User manual | Yamaha G16A Operator`s manual

OWNER’S/

OPERATORS

MANUAL

GOLF CAR

07/12/0 1

1PC - G16A/E O/M

LIT196261600

*LIT196261600*

USA Yamaha Motor Corp., USA

Cypress, California made in

YAMAHA MOTOR

MANUFACTURING CORP.

OF AMERICA

Printed in U.S.A.

KCC

LIT-19626-16-00

G16A

G16E

JN6-F8199-13

G21A O_M IFC 8/8/00 7:56 AM Page 1

WARNING

The engine exhaust from this product contains chemicals known to the

State of California to cause cancer, birth defects or other reproductive harm.

YAMAHA LIT-CALIF-65-01

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G16A/E

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.

TECHNICAL SERVICE DEPT

GOLF CAR SALES GROUP

YAMAHA MOTOR

MANUFACTURING CORP OF

AMERICA

G16A, G16E

OWNER’S/OPERATOR’S

MANUAL

© 2000 by Yamaha Motor

Manufacturing Corporation of America

1st edition

All rights reserved. Any reprinting or unauthorized use without the written permission of

Yamaha Motor Manufacturing

Corporation of America is expressly prohibited.


P/N LIT-19626-16-00 i

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IMPORTