
flows from the level plug hole ().
5. Allow excess gear oil to flow out
until it stops.
Do not allow foreign material to
enter the gear box.
6. Reinstall the oil level plug.
NOTE:
For gear oil replacement, consult a
Yamaha dealer or other qualified
mechanic.
8-10
MAINTENANCE
г № ВЕ В TR
| y | X
= A CLR
Before performing wheel or brake
maintenance, verify that the main
switch is in the “OFF” position.
Wheel Replacement
To remove and install a wheel on your
golf car:
1. With the wheels blocked to pre-
vent the golf car from moving,
loosen the wheel nuts.
2. Elevate the golf car with a jack
and remove the wheel nuts and
the wheel.
3. Reverse the removal steps when
installing the wheel.
Wheel nut tightening torque:
58 ft-lb (80 Nm, 8.0 m-kg)
Brake Adjustment
The brakes on your golf car are self-
adjusting.
Before you operate the car, press
down on the brake pedal several
times to make sure the brakes are
functioning properly.
à WARNIN
Consult your Yamaha dealer
before using your golf car if you
suspect brake problems. Brake
failure could result in a serious
accident.
G22A
MAINTENANCE |
Brake Pedal Free Play
Adjustment
Before adjusting brake pedal free
play, pump the brake pedal sever-
al times to self-adjust the brakes.
To adjust the brake pedal free play:
1. Remove the service lid from the
floor of the golf car.
2. Check the brake pedal free play
by pressing against the pedal
with two fingers (using light force)
and measuring the distance the
pedal travels before resistance is
felt.
Brake pedal free play (a):
20-25 mm (0.79-0.98 in.)
3. If the free play distance needs
adjusting, loosen the lock nut and
turn the adjusting nut in or out
until the free play specification is
met. Then tighten the lock nut in
place.
TIEN
Do not overtighten the brake
cables. The self adjusters may not
operate properly, reducing braking
performance.
8-12
| STORAGE
Perform the following preparations
when storing your golf car for
extended periods of time:
NOTE:
Turn main switch key to “OFF”
position, remove key, and store key
in a safe place.
DRAINING FUEL
AL WARNING.
Gasoline and its vapors are highly
flammable and explosive.
e Do not smoke when draining
fuel and keep away from sparks,
flames, or other sources of
ignition.
e Stop engine and allow it to cool
for several minutes before
draining fuel.
e Drain fuel in a well-ventilated
area.
e Take care not to spill gasoline.
If gasoline spills, wipe it up
immediately with dry rags.
Always dispose of gasoline-
soaked rags properly.
eo Tighten the filler cap securely
after checking fuel level.
e If you inhale a lot of gasoline
vapor, or get gasoline in your
eyes, get immediate medical
attention.
e If any gasoline gets on your
skin, immediately wash with
soap and water. Change
clothing if gasoline spills on it.
9-1
1. Fill the fuel tank with fresh fuel
and add the specified amount of
Yamaha Fuel Stabilizer and
Conditioner or equivalent
product. Operate the vehicle for
at least five minutes to distribute
treated fuel through the fuel
system.
@) Float bowl drain screw
2. Turn the fuel shutoff valve to the
“CLOSED” position.
3. Drain the carburetor float
chamber into a clean container by
loosening the drain bolt (see item
A below); this will help prevent
fuel deposits from building up.
Pour the drained fuel into the fuel
tank.
>
Ú
Y-521
Specified amount:
1 oz. of stabilizer for each gallon of
fuel (7.5 cc of stabilizer for each liter
of fuel)
NOTE:
Use of fuel stabilizer and conditioner
eliminates the need to drain the fuel
system. Consult a Yamaha dealer if
the fuel system needs to be drained
instead.
G22A
-
ENGINE PREPARATION
With the key removed and the spark
plug lead disconnected, turn the
clutch by hand until compression is
felt. This puts the valves in the closed
position.
CHASSIS
PREPARATION
1. Increase the tire pressure to
20 psi (137 kPa, 1.4 kgf/cm?).
2. Clean exterior of the golf car and
apply a rust inhibitor.
3. Cover the golf car with a breath-
able cover and store it in a dry,
well-ventilated area.
BATTERY
PREPARATION
1. Remove the battery from the golf
car and store it in a cool, dry
place that stays between 32°F
(0°C) and 90°F (30°C).
STORAGE |
2. Have the battery recharged every
60-90 days to keep it fully
charged. The battery must be
kept fully charged to avoid dam-
age.
NOTE:
Batteries like the one supplied with
your car normally do not require you
to check the water level inside the
battery for the one year warranty
period provided by the manufacturer.
3. Clean the top of the battery with
a solution of baking soda and
water, as necessary, to remove
corrosion.
Do not allow cleaning solution to
enter battery cells.
9-2
| SPECIFICATIONS
GENERAL SPECIFICATIONS
ltems G22A
Dimensions:
Overall length 93.9 in. (2385 mm)
Overall width 47.2 in. (1200 mm)
Overall height (steering height) 46.8 in. (1190 mm)
Height of floor 11.8 in. (300 mm)
Wheelbase 64.3 in. (1632 mm)
Tread:
Front 34.3 in. (870 mm)
Rear 38.6 in. (980 mm)
Min. ground clearance 3.8 in. (97 mm)
Weight:
Dry weight (without battery) 670 Ib (304 kg)
Performance:
Factory speed setting 12 mph (19 km/h)
Maximum speed 15 mph (24 km/h)
Minimum turning radius 114.2 in. (2.9 m)
Seating capacity 2 persons per seat
Fuel Tank Capacity 6.3 U.S. Gallons (24L)
10-1
L
SPECIFICATIONS |
ENGINE
ltems G22A
Description:
Engine type 4-stroke, Gasoline, OHV
Number of cylinders Single
Displacement 357 cm?
Bore x stroke 3.30 x 2.48 in. (85 x 63 mm)
Compression ratio 8.1:1
Rated output
Cooling system
Starting system
Ignition system
Spark plug type
Spark plug gap
Lubrication system
Engine oil type
Engine oil capacity
Qil change quantity
11.4 hp (8.5 kw)/3500 rpm
Forced air cooled
Starter
TCI Magneto
BPR2ES
0.028-0.031 in. (0.7-0.8 mm)
Splash
YAMALUBE 4 cycle oil or SAE 10W30
1.16 US gt (1.1 L, 1100 cc)
1.0 US gt (0.9 L, 900 cc)
TRANSMISSION
ltems G22A
Transmission:
Type V-belt automatic centrifugal engagement
V-belt width and outer line length
V-belt wear limit
1.22 x 39.76 in. (31 x 1010 mm)
1.06 in. (27 mm)
Governor:
Type
Factory speed setting
Oil bath flyweight
12 mph (19 km/h)
Differential/reduction gear: G22A
Differential type Bevel gear
Lubricant/capacity SAE 90 gear oil/
0.44 US gt (415 mL,
415 cc)
BATTERIES
ltems G22A
Battery: BCI group 24,
RC: minimum 75 min
CCA: minimum 400A
10-2
| SPECIFICATIONS
CHASSIS
Items G22A
Steering system:
Type Rack and Pinion
Steering angle (L.H.) 1.55 turn
Steering angle (R.H.) 1.55 turn
Brakes:
Brake system
Type of brake
Brake pedal freeplay linkage
adjustment
(Brake cable end play)
Mechanical drum brake on each rear wheel
with self-adjusters.
Dual internal expanding shoe.
Leading/trailing shoes (self-adjusting)
20-25 mm
0.004-0.02 in. (0.1-0.5 mm)
Parking brake:
Type Foot type; parking brake with automatic
release.
Release timing
(With pedal segment in second
| notch)
(Bolt heads round parallel to arm) 0.000 ~ 0.001 in. (0.0 ~ 0.3 mm)
A Wheel:
| Tire size:
| Front 18 x 8.50—8.00/4 PR
Rear 18 x 8.50-8.00/4 PR
Rim size: 7.00-1-8.00
Tire pressure:
16 psi (110 kPa, 1.1 kgf/cm?)
10-3
G22A
WIRING |
| G22A WIRING DIAGRAM
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11-1
NOTES
[
NOTES
NOTES
Printed in U.S.A YAMAHA GOLF-CAR
2006-KCC COMPANY
a 1000 Hwy 34 Eas
Newnan, GA 30
770-254-4
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