Yamaha 48 VOLT GOLF CAR

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Yamaha 48 VOLT GOLF CAR | Manualzz

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Printed in U.S.A

2009-KCC

OWNER’S / OPERATOR’S

MANUAL

!

READ THIS MANUAL CAREFULLY!

It contains important safety information.

YDRE

48 VOLT GOLF CAR

YAMAHA GOLF-CAR

COMPANY

1000 HWY 34 East

Newnan, GA 30265

770-254-4000

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NOTES

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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

YDRE OWNER’S/OPERATOR’S

MANUAL

© 2009 by Yamaha Golf-Car Company

2nd 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.

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IMPORTANT MANUAL

INFORMATION

Particularly important information is distinguished in this manual by the following notations:

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

TIP

Yamaha continually seeks advancements 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.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.

Read and understand this manual completely before operating your golf car. This manual should be considered a permanent part of your golf car and should remain with the car when resold.

TIP

A TIP provides key information to make procedures easier or clearer.

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YDRE WIRING DIAGRAM

TACH

FUSE (3 AMP)

WIRING

PWM OUTPUT

GATE DRIVER CIRCUIT

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SPECIFICATIONS

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BATTERIES

Items

Battery:

YDRE

Trojan - Golf Car Type T-1275 (4x12-volt)

RC: minimum 102 min

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CHASSIS

Items

Steering system:

Type

Steering angle (L.H.)

Steering angle (R.H.)

Brakes:

Brake system

Type of brake

Brake pedal freeplay linkage adjustment

YDRE

Rack and Pinion

1.85 turn

1.85 turn

Mechanical

Maintenance-Free internal transaxle disc brake

45-50 mm

(1.77-1.96 in.)

0.1-0.5 mm (0.004-0.02 in.) (Brake cable end play)

Parking brake:

Type

7

Foot type; parking brake with automatic release.

8

9

Release timing

(With pedal segment in second notch)

(Bolt heads round parallel to arm)

Wheel:

Tire size:

Front

Rear

Rim size:

Tire pressure:

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PAINT CODES

OEM Code

SPU60185

W44145

W49874

AH2039

AH5068

AH5080

AH9064

0.0 ~ 0.3 mm (0.000 ~ 0.001 in.)

18 x 8.50–8.00/4 PR

18 x 8.50–8.00/4 PR

7.00–I–8.00

138 kPa, 1.4 kgf/cm 2 (20 psi)

Name

Glacier

Emerald

Garnet

Onyx Metallic

Cobalt Metallic

Anthracite Metallic

Sandstone Metallic

Ditzler Number

918519

48748

701739

918520

918521

918522

918523

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WARRANTY

IMPORTANT LABELS

OPERATOR SAFETY

SAFETY CONSIDERATIONS

CONTROLS

PRE-OPERATION CHECKS

OPERATION

MAINTENANCE

STORAGE

SPECIFICATIONS

WIRING

CONTENTS

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WARRANTY

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Yamaha Golf-Car Company hereby warrants that any new YDRA gas or YDRE 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 FOUR 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 vehicle’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.

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 other than 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 Exclusions below.

Year 2:

The second year exclusions are the YDRA battery, body parts, seats, mats, bumper assembly, bag carrier, scorecard holder, trim, and the Specific Exclusions below.

Year 3:

The third year exclusions include the second year exclusions, plus the control cables and electrical system (except electronic speed controller, battery charger, and electric motor), and the Specific Exclusions below.

Year 4:

The fourth year of the warranty covers only the electric motor, speed controller, battery charger, and transaxle on the YDRE and the engine, clutch system (except drive belt), and transaxle on the YDRA.

SPECIFIC EXCLUSIONS:

Specific exclusions from this warranty shall include the following:

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

LIMITED 4-YEAR GOLF CAR LIMITED WARRANTY

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 are also excluded from this warranty.

Gasoline powered golf car starting batteries on vehicles equipped with a golf course GPS device, or any other device with a high parasitic current draw, unless the vehicle is equipped with an optional factory installed deep cycle starting battery.

THE CUSTOMER’S RESPONSIBILITY

under this warranty shall be to:

1.

Operate and maintain the golf car 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 vehicle or charger available at that time for inspection and repairs by the dealer’s authorized representative.

WARRANTY TRANSFER:

Any transfer of warranty must take place within the first three years of the original in-service date of the vehicle. The vehicle must be re-registered by an authorized Yamaha Golf-

Car Dealer within 30 days of transfer. A fee may be charged for the transfer of the warranty.

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 IMPLIED WARRANTY LASTS, SO

THE ABOVE LIMITATION MAY NOT APPLY TO

YOU. ALSO EXCLUDED FROM THIS WARRANTY

IS 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: 6/1/09 LIT-13710-01-10

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SPECIFICATIONS

GENERAL SPECIFICATIONS

Items

Dimensions:

Overall length

Overall width

Overall height (steering height)

Height of floor

Wheelbase

Tread:

Front

Rear

Min. ground clearance

Weight:

Dry weight (without battery)

Vibration Level:

Vibration on seat (EN1032,

ISO5008) (for Europe

Vibration on steering wheel

(EN1032, ISO5008) (for Europe)

Performance:

Factory speed setting

Maximum speed

Turning radius

Seating capacity

YDRE

2395 mm (93.4 in.)

1200 mm (47.2 in.)

1190 mm (46.9 in.)

310 mm (12.2 in.)

1640 mm (64.6 in.)

870 mm (34.3 in.)

980 mm (38.6 in.)

110 mm (4.3 in.)

243 kg (536 lb)

Will not exceed 0.5 m/s 2

Will not exceed 2.5 m/s

2

19 km/h (12 mph)

24 km/h (15 mph)

2.8 m (9.2 ft)

2 persons per seat

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TRANSMISSION

Items

Differential/reduction gear:

Differential type

Lubricant/capacity

YDRE

Bevel gear

Yamalube Shaft Drive Gear Oil/

1350 mL, 1350 cc

(1.43 US quarts)

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Perform the following preparations when storing your golf car for extended periods of time:

TIP

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

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CHASSIS

PREPARATION

1. Verify the tire pressure is set to

138 kPa, 1.4 kgf/cm 2 (20 psi).

2. Clean exterior of the golf car and apply a rust inhibitor.

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

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BATTERY

PREPARATION

1. Remove the batteries from the golf car and store them in a cool, dry place that stays between

0°C (32°F) and 30°C (90°F).

STORAGE

2. Have the batteries recharged every 60-90 days to keep them fully charged. The batteries must be kept fully charged to avoid damage.

NOTICE

Do not allow cleaning solution to enter battery cells. Serious battery damage can result.

3.

Clean the top of the batteries with a solution of baking soda and water, as necessary, to remove corrosion.

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WARRANTY

YAMAHA FOUR-YEAR LIMITED WARRANTY FOR TROJAN BRAND

ELECTRIC GOLF CAR AND UTILITY VEHICLE BATTERIES WHEN

CHARGED WITH A YAMAHA SUPPLIED 48-VOLT CHARGER

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YAMAHA Golf-Car Company (herein referred to as “YGC”) hereby warrants to the Original Retail Purchaser or Lessee of a YAMAHA

YDRE golf car or PTV, U-MAX or Adventurer utility vehicle, or

YAMAHA transportation or specialty vehicle purchased from an

Authorized YGC Dealer, that the Trojan batteries charged with a

YAMAHA

supplied battery charger will be free from defects in materials and workmanship, and will provide “36-hole performance” for a period of four-years or “1,000 rounds” from the date of purchase, whichever event occurs first, subject to the terms and conditions contained herein.

This limited warranty covers defects in materials and workmanship only for a period of four-years or “1,000 rounds”, as applicable, from date of purchase, whichever event occurs first. The terms of this

FOUR-YEAR LIMITED WARRANTY shall be to furnish one or more replacement batteries within the four-year period or before 20,000 amp-hours are discharged, whichever event occurs first, as determined by YGC using the information recorded and stored in the

Genius controller.

• This warranty only applies to factory installed Trojan battery sets charged with a Yamaha supplied battery charger.

• “1,000 rounds” means 20,000 amp-hours discharged, as recorded in the Genius controller.

• The customer must perform (or have a contracted Yamaha

Dealer perform) all periodic maintenance and discharge testing as specified in the Yamaha Service Manual Maintenance

Schedule. No labor or transportation expenses are included in this limited warranty. Maintenance records must be kept.

• Replacement batteries may be of a different brand or capacity, but are warranted to provide 36-hole performance for the remainder of the warranty term.

• “36-hole performance” is defined as 60-minutes discharge time as tested and recorded using a Lester model #17770 discharge machine at an ambient temperature of between 60 and 100 degrees F (16 and 38 degrees C). Ambient temperatures between 60 and 80 degrees F (16 and 27 degrees C) must be corrected using the formula: Adjusted Discharge Time =

(Discharge Minutes) / (1-(((80-TEMP)/100) x 0.64)).

• The customer must notify the Dealer within 10 days that a vehicle has failed to make 36 holes per day. YGC reserves the right to test and recharge any batteries in question.

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED

SUBSEQUENT TO ONE YEAR FROM THE DATE OF PURCHASE.

THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE

REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED

WARRANTY. YAMAHA MAKES NO OTHER REPRESENTATION

OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE,

EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA HAS THE

AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION,

PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE

TERMS OF THIS LIMITED WARRANTY.

LIMITED WARRANTY EXCLUSIONS

Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, YAMAHA does not warrant that its battery is suitable for use in any application other than in a golf car or utility vehicle. As in the use of any battery, a prudent owner will read and study the charger owner’s manual, the vehicle owner’s manual, the operator’s instructions, and the battery warning labels; and will exercise due care in working on or around batteries.

THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT

APPLY IF BATTERIES ARE SUBJECTED TO ANY OF THE

FOLLOWING CONDITIONS:

• Abuse or neglect such as improper fluid levels, loose wiring, rusted or corroded hardware.

Yamaha Golf-Car Company,

NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 06/01/09

• Lack of proper maintenance as outlined in the electric vehicle

Owner’s/Operator’s Manual. For example, lack of regular battery watering or adding water to the battery before charging.

• Damage caused by improper installation of the battery.

• Neglect, breakage, freezing, fire, explosion, wreckage, the addition of any chemical, or the operation of the battery in an uncharged condition (below half-charge – 1.200 specific gravity).

• Battery charged by systems other than the original equipment type battery charger.

• On fleet golf cars, the use of any non-YAMAHA supplied electrical devices that consume more than one amp-hour per round or two amp-hours per day of battery energy. Examples of these devices include, but are not limited to: heating or cooling systems; GPS (global position system) devices; information gathering devices; lights; radios or stereos; or yardage measuring devices.

• Inadequate facility electrical power to power all chargers.

Examples include more than one charger on a single circuit or not enough circuits for the number of cars.

• In fleet applications, less than one battery charger per vehicle.

For example, using only 10 battery chargers to charge a 15 car fleet.

• The use of any system that does not allow the battery chargers to shut off automatically. For example, timer systems that are designed to switch battery charger AC power on and off during peak demand hours.

THIS BATTERY IS INTENDED TO BE USED BY PERSONS

WITH TRAINING AND EXPERIENCE WITH BATTERIES AND

ONLY IN YAMAHA ELECTRIC VEHICLES. ANY OTHER USE

RENDERS THE LIMITED WARRANTIES EXPRESSED HEREIN

AND ALL IMPLIED WARRANTIES NULL AND VOID AND SAME

ARE HEREBY EXCLUDED.

ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE

ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR

REVENUE, LOSS OF TIME, INCONVENIENCE OR ANY

OTHER ECONOMIC LOSS.

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Some states do not allow limitation on the duration of an implied warranty, exclusions or limitations of incidental or consequential damages. Therefore, the above limitations or exclusions may not apply to you.

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WARRANTY LIMITATIONS

Yamaha Golf-Car Company’s and Trojan Battery Company’s limit of liability shall be to replace a defective battery. Replacement shall mean furnishing a new battery or used battery with sufficient life to complete the remainder of the warranty term, which is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the limited warranty period, except for labor or transportation expenses.

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Damage not resulting from a defect in materials or workmanship or which occurs due to abuse or neglect (including failure to provide reasonable and necessary maintenance), accident, alteration or acts of God is excluded from this limited warranty.

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This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.

For further information or to submit a warranty claim, contact your local Yamaha Golf-Car Dealer or contact Yamaha Golf-Car

Company toll free at (877) 811-8250.

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IMPORTANT LABELS

SAFETY AND INSTRUCTION LABELS

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Read the following labels carefully before operating your golf car, and promptly replace any labels which become damaged or removed. Death or serious personal injury can result from failing to read and comply with the safety instruction labels.

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NOTICE

Move switch to the “TOW” position before towing or storage. Failure to do so may lead to:

• Drive system damage when towing.

• Complete battery discharge and battery damage when storing long term.

• After moving switch from “RUN” to “TOW”, wait 15 seconds minimum before switching again.

TOW

RUN

JW2-K8298-10

Y-1699a

4

Y-924a

Y-500c

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B

Y-61c

Y-62b

Y-909A

MAINTENANCE

Brake Pedal Free Play

Adjustment

NOTICE

Before adjusting brake pedal free play, pump the brake pedal several times to self-adjust the brakes.

To adjust the brake pedal free play:

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

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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.

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Brake pedal free play Å:

45-50 mm (1.77-1.96 in.)

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3. If the free play distance needs adjusting, loosen the lock nut å and turn the adjusting nut ∫ in or out until the free play specification is met. Then tighten the lock nut in place.

NOTICE

Do not over-tighten the brake cables. Over-tightening will increase brake wear and affect overall performance of car.

Premature brake wear can result.

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MAINTENANCE

Y-57

TIP

For transaxle oil replacement, consult a Yamaha dealer or other qualified mechanic.

NOTICE

Before performing wheel or brake maintenance, verify that the main switch is in the “OFF” position.

Serious transaxle damage can result.

Wheel Replacement

To remove and install a wheel on your 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 jack and remove the wheel nuts and the wheel.

3. Reverse the removal steps when installing 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, press down on the brake pedal several times to make sure the brakes are functioning properly.

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Consult your Yamaha dealer before using your golf car if you suspect brake problems. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

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IMPORTANT LABELS

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IMPORTANT LABELS

GOLF CAR SERIAL

NUMBER

The golf car serial number 1 is identified in the location shown.

TIP

The first three digits of the serial number 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 Yamaha

Golf-Car Company dealer.

Y-1539

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Y-1215

Y-1214

MAINTENANCE

Transaxle Oil

To check transaxle oil level:

1. Place the golf car on a flat, level surface.

2. Remove seven plastic rivets 1 and two bolts 2, and remove the bag holder insert 3.

3. Place an oil pan under the transaxle case.

4. Clean area around servicing plug 4.

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

6. Transaxle oil should be at the top of the oil servicing hole or just beginning to run out of hole.

NOTICE

Do not allow foreign material to enter transaxle. Serious transaxle damage can result.

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7.

If needed, add Yamalube Shaft

Drive Gear Oil until it is at the top of the plug hole or just beginning to run out of servicing hole.

TIP

The YDRE Golf Car is equipped with an internal wet brake. Use of oil other than Yamalube Shaft Drive Gear Oil will cause brake noise.

8.

Install the transaxle servicing plug and tighten to 14-19 Nm,

1.4-1.9 m•kg (120-168 in•lb).

9.

Install the bag holder insert

3 and secure with two bolts 2 and seven plastic rivets 1.

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MAINTENANCE

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A

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Fuse Type:

3 Amp, Blade Style

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Y-523a

NOTICE

Do not overtighten the battery holddown nuts. Excessive force will damage the battery casing.

Fuse Replacement

Be sure to use the specified fuse.

Using a wrong fuse can cause electrical system damage and create a fire hazard. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

NOTICE

When replacing a fuse be sure the main switch is turned off to prevent accidental shortcircuiting and electrical system damage.

1. Locate the in-line fuse holder on the main wire harness adjacent to the tow switch.

2. Pull fuse holder cover off.

3. Pull fuse out, inspect and replace if necessary.

å Fuse holder

∫ Fuse

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OPERATOR SAFETY

Y-68

Y-928

Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following to reduce the risk of serious injury or death due to loss of control and other hazards:

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BEFORE OPERATING

THE GOLF CAR

l

Read this Owner’s/Operator’s manual and all safety and instruction labels on the golf car before operating.

l

Perform the pre-operation checks found in Section 6 of this manual.

l

Only authorized people should drive the golf car, from the driver’s side only, and only in designated areas.

l

Do not allow more than two occupants per seat. This golf car is restricted to two occupants unless equipped with a rear seat.

l

Do not operate the golf car while under the influence of alcohol or drugs; their effect on vision and judgment make operating a golf car dangerous.

l

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

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WHILE OPERATING THE

GOLF CAR

l

Keep your entire body inside the golf car, remain seated, and hold on when the car is in motion.

l

Do not start the golf car until all occupants are seated.

l

Keep your hands on the steering wheel and your eyes on the path ahead.

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OPERATOR SAFETY

l

Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully.

l

Avoid starting or stopping abruptly.

l

Vary the speed of the golf car to match the terrain of the course.

l

Avoid turning the steering wheel too sharply at higher speeds to avoid tipping or rolling the golf car.

l

Always drive slowly straight up or straight down slopes – never at an angle to avoid tipping or rolling the golf car.

Y-921 l

Do not run the engine indoors.

Exhaust gas is poisonous and could result in carbon monoxide poisoning.

Y-922 l

Do not make any modification or addition which affects capacity or safe operation, or make any changes not in accordance with the owner’s/operator’s manual.

Y-923

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C

A

Y-751B

Y-672b

MAINTENANCE

8. After the charger has turned off, disconnect the DC output plug from the golf car receptacle by grasping the plug body and pulling the plug straight out of the receptacle.

Battery Installation

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2

3

When working with batteries, do not put wrenches or other metal objects across the battery terminals. An arc can occur causing an explosion or fire at the battery. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

4

5

1. Install the battery holddown plates and torque to 7-9 Nm,

0.7-0.9 m•kg (62-80 in•lb) as shown.

å Forward

∫ Battery

ç Battery holddown plate

2. Connect the wire leads and torque to 9-10 Nm, 0.9-1.0 m•kg

(80-89 in•lb) as shown.

6

7

8

9

When installing batteries:

l

Carefully place battery cables and hold-downs making sure that cables do not lay across

l

vent caps.

Always remove the negative (–) cable to the motor controller first, and install it last. A spark can occur causing an explosion or fire at the battery. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

8-7

10

11

JW2

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7

8

5

6

9

10

11

1

2

3

4

8-6

MAINTENANCE

NOTICE

Use only battery chargers that are rated for use with 48-volt Yamaha

Golf Cars. Serious battery damage can result. Thoroughly read and understand the user manual supplied with your 48-volt charger.

3. With the charger properly connected and grounded (see charger’s owner’s manual), insert the DC output into the golf car receptacle.

POWER ON

ERROR1

ERROR2

CHARGING

90%

CHARGED

A

B

C

D

E

Y-669

Y-1559

Do not disconnect the DC output cord from the battery receptacle when the charger is on or an arc could occur that may cause an explosion. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

å Power ON Light (Red)

∫ Error Light 1 (Red)

ç Error Light 2 (Red)

∂ Charging Light (Yellow) fl Charged Light (Green)

4. When the charger is plugged into the AC power, the Power ON

Light illuminates continuously.

5. If Error 1 or Error 2 light is blinking, there is a problem with the batteries or the charger.

Contact your Yamaha Dealer.

6. During normal charging, the

Charging Light blinks or continually illuminates.

7. The charger turns off automatically when the batteries reach full charge.

JW2

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!

SAFETY CONSIDERATIONS

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 personnel should establish any additional safety practices that may be required for safe operation.

Experience has shown that golf cars are safe when operated in accordance 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.

Do not operate golf cars when under the influence of alcohol or drugs. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

GOLF COURSE SAFETY

SURVEY

Perform safety surveys regularly to identify hazardous areas where golf cars should not be operated.

GOLF COURSE HAZARD

PREVENTION

The following golf course hazards must be made safe: l

Steep Grades

. Where steep grades exist, restrict golf cars to designated golf car pathways where possible. In addition, identify steep grades with a suitable warning like:

DRIVER

QUALIFICATIONS

Allow only authorized people to operate golf cars. It is recommended that only people who possess a valid motor vehicle driver’s license be allowed to operate golf cars.

Place operation and safety instructions recommended by the golf car manufacturer, along with the golf course safety rules, in a conspicuous place near the golf car rental area or golf car pick-up area.

It is also recommended that the following warning be posted in a conspicuous location:

JW2

Descend steep grades slowly with foot on brake. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

l

Sharp Turns, Blind Corners,

Bridge Approaches

. Chain or rope off these potentially hazardous areas or identify them with a suitable warning describing the nature of the hazard and the proper precautions to be taken to avoid the hazard.

4-1

1

2

3

4

5

6

7

8

9

10

11

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!

SAFETY CONSIDERATIONS

1

2

3

4

5

6

l

Wet Areas

. Wet grass may cause a golf car to lose traction and may affect stability. Golf car operators should reduce speed in wet areas or during periods of inclement weather.

l

Loose Terrain

. Loose terrain may cause a golf car to lose traction and may affect stability. Repair loose terrain, chain or rope off these 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 possible to prevent accidents. If it is impractical to reroute traffic, erect warning signs to warn pedestrians of golf car traffic, and to warn golf car operators to drive slowly, use caution, and watch for pedestrians.

7

8

MAINTENANCE

REQUIRED FOR GOLF

CAR SAFETY

Practice the following to help ensure the safety of golf car operators:

9

10

11

l

Preventative Maintenance

.

Perform all scheduled maintenance in accordance with manufacturer’s recommendations to provide the golfing patron with a safe, properly operating golf car.

l

Personnel

. Allow only qualified, trained, and authorized personnel to inspect, adjust, and maintain golf cars.

l

Parts and Materials

. Use only replacement parts and materials recommended by the manufacturer.

l

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.

For electric powered golf cars, the amount of hydrogen gas emitted during charging depends on a number of factors, such as the condition of the batteries, the output rate of the battery charger, and the amount of time the batteries are on charge. Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air changes per hour is recommended. Consult applicable fire and safety codes for the specific ventilation levels requirement, as well as requirements for the use of explosion proof electrical apparatus.

4-2

JW2

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JW2

REV

FWD

OFF

ON

Y-912

MAINTENANCE

Battery Charging

1

Read and understand the owner’s manual provided with your golf car’s battery charger before charging batteries. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

2

3

4

Explosive hydrogen gas is produced while batteries are being charged. Only charge batteries in well ventilated areas

(a minimum of five air changes per hour is recommended). Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

5

6

7

To charge the batteries in your golf car, follow the instructions contained in your battery charger’s owner’s manual. The following is a summary of the charging steps.

1. Turn main switch key to “OFF” position.

NOTICE

Always put the tow switch in the

“TOW” position before charging battery or damage to the electrical system may result.

2. Lift up the seat and move the tow switch to the TOW position.

8

9

10

11

8-5

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1

2

3

4

5

6

7

8

9

10

11

MAINTENANCE

Electrolyte 1/8” Below

Bottom of Fill Well

Max. Level - charged battery

Max. Level - discharged battery

1/8”

(3 mm)

Fill Well

Electrolyte l

Before charging:

only add distilled water if fluid is below the top of the plates, and then add just enough to cover plates.

l

After charging:

open the vent caps and look inside the fill wells. Add distilled water until the electrolyte level is 3 mm (1/8") below the bottom of the fill well. A piece of rubber can be used safely as a dipstick to help determine this level.

Clean, replace and tighten all vent caps.

NEG

POS

Y-937

Y-936

NOTICE

Normal tap water contains minerals which are harmful to a battery; therefore, refill only with distilled water.

3. Using a hydrometer, check the specific gravity of the battery fluid in each cell against the readings on the chart below. Consult a

Yamaha dealer if any low readings are found, or if readings vary more than one point between cells.

Temperature

˚C

48.9

43.3

37.8

32.2

26.7

21.1

15.6

10.0

4.4

-1.1

90

80

70

60

˚F

120

110

100

50

40

30

Satisfactory Uncorrected

Hydrometer Reading

1.244

1.248

1.252

1.256

1.260

1.264

1.268

1.272

1.276

1.280

8-4

JW2

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!

SAFETY CONSIDERATIONS

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: l

Properly immobilize golf car before beginning any maintenance to avoid any unexpected vehicle movement.

l

Properly block chassis before working underneath golf car to avoid any unexpected vehicle movement.

l

When working on the fuel system or the battery, do not smoke, or allow any sparks or open flames near the vehicle, to avoid any fires or explosions.

l

Before working on an electric golf car, disable the car’s electrical system in accordance with the manufacturer’s instructions to avoid electrical shock or damage to the electrical system.

l

Use only properly insulated tools when working on electrically powered golf cars or around batteries to avoid electrical shock or damage to the electrical system.

l

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.

l

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.

JW2 l

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.

l

Provide operator comment cards to assist in identifying non-periodic maintenance needs for specific golf cars.

l

Maintain in a legible condition all nameplates, warnings, and instructions provided by the manufacturer.

l

If new nameplates, warnings, or instructions are needed, contact your Yamaha Golf-Car Company dealer.

STORAGE AND

BATTERY CHARGING

Take the following precautions to ensure maintenance worker safety: l

Only use battery charging facilities and procedures that are in accordance with applicable ordinances and regulations to avoid explosions, electrical shock or damage to the electrical system.

l

Periodically inspect charging facilities and procedures to be certain that applicable safety codes, regulations, and procedures are being followed to avoid any fires or explosions.

4-3

1

2

3

4

5

6

7

8

9

10

11

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1

CONTROLS

16

4

2

3

5

3

2

1

Y-916a

4

5

6

10

11

7

8

9

9

11

8

7

Y-935

10

6

Y-918a

FEATURES

1 Brake pedal

2 Parking brake pedal

3 Accelerator pedal

4 Steering wheel

5 Main switch

6 Receptacle

7 Batteries

8 Seat

9 Front body a Front tire b Front bumper c Rear body d Rear tire e Rear bumper f Tow switch g Drive select switch

12

14 13

15

Y-919a

5-1

Y-930a

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MAINTENANCE

Battery Care

1

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 vegetable oil. Call physician immediately.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes, etc., away.

Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF

CHILDREN.

Four 12-volt deep cycle batteries provide power for your electric golf car and must be properly maintained and recharged for maximum performance and service life.

To maintain your batteries:

1.

Clean the tops of the batteries with a solution of baking soda and water, as necessary, to remove corrosion.

NOTICE

Do not allow cleaning solution to enter battery cells. Serious battery damage can result.

2

3

4

5

6

7

8

9

10

11

2. Check the fluid level before and after charging.

8-3

JW2

JW2

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9

10

11

MAINTENANCE

1

2

3

4

5

6

FOR JW2

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

Remarks

Daily

Pre-

Operation

40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds

20 hours

100 miles

160 kms

(Every

Month)

125 hrs

600 mls

1000 kms

(Every 6 months)

250 hrs

1200 mls

2000 kms

(Every

Year)

500 hrs

2500 mls

4000 kms

(Every 2 years)

1000 hrs

5000 mls

8000 kms

(Every 4 years)

Page

EVERY

YEAR

Perform a discharge test

Apply Terminal protectant

S

S

S

S

S

S

*

Check rear axle bearing play for roughness or freeplay

Check steering knuckle bushing freeplay / Adjust wheel alignment

Check wheel nut tightness, front wheel bearing play

Check transaxle oil level and inspect for leakage

Check pedal stop operation and adjust if necessary

EVERY 4

YEARS

Replace transaxle oil

Inspect internal wet brake and replace pads if necessary

CS

CA

CS

CS

CA

CS

CA

CS

CS

CA

CS

CA

CS

CS

CA

R

CA

*

*

*

8-9

*

*

*

*

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.

7

8

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REV

FWD

OFF

ON

Y-912

CONTROLS

MAIN SWITCH

The main switch controls the following items:

OFF

Ignition circuit is switched off.

The key can be removed only in this position.

1

2

3

4

REV

FWD

OFF

ON

Y-913

ON

Electrical circuits are switched on.

The golf car can be driven.

9

10

11

7

8

5

6

8-2

5-2

JW2

JW2

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9

10

7

8

3

4

1

CONTROLS

REV

FWD

OFF

ON

2

5

6

BEEP

Y-904

DRIVE SELECT SWITCH

The drive select switch is used to shift the golf car into forward or reverse. After coming to a complete stop, move the lever to the desired position.

Switch Position

FWD

REV

Car Movement

FORWARD

REVERSE

TIP

The back-up buzzer will beep when the drive select switch is turned to

“REV.”

Y-920

A

11

B

Y-20A

ACCELERATOR PEDAL

The accelerator pedal controls the golf car’s speed.

Action

Depress pedal

Release pedal

å Accelerator pedal

Car Speed

Increase

Decrease

BRAKE PEDAL

Press down on the brake pedal to stop the golf car.

∫ Brake pedal

Y-21a

5-3

JW2

MAINTENANCE

PERIODIC MAINTENANCE CHARTS

Regular maintenance is required for the best performance and safe operation of your golf car.

1

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 servicing the machine, death or serious personal injury can result. When in doubt the work should be done by a Yamaha dealer or other qualified mechanic.

2

3

FOR JW2

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

Remarks

Daily

Pre-

Operation

40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds

20 hours

100 miles

160 kms

(Every

Month)

125 hrs

600 mls

1000 kms

(Every 6 months)

250 hrs

1200 mls

2000 kms

(Every

Year)

500 hrs

2500 mls

4000 kms

(Every 2 years)

1000 hrs

5000 mls

8000 kms

(Every 4 years)

Page

PRE-OP

Charge

S S S S S S

4-3/

8-5

Clean battery tops, check for tightness of hold-down screws and terminals

Check brake pedal freeplay and adjust if necessary

Check steering operation

Check tire pressure, tread depth, tire surface for damage

Check body and chassis for damage

S

CS

CS

CS

CS

S

CA

CS

CA

CS

S

CA

CS

CA

CS

S

CA

CS

CA

CS

S

CA

CS

CA

CS

S

CA

CS

CA

CS

6-2/

8-3

6-4/

8-10

6-3

6-2

6-4

EVERY

MONTH

Check tightness of all bolts, nuts, screws and rivets

Check reverse buzzer operation

Check electrolyte level

Check for loose or broken connections

Clean/Lube pedal control area

EVERY 6

MONTHS

Check all wire insulation for cracks and/or worn spots

Check shock absorbers for oil leaks and damaged springs

CS

CS

CS

CS

CS

CS

CL

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

*

6-3

8-3/8-4

*

*

*

*

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.

4

5

6

7

8

9

10

11

8-1

JW2

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7

8

5

6

9

10

11

1

2

3

4

OPERATION

B

A

Y-65c

STOPPING

To stop the golf car, gradually press down on the brake pedal.

å Brake pedal

NOTICE

Do not hold the golf car on an incline with the accelerator – use the brake. Transmission damage can result.

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

∫ Parking brake pedal

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C

Y-22a

CONTROLS

PARKING BRAKE

PEDAL

Press down on the parking brake pedal whenever parking the golf car.

ç Parking brake pedal

TIP

Release the parking brake by depressing the accelerator pedal.

1

2

3

4

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. Death or serious personal injury can result from failing to comply with the safety labels in this manual.

5

6

7

8

9

10

11

7-2

5-4

JW2

JW2

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9

10

11

7

8

1

2

3

4

5

6

CONTROLS

NOTICE

TOW

RUN

A

Y-666a

TOW SWITCH

Before operating the car, make sure the tow switch is in the “RUN” position.

å Tow switch

NOTICE

Ensure that the “Drive Select

Switch” is in the “FWD” position and then move the “TOW Switch” to “TOW” before towing.

After moving switch from “RUN” to “TOW,” wait 15 seconds minimum before switching again.

Failure to do so may lead to drive system damage while towing.

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REV

FWD

OFF

ON

REV

FWD

OFF

ON

A

Y-933

Y-911b

Y-20A

OPERATION

STARTING

1. With the parking brake applied, turn the drive select switch to

“FWD” for forward, or “REV” for reverse.

NOTICE

Do not shift from “FWD” forward to “REV” reverse while the golf car is moving. Transmission damage can result.

1

2

3

4

2. Turn the main switch to “ON.”

5

Do not depress the accelerator pedal when turning on the main switch or the golf car may start moving unexpectedly. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

3. Check that your path is clear in the direction you plan to go, and slowly depress the accelerator pedal. The golf car will start to move.

å Accelerator pedal

6

7

8

9

TIP

The parking brake automatically releases when the accelerator pedal is depressed.

10

11

5-5

7-1

JW2

JW2

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10

11

1

2

3

4

5

6

PRE-OPERATION CHECKS

Brake Pedal

Make sure the brake pedal feels firm when pressed and returns to its original position when released.

∫ Brake pedal

B

Y-21a

C

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.

ç Parking brake pedal

TIP

Release the parking brake by depressing the accelerator pedal.

7

8

BODY AND CHASSIS

Before each use, visually inspect the golf car body and chassis for damage and/or missing parts.

9

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6-4

PRE-OPERATION CHECKS

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.

1

2

3

To keep car from moving while performing pre-operation checks:

l

Remove main switch key.

l

Apply parking brake.

Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

4

5

PRE-OPERATION

CHECKLIST

Before each use check the following:

4 Batteries

4 Tire condition

4 Steering system

4 Back-up buzzer

4 Pedal operation

4 Body and chassis

SEAT

Open the seat for checking and servicing.

6

7

8

9

10

11

Y-905

6-1

JW2

JW2

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1

2

3

PRE-OPERATION CHECKS

BATTERIES

Check that the batteries are held securely in place to prevent them from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the batteries.

Check the battery terminals for corrosion.

4

5

6

7

8

9

10

11

A

Y-30

Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT

OF REACH OF CHILDREN.

TIRE CONDITION

Tire Air Pressure

Check the tire air pressure before operating the golf car.

Tire pressure:

For JW2: 138 kPa, 1.4 kgf/cm 2

(20 psi)

Tire Wear Limit

Check the tire surface for damage, cracks or embedded objects. When tire tread wears down to 1 mm

(0.04 in.), replace the tire.

å Wear limit

Y-31

6-2

JW2

JW2

REV

FWD

PRE-OPERATION CHECKS

OFF

ON

A

Y-932

Y-911b

STEERING SYSTEM

Check the steering system for excessive 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, or hear rattling sounds which may indicate loose steering components, consult a Yamaha dealer.

1

2

3

4

BACK-UP BUZZER

Check the back-up buzzer by moving the drive select switch to

“REV” for reverse. The buzzer should sound.

5

6

PEDAL OPERATION

Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha dealer.

Accelerator Pedal

1.

WARNING! Make sure the main switch is in the “OFF” position.

2.

Make sure the accelerator pedal operates smoothly.

7

8

9

10

11

å Accelerator pedal

Y-20A

6-3

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1

2

3

PRE-OPERATION CHECKS

BATTERIES

Check that the batteries are held securely in place to prevent them from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the batteries.

Check the battery terminals for corrosion.

4

5

6

7

8

9

10

11

A

Y-30

Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT

OF REACH OF CHILDREN.

TIRE CONDITION

Tire Air Pressure

Check the tire air pressure before operating the golf car.

Tire pressure:

For JW2: 138 kPa, 1.4 kgf/cm 2

(20 psi)

Tire Wear Limit

Check the tire surface for damage, cracks or embedded objects. When tire tread wears down to 1 mm

(0.04 in.), replace the tire.

å Wear limit

Y-31

6-2

JW2

JW2

REV

FWD

PRE-OPERATION CHECKS

OFF

ON

A

Y-932

Y-911b

STEERING SYSTEM

Check the steering system for excessive 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, or hear rattling sounds which may indicate loose steering components, consult a Yamaha dealer.

1

2

3

4

BACK-UP BUZZER

Check the back-up buzzer by moving the drive select switch to

“REV” for reverse. The buzzer should sound.

5

6

PEDAL OPERATION

Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha dealer.

Accelerator Pedal

1.

WARNING! Make sure the main switch is in the “OFF” position.

2.

Make sure the accelerator pedal operates smoothly.

7

8

9

10

11

å Accelerator pedal

Y-20A

6-3

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10

11

1

2

3

4

5

6

PRE-OPERATION CHECKS

Brake Pedal

Make sure the brake pedal feels firm when pressed and returns to its original position when released.

∫ Brake pedal

B

Y-21a

C

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.

ç Parking brake pedal

TIP

Release the parking brake by depressing the accelerator pedal.

7

8

BODY AND CHASSIS

Before each use, visually inspect the golf car body and chassis for damage and/or missing parts.

9

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6-4

PRE-OPERATION CHECKS

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.

1

2

3

To keep car from moving while performing pre-operation checks:

l

Remove main switch key.

l

Apply parking brake.

Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

4

5

PRE-OPERATION

CHECKLIST

Before each use check the following:

4 Batteries

4 Tire condition

4 Steering system

4 Back-up buzzer

4 Pedal operation

4 Body and chassis

SEAT

Open the seat for checking and servicing.

6

7

8

9

10

11

Y-905

6-1

JW2

JW2

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9

10

11

7

8

1

2

3

4

5

6

CONTROLS

NOTICE

TOW

RUN

A

Y-666a

TOW SWITCH

Before operating the car, make sure the tow switch is in the “RUN” position.

å Tow switch

NOTICE

Ensure that the “Drive Select

Switch” is in the “FWD” position and then move the “TOW Switch” to “TOW” before towing.

After moving switch from “RUN” to “TOW,” wait 15 seconds minimum before switching again.

Failure to do so may lead to drive system damage while towing.

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REV

FWD

OFF

ON

REV

FWD

OFF

ON

A

Y-933

Y-911b

Y-20A

OPERATION

STARTING

1. With the parking brake applied, turn the drive select switch to

“FWD” for forward, or “REV” for reverse.

NOTICE

Do not shift from “FWD” forward to “REV” reverse while the golf car is moving. Transmission damage can result.

1

2

3

4

2. Turn the main switch to “ON.”

5

Do not depress the accelerator pedal when turning on the main switch or the golf car may start moving unexpectedly. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

3. Check that your path is clear in the direction you plan to go, and slowly depress the accelerator pedal. The golf car will start to move.

å Accelerator pedal

6

7

8

9

TIP

The parking brake automatically releases when the accelerator pedal is depressed.

10

11

5-5

7-1

JW2

JW2

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7

8

5

6

9

10

11

1

2

3

4

OPERATION

B

A

Y-65c

STOPPING

To stop the golf car, gradually press down on the brake pedal.

å Brake pedal

NOTICE

Do not hold the golf car on an incline with the accelerator – use the brake. Transmission damage can result.

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

∫ Parking brake pedal

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C

Y-22a

CONTROLS

PARKING BRAKE

PEDAL

Press down on the parking brake pedal whenever parking the golf car.

ç Parking brake pedal

TIP

Release the parking brake by depressing the accelerator pedal.

1

2

3

4

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. Death or serious personal injury can result from failing to comply with the safety labels in this manual.

5

6

7

8

9

10

11

7-2

5-4

JW2

JW2

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9

10

7

8

3

4

1

CONTROLS

REV

FWD

OFF

ON

2

5

6

BEEP

Y-904

DRIVE SELECT SWITCH

The drive select switch is used to shift the golf car into forward or reverse. After coming to a complete stop, move the lever to the desired position.

Switch Position

FWD

REV

Car Movement

FORWARD

REVERSE

TIP

The back-up buzzer will beep when the drive select switch is turned to

“REV.”

Y-920

A

11

B

Y-20A

ACCELERATOR PEDAL

The accelerator pedal controls the golf car’s speed.

Action

Depress pedal

Release pedal

å Accelerator pedal

Car Speed

Increase

Decrease

BRAKE PEDAL

Press down on the brake pedal to stop the golf car.

∫ Brake pedal

Y-21a

5-3

JW2

MAINTENANCE

PERIODIC MAINTENANCE CHARTS

Regular maintenance is required for the best performance and safe operation of your golf car.

1

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 servicing the machine, death or serious personal injury can result. When in doubt the work should be done by a Yamaha dealer or other qualified mechanic.

2

3

FOR JW2

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

Remarks

Daily

Pre-

Operation

40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds

20 hours

100 miles

160 kms

(Every

Month)

125 hrs

600 mls

1000 kms

(Every 6 months)

250 hrs

1200 mls

2000 kms

(Every

Year)

500 hrs

2500 mls

4000 kms

(Every 2 years)

1000 hrs

5000 mls

8000 kms

(Every 4 years)

Page

PRE-OP

Charge

S S S S S S

4-3/

8-5

Clean battery tops, check for tightness of hold-down screws and terminals

Check brake pedal freeplay and adjust if necessary

Check steering operation

Check tire pressure, tread depth, tire surface for damage

Check body and chassis for damage

S

CS

CS

CS

CS

S

CA

CS

CA

CS

S

CA

CS

CA

CS

S

CA

CS

CA

CS

S

CA

CS

CA

CS

S

CA

CS

CA

CS

6-2/

8-3

6-4/

8-10

6-3

6-2

6-4

EVERY

MONTH

Check tightness of all bolts, nuts, screws and rivets

Check reverse buzzer operation

Check electrolyte level

Check for loose or broken connections

Clean/Lube pedal control area

EVERY 6

MONTHS

Check all wire insulation for cracks and/or worn spots

Check shock absorbers for oil leaks and damaged springs

CS

CS

CS

CS

CS

CS

CL

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

CS

*

6-3

8-3/8-4

*

*

*

*

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.

4

5

6

7

8

9

10

11

8-1

JW2

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9

10

11

MAINTENANCE

1

2

3

4

5

6

FOR JW2

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

Remarks

Daily

Pre-

Operation

40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds

20 hours

100 miles

160 kms

(Every

Month)

125 hrs

600 mls

1000 kms

(Every 6 months)

250 hrs

1200 mls

2000 kms

(Every

Year)

500 hrs

2500 mls

4000 kms

(Every 2 years)

1000 hrs

5000 mls

8000 kms

(Every 4 years)

Page

EVERY

YEAR

Perform a discharge test

Apply Terminal protectant

S

S

S

S

S

S

*

Check rear axle bearing play for roughness or freeplay

Check steering knuckle bushing freeplay / Adjust wheel alignment

Check wheel nut tightness, front wheel bearing play

Check transaxle oil level and inspect for leakage

Check pedal stop operation and adjust if necessary

EVERY 4

YEARS

Replace transaxle oil

Inspect internal wet brake and replace pads if necessary

CS

CA

CS

CS

CA

CS

CA

CS

CS

CA

CS

CA

CS

CS

CA

R

CA

*

*

*

8-9

*

*

*

*

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.

7

8

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REV

FWD

OFF

ON

Y-912

CONTROLS

MAIN SWITCH

The main switch controls the following items:

OFF

Ignition circuit is switched off.

The key can be removed only in this position.

1

2

3

4

REV

FWD

OFF

ON

Y-913

ON

Electrical circuits are switched on.

The golf car can be driven.

9

10

11

7

8

5

6

8-2

5-2

JW2

JW2

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1

CONTROLS

16

4

2

3

5

3

2

1

Y-916a

4

5

6

10

11

7

8

9

9

11

8

7

Y-935

10

6

Y-918a

FEATURES

1 Brake pedal

2 Parking brake pedal

3 Accelerator pedal

4 Steering wheel

5 Main switch

6 Receptacle

7 Batteries

8 Seat

9 Front body a Front tire b Front bumper c Rear body d Rear tire e Rear bumper f Tow switch g Drive select switch

12

14 13

15

Y-919a

5-1

Y-930a

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MAINTENANCE

Battery Care

1

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 vegetable oil. Call physician immediately.

EYES: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes, etc., away.

Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF

CHILDREN.

Four 12-volt deep cycle batteries provide power for your electric golf car and must be properly maintained and recharged for maximum performance and service life.

To maintain your batteries:

1.

Clean the tops of the batteries with a solution of baking soda and water, as necessary, to remove corrosion.

NOTICE

Do not allow cleaning solution to enter battery cells. Serious battery damage can result.

2

3

4

5

6

7

8

9

10

11

2. Check the fluid level before and after charging.

8-3

JW2

JW2

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1

2

3

4

5

6

7

8

9

10

11

MAINTENANCE

Electrolyte 1/8” Below

Bottom of Fill Well

Max. Level - charged battery

Max. Level - discharged battery

1/8”

(3 mm)

Fill Well

Electrolyte l

Before charging:

only add distilled water if fluid is below the top of the plates, and then add just enough to cover plates.

l

After charging:

open the vent caps and look inside the fill wells. Add distilled water until the electrolyte level is 3 mm (1/8") below the bottom of the fill well. A piece of rubber can be used safely as a dipstick to help determine this level.

Clean, replace and tighten all vent caps.

NEG

POS

Y-937

Y-936

NOTICE

Normal tap water contains minerals which are harmful to a battery; therefore, refill only with distilled water.

3. Using a hydrometer, check the specific gravity of the battery fluid in each cell against the readings on the chart below. Consult a

Yamaha dealer if any low readings are found, or if readings vary more than one point between cells.

Temperature

˚C

48.9

43.3

37.8

32.2

26.7

21.1

15.6

10.0

4.4

-1.1

90

80

70

60

˚F

120

110

100

50

40

30

Satisfactory Uncorrected

Hydrometer Reading

1.244

1.248

1.252

1.256

1.260

1.264

1.268

1.272

1.276

1.280

8-4

JW2

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!

SAFETY CONSIDERATIONS

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: l

Properly immobilize golf car before beginning any maintenance to avoid any unexpected vehicle movement.

l

Properly block chassis before working underneath golf car to avoid any unexpected vehicle movement.

l

When working on the fuel system or the battery, do not smoke, or allow any sparks or open flames near the vehicle, to avoid any fires or explosions.

l

Before working on an electric golf car, disable the car’s electrical system in accordance with the manufacturer’s instructions to avoid electrical shock or damage to the electrical system.

l

Use only properly insulated tools when working on electrically powered golf cars or around batteries to avoid electrical shock or damage to the electrical system.

l

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.

l

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.

JW2 l

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.

l

Provide operator comment cards to assist in identifying non-periodic maintenance needs for specific golf cars.

l

Maintain in a legible condition all nameplates, warnings, and instructions provided by the manufacturer.

l

If new nameplates, warnings, or instructions are needed, contact your Yamaha Golf-Car Company dealer.

STORAGE AND

BATTERY CHARGING

Take the following precautions to ensure maintenance worker safety: l

Only use battery charging facilities and procedures that are in accordance with applicable ordinances and regulations to avoid explosions, electrical shock or damage to the electrical system.

l

Periodically inspect charging facilities and procedures to be certain that applicable safety codes, regulations, and procedures are being followed to avoid any fires or explosions.

4-3

1

2

3

4

5

6

7

8

9

10

11

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!

SAFETY CONSIDERATIONS

1

2

3

4

5

6

l

Wet Areas

. Wet grass may cause a golf car to lose traction and may affect stability. Golf car operators should reduce speed in wet areas or during periods of inclement weather.

l

Loose Terrain

. Loose terrain may cause a golf car to lose traction and may affect stability. Repair loose terrain, chain or rope off these 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 possible to prevent accidents. If it is impractical to reroute traffic, erect warning signs to warn pedestrians of golf car traffic, and to warn golf car operators to drive slowly, use caution, and watch for pedestrians.

7

8

MAINTENANCE

REQUIRED FOR GOLF

CAR SAFETY

Practice the following to help ensure the safety of golf car operators:

9

10

11

l

Preventative Maintenance

.

Perform all scheduled maintenance in accordance with manufacturer’s recommendations to provide the golfing patron with a safe, properly operating golf car.

l

Personnel

. Allow only qualified, trained, and authorized personnel to inspect, adjust, and maintain golf cars.

l

Parts and Materials

. Use only replacement parts and materials recommended by the manufacturer.

l

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.

For electric powered golf cars, the amount of hydrogen gas emitted during charging depends on a number of factors, such as the condition of the batteries, the output rate of the battery charger, and the amount of time the batteries are on charge. Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air changes per hour is recommended. Consult applicable fire and safety codes for the specific ventilation levels requirement, as well as requirements for the use of explosion proof electrical apparatus.

4-2

JW2

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JW2

REV

FWD

OFF

ON

Y-912

MAINTENANCE

Battery Charging

1

Read and understand the owner’s manual provided with your golf car’s battery charger before charging batteries. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

2

3

4

Explosive hydrogen gas is produced while batteries are being charged. Only charge batteries in well ventilated areas

(a minimum of five air changes per hour is recommended). Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

5

6

7

To charge the batteries in your golf car, follow the instructions contained in your battery charger’s owner’s manual. The following is a summary of the charging steps.

1. Turn main switch key to “OFF” position.

NOTICE

Always put the tow switch in the

“TOW” position before charging battery or damage to the electrical system may result.

2. Lift up the seat and move the tow switch to the TOW position.

8

9

10

11

8-5

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7

8

5

6

9

10

11

1

2

3

4

8-6

MAINTENANCE

NOTICE

Use only battery chargers that are rated for use with 48-volt Yamaha

Golf Cars. Serious battery damage can result. Thoroughly read and understand the user manual supplied with your 48-volt charger.

3. With the charger properly connected and grounded (see charger’s owner’s manual), insert the DC output into the golf car receptacle.

POWER ON

ERROR1

ERROR2

CHARGING

90%

CHARGED

A

B

C

D

E

Y-669

Y-1559

Do not disconnect the DC output cord from the battery receptacle when the charger is on or an arc could occur that may cause an explosion. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

å Power ON Light (Red)

∫ Error Light 1 (Red)

ç Error Light 2 (Red)

∂ Charging Light (Yellow) fl Charged Light (Green)

4. When the charger is plugged into the AC power, the Power ON

Light illuminates continuously.

5. If Error 1 or Error 2 light is blinking, there is a problem with the batteries or the charger.

Contact your Yamaha Dealer.

6. During normal charging, the

Charging Light blinks or continually illuminates.

7. The charger turns off automatically when the batteries reach full charge.

JW2

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!

SAFETY CONSIDERATIONS

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 personnel should establish any additional safety practices that may be required for safe operation.

Experience has shown that golf cars are safe when operated in accordance 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.

Do not operate golf cars when under the influence of alcohol or drugs. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

GOLF COURSE SAFETY

SURVEY

Perform safety surveys regularly to identify hazardous areas where golf cars should not be operated.

GOLF COURSE HAZARD

PREVENTION

The following golf course hazards must be made safe: l

Steep Grades

. Where steep grades exist, restrict golf cars to designated golf car pathways where possible. In addition, identify steep grades with a suitable warning like:

DRIVER

QUALIFICATIONS

Allow only authorized people to operate golf cars. It is recommended that only people who possess a valid motor vehicle driver’s license be allowed to operate golf cars.

Place operation and safety instructions recommended by the golf car manufacturer, along with the golf course safety rules, in a conspicuous place near the golf car rental area or golf car pick-up area.

It is also recommended that the following warning be posted in a conspicuous location:

JW2

Descend steep grades slowly with foot on brake. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

l

Sharp Turns, Blind Corners,

Bridge Approaches

. Chain or rope off these potentially hazardous areas or identify them with a suitable warning describing the nature of the hazard and the proper precautions to be taken to avoid the hazard.

4-1

1

2

3

4

5

6

7

8

9

10

11

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1

2

3

4

7

8

5

6

9

10

11

!

OPERATOR SAFETY

l

Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully.

l

Avoid starting or stopping abruptly.

l

Vary the speed of the golf car to match the terrain of the course.

l

Avoid turning the steering wheel too sharply at higher speeds to avoid tipping or rolling the golf car.

l

Always drive slowly straight up or straight down slopes – never at an angle to avoid tipping or rolling the golf car.

Y-921 l

Do not run the engine indoors.

Exhaust gas is poisonous and could result in carbon monoxide poisoning.

Y-922 l

Do not make any modification or addition which affects capacity or safe operation, or make any changes not in accordance with the owner’s/operator’s manual.

Y-923

LIT_19626_21_09:LIT_19626_16_05.qxd 7/1/09 8:33 AM Page 31

3-2

JW2

B

C

A

Y-751B

Y-672b

MAINTENANCE

8. After the charger has turned off, disconnect the DC output plug from the golf car receptacle by grasping the plug body and pulling the plug straight out of the receptacle.

Battery Installation

1

2

3

When working with batteries, do not put wrenches or other metal objects across the battery terminals. An arc can occur causing an explosion or fire at the battery. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

4

5

1. Install the battery holddown plates and torque to 7-9 Nm,

0.7-0.9 m•kg (62-80 in•lb) as shown.

å Forward

∫ Battery

ç Battery holddown plate

2. Connect the wire leads and torque to 9-10 Nm, 0.9-1.0 m•kg

(80-89 in•lb) as shown.

6

7

8

9

When installing batteries:

l

Carefully place battery cables and hold-downs making sure that cables do not lay across

l

vent caps.

Always remove the negative (–) cable to the motor controller first, and install it last. A spark can occur causing an explosion or fire at the battery. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

8-7

10

11

JW2

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MAINTENANCE

1

9

10

11

2

3

4

5

B

A

6

Fuse Type:

3 Amp, Blade Style

7

8

Y-523a

NOTICE

Do not overtighten the battery holddown nuts. Excessive force will damage the battery casing.

Fuse Replacement

Be sure to use the specified fuse.

Using a wrong fuse can cause electrical system damage and create a fire hazard. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

NOTICE

When replacing a fuse be sure the main switch is turned off to prevent accidental shortcircuiting and electrical system damage.

1. Locate the in-line fuse holder on the main wire harness adjacent to the tow switch.

2. Pull fuse holder cover off.

3. Pull fuse out, inspect and replace if necessary.

å Fuse holder

∫ Fuse

8-8

JW2

LIT_19626_21_09:LIT_19626_16_05.qxd 7/1/09 8:33 AM Page 9

!

OPERATOR SAFETY

Y-68

Y-928

Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following to reduce the risk of serious injury or death due to loss of control and other hazards:

1

2

BEFORE OPERATING

THE GOLF CAR

l

Read this Owner’s/Operator’s manual and all safety and instruction labels on the golf car before operating.

l

Perform the pre-operation checks found in Section 6 of this manual.

l

Only authorized people should drive the golf car, from the driver’s side only, and only in designated areas.

l

Do not allow more than two occupants per seat. This golf car is restricted to two occupants unless equipped with a rear seat.

l

Do not operate the golf car while under the influence of alcohol or drugs; their effect on vision and judgment make operating a golf car dangerous.

l

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

3

4

5

6

7

8

9

10

WHILE OPERATING THE

GOLF CAR

l

Keep your entire body inside the golf car, remain seated, and hold on when the car is in motion.

l

Do not start the golf car until all occupants are seated.

l

Keep your hands on the steering wheel and your eyes on the path ahead.

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IMPORTANT LABELS

GOLF CAR SERIAL

NUMBER

The golf car serial number 1 is identified in the location shown.

TIP

The first three digits of the serial number 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 Yamaha

Golf-Car Company dealer.

Y-1539

5

6

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2

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3

Y-1215

Y-1214

MAINTENANCE

Transaxle Oil

To check transaxle oil level:

1. Place the golf car on a flat, level surface.

2. Remove seven plastic rivets 1 and two bolts 2, and remove the bag holder insert 3.

3. Place an oil pan under the transaxle case.

4. Clean area around servicing plug 4.

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

6. Transaxle oil should be at the top of the oil servicing hole or just beginning to run out of hole.

NOTICE

Do not allow foreign material to enter transaxle. Serious transaxle damage can result.

1

2

3

4

5

6

7

7.

If needed, add Yamalube Shaft

Drive Gear Oil until it is at the top of the plug hole or just beginning to run out of servicing hole.

TIP

The YDRE Golf Car is equipped with an internal wet brake. Use of oil other than Yamalube Shaft Drive Gear Oil will cause brake noise.

8.

Install the transaxle servicing plug and tighten to 14-19 Nm,

1.4-1.9 m•kg (120-168 in•lb).

9.

Install the bag holder insert

3 and secure with two bolts 2 and seven plastic rivets 1.

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2

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MAINTENANCE

Y-57

TIP

For transaxle oil replacement, consult a Yamaha dealer or other qualified mechanic.

NOTICE

Before performing wheel or brake maintenance, verify that the main switch is in the “OFF” position.

Serious transaxle damage can result.

Wheel Replacement

To remove and install a wheel on your 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 jack and remove the wheel nuts and the wheel.

3. Reverse the removal steps when installing 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, press down on the brake pedal several times to make sure the brakes are functioning properly.

8-10

Consult your Yamaha dealer before using your golf car if you suspect brake problems. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

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IMPORTANT LABELS

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1

IMPORTANT LABELS

SAFETY AND INSTRUCTION LABELS

5

6

2

3

Read the following labels carefully before operating your golf car, and promptly replace any labels which become damaged or removed. Death or serious personal injury can result from failing to read and comply with the safety instruction labels.

4

1

4

3

2

7

8

9

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11

2

NOTICE

Move switch to the “TOW” position before towing or storage. Failure to do so may lead to:

• Drive system damage when towing.

• Complete battery discharge and battery damage when storing long term.

• After moving switch from “RUN” to “TOW”, wait 15 seconds minimum before switching again.

TOW

RUN

JW2-K8298-10

Y-1699a

4

Y-924a

Y-500c

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12

13

14

15

16

17

18

A

B

Y-61c

Y-62b

Y-909A

MAINTENANCE

Brake Pedal Free Play

Adjustment

NOTICE

Before adjusting brake pedal free play, pump the brake pedal several times to self-adjust the brakes.

To adjust the brake pedal free play:

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

1

2

3

4

5

6

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.

7

8

Brake pedal free play Å:

45-50 mm (1.77-1.96 in.)

9

3. If the free play distance needs adjusting, loosen the lock nut å and turn the adjusting nut ∫ in or out until the free play specification is met. Then tighten the lock nut in place.

NOTICE

Do not over-tighten the brake cables. Over-tightening will increase brake wear and affect overall performance of car.

Premature brake wear can result.

8-11

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1

2

Perform the following preparations when storing your golf car for extended periods of time:

TIP

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

3

4

5

6

CHASSIS

PREPARATION

1. Verify the tire pressure is set to

138 kPa, 1.4 kgf/cm 2 (20 psi).

2. Clean exterior of the golf car and apply a rust inhibitor.

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

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8

9

BATTERY

PREPARATION

1. Remove the batteries from the golf car and store them in a cool, dry place that stays between

0°C (32°F) and 30°C (90°F).

STORAGE

2. Have the batteries recharged every 60-90 days to keep them fully charged. The batteries must be kept fully charged to avoid damage.

NOTICE

Do not allow cleaning solution to enter battery cells. Serious battery damage can result.

3.

Clean the top of the batteries with a solution of baking soda and water, as necessary, to remove corrosion.

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WARRANTY

YAMAHA FOUR-YEAR LIMITED WARRANTY FOR TROJAN BRAND

ELECTRIC GOLF CAR AND UTILITY VEHICLE BATTERIES WHEN

CHARGED WITH A YAMAHA SUPPLIED 48-VOLT CHARGER

1

YAMAHA Golf-Car Company (herein referred to as “YGC”) hereby warrants to the Original Retail Purchaser or Lessee of a YAMAHA

YDRE golf car or PTV, U-MAX or Adventurer utility vehicle, or

YAMAHA transportation or specialty vehicle purchased from an

Authorized YGC Dealer, that the Trojan batteries charged with a

YAMAHA

supplied battery charger will be free from defects in materials and workmanship, and will provide “36-hole performance” for a period of four-years or “1,000 rounds” from the date of purchase, whichever event occurs first, subject to the terms and conditions contained herein.

This limited warranty covers defects in materials and workmanship only for a period of four-years or “1,000 rounds”, as applicable, from date of purchase, whichever event occurs first. The terms of this

FOUR-YEAR LIMITED WARRANTY shall be to furnish one or more replacement batteries within the four-year period or before 20,000 amp-hours are discharged, whichever event occurs first, as determined by YGC using the information recorded and stored in the

Genius controller.

• This warranty only applies to factory installed Trojan battery sets charged with a Yamaha supplied battery charger.

• “1,000 rounds” means 20,000 amp-hours discharged, as recorded in the Genius controller.

• The customer must perform (or have a contracted Yamaha

Dealer perform) all periodic maintenance and discharge testing as specified in the Yamaha Service Manual Maintenance

Schedule. No labor or transportation expenses are included in this limited warranty. Maintenance records must be kept.

• Replacement batteries may be of a different brand or capacity, but are warranted to provide 36-hole performance for the remainder of the warranty term.

• “36-hole performance” is defined as 60-minutes discharge time as tested and recorded using a Lester model #17770 discharge machine at an ambient temperature of between 60 and 100 degrees F (16 and 38 degrees C). Ambient temperatures between 60 and 80 degrees F (16 and 27 degrees C) must be corrected using the formula: Adjusted Discharge Time =

(Discharge Minutes) / (1-(((80-TEMP)/100) x 0.64)).

• The customer must notify the Dealer within 10 days that a vehicle has failed to make 36 holes per day. YGC reserves the right to test and recharge any batteries in question.

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED

SUBSEQUENT TO ONE YEAR FROM THE DATE OF PURCHASE.

THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE

REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED

WARRANTY. YAMAHA MAKES NO OTHER REPRESENTATION

OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE,

EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA HAS THE

AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION,

PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE

TERMS OF THIS LIMITED WARRANTY.

LIMITED WARRANTY EXCLUSIONS

Without limiting the generality of the foregoing in any way, and as part of its limited warranty exclusion, YAMAHA does not warrant that its battery is suitable for use in any application other than in a golf car or utility vehicle. As in the use of any battery, a prudent owner will read and study the charger owner’s manual, the vehicle owner’s manual, the operator’s instructions, and the battery warning labels; and will exercise due care in working on or around batteries.

THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT

APPLY IF BATTERIES ARE SUBJECTED TO ANY OF THE

FOLLOWING CONDITIONS:

• Abuse or neglect such as improper fluid levels, loose wiring, rusted or corroded hardware.

Yamaha Golf-Car Company,

NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 06/01/09

• Lack of proper maintenance as outlined in the electric vehicle

Owner’s/Operator’s Manual. For example, lack of regular battery watering or adding water to the battery before charging.

• Damage caused by improper installation of the battery.

• Neglect, breakage, freezing, fire, explosion, wreckage, the addition of any chemical, or the operation of the battery in an uncharged condition (below half-charge – 1.200 specific gravity).

• Battery charged by systems other than the original equipment type battery charger.

• On fleet golf cars, the use of any non-YAMAHA supplied electrical devices that consume more than one amp-hour per round or two amp-hours per day of battery energy. Examples of these devices include, but are not limited to: heating or cooling systems; GPS (global position system) devices; information gathering devices; lights; radios or stereos; or yardage measuring devices.

• Inadequate facility electrical power to power all chargers.

Examples include more than one charger on a single circuit or not enough circuits for the number of cars.

• In fleet applications, less than one battery charger per vehicle.

For example, using only 10 battery chargers to charge a 15 car fleet.

• The use of any system that does not allow the battery chargers to shut off automatically. For example, timer systems that are designed to switch battery charger AC power on and off during peak demand hours.

THIS BATTERY IS INTENDED TO BE USED BY PERSONS

WITH TRAINING AND EXPERIENCE WITH BATTERIES AND

ONLY IN YAMAHA ELECTRIC VEHICLES. ANY OTHER USE

RENDERS THE LIMITED WARRANTIES EXPRESSED HEREIN

AND ALL IMPLIED WARRANTIES NULL AND VOID AND SAME

ARE HEREBY EXCLUDED.

ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE

ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR

REVENUE, LOSS OF TIME, INCONVENIENCE OR ANY

OTHER ECONOMIC LOSS.

2

3

4

5

6

7

8

Some states do not allow limitation on the duration of an implied warranty, exclusions or limitations of incidental or consequential damages. Therefore, the above limitations or exclusions may not apply to you.

9

WARRANTY LIMITATIONS

Yamaha Golf-Car Company’s and Trojan Battery Company’s limit of liability shall be to replace a defective battery. Replacement shall mean furnishing a new battery or used battery with sufficient life to complete the remainder of the warranty term, which is identical or reasonably equivalent to the warranted product at no cost to the purchaser during the limited warranty period, except for labor or transportation expenses.

10

Damage not resulting from a defect in materials or workmanship or which occurs due to abuse or neglect (including failure to provide reasonable and necessary maintenance), accident, alteration or acts of God is excluded from this limited warranty.

11

This warranty gives you specific legal rights, and you may also have other rights, which vary from state to state.

For further information or to submit a warranty claim, contact your local Yamaha Golf-Car Dealer or contact Yamaha Golf-Car

Company toll free at (877) 811-8250.

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WARRANTY

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Yamaha Golf-Car Company hereby warrants that any new YDRA gas or YDRE 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 FOUR 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 vehicle’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.

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 other than 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 Exclusions below.

Year 2:

The second year exclusions are the YDRA battery, body parts, seats, mats, bumper assembly, bag carrier, scorecard holder, trim, and the Specific Exclusions below.

Year 3:

The third year exclusions include the second year exclusions, plus the control cables and electrical system (except electronic speed controller, battery charger, and electric motor), and the Specific Exclusions below.

Year 4:

The fourth year of the warranty covers only the electric motor, speed controller, battery charger, and transaxle on the YDRE and the engine, clutch system (except drive belt), and transaxle on the YDRA.

SPECIFIC EXCLUSIONS:

Specific exclusions from this warranty shall include the following:

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

LIMITED 4-YEAR GOLF CAR LIMITED WARRANTY

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 are also excluded from this warranty.

Gasoline powered golf car starting batteries on vehicles equipped with a golf course GPS device, or any other device with a high parasitic current draw, unless the vehicle is equipped with an optional factory installed deep cycle starting battery.

THE CUSTOMER’S RESPONSIBILITY

under this warranty shall be to:

1.

Operate and maintain the golf car 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 vehicle or charger available at that time for inspection and repairs by the dealer’s authorized representative.

WARRANTY TRANSFER:

Any transfer of warranty must take place within the first three years of the original in-service date of the vehicle. The vehicle must be re-registered by an authorized Yamaha Golf-

Car Dealer within 30 days of transfer. A fee may be charged for the transfer of the warranty.

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 IMPLIED WARRANTY LASTS, SO

THE ABOVE LIMITATION MAY NOT APPLY TO

YOU. ALSO EXCLUDED FROM THIS WARRANTY

IS 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: 6/1/09 LIT-13710-01-10

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SPECIFICATIONS

GENERAL SPECIFICATIONS

Items

Dimensions:

Overall length

Overall width

Overall height (steering height)

Height of floor

Wheelbase

Tread:

Front

Rear

Min. ground clearance

Weight:

Dry weight (without battery)

Vibration Level:

Vibration on seat (EN1032,

ISO5008) (for Europe

Vibration on steering wheel

(EN1032, ISO5008) (for Europe)

Performance:

Factory speed setting

Maximum speed

Turning radius

Seating capacity

YDRE

2395 mm (93.4 in.)

1200 mm (47.2 in.)

1190 mm (46.9 in.)

310 mm (12.2 in.)

1640 mm (64.6 in.)

870 mm (34.3 in.)

980 mm (38.6 in.)

110 mm (4.3 in.)

243 kg (536 lb)

Will not exceed 0.5 m/s 2

Will not exceed 2.5 m/s

2

19 km/h (12 mph)

24 km/h (15 mph)

2.8 m (9.2 ft)

2 persons per seat

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9

TRANSMISSION

Items

Differential/reduction gear:

Differential type

Lubricant/capacity

YDRE

Bevel gear

Yamalube Shaft Drive Gear Oil/

1350 mL, 1350 cc

(1.43 US quarts)

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SPECIFICATIONS

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2

BATTERIES

Items

Battery:

YDRE

Trojan - Golf Car Type T-1275 (4x12-volt)

RC: minimum 102 min

3

4

5

6

CHASSIS

Items

Steering system:

Type

Steering angle (L.H.)

Steering angle (R.H.)

Brakes:

Brake system

Type of brake

Brake pedal freeplay linkage adjustment

YDRE

Rack and Pinion

1.85 turn

1.85 turn

Mechanical

Maintenance-Free internal transaxle disc brake

45-50 mm

(1.77-1.96 in.)

0.1-0.5 mm (0.004-0.02 in.) (Brake cable end play)

Parking brake:

Type

7

Foot type; parking brake with automatic release.

8

9

Release timing

(With pedal segment in second notch)

(Bolt heads round parallel to arm)

Wheel:

Tire size:

Front

Rear

Rim size:

Tire pressure:

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11

PAINT CODES

OEM Code

SPU60185

W44145

W49874

AH2039

AH5068

AH5080

AH9064

0.0 ~ 0.3 mm (0.000 ~ 0.001 in.)

18 x 8.50–8.00/4 PR

18 x 8.50–8.00/4 PR

7.00–I–8.00

138 kPa, 1.4 kgf/cm 2 (20 psi)

Name

Glacier

Emerald

Garnet

Onyx Metallic

Cobalt Metallic

Anthracite Metallic

Sandstone Metallic

Ditzler Number

918519

48748

701739

918520

918521

918522

918523

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WARRANTY

IMPORTANT LABELS

OPERATOR SAFETY

SAFETY CONSIDERATIONS

CONTROLS

PRE-OPERATION CHECKS

OPERATION

MAINTENANCE

STORAGE

SPECIFICATIONS

WIRING

CONTENTS

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IMPORTANT MANUAL

INFORMATION

Particularly important information is distinguished in this manual by the following notations:

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

TIP

Yamaha continually seeks advancements 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.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.

Read and understand this manual completely before operating your golf car. This manual should be considered a permanent part of your golf car and should remain with the car when resold.

TIP

A TIP provides key information to make procedures easier or clearer.

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YDRE WIRING DIAGRAM

TACH

FUSE (3 AMP)

WIRING

PWM OUTPUT

GATE DRIVER CIRCUIT

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NOTES

LIT_19626_21_09:LIT_19626_16_05.qxd 7/1/09 8:33 AM Page 1

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

YDRE OWNER’S/OPERATOR’S

MANUAL

© 2009 by Yamaha Golf-Car Company

2nd 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-19626-21-09

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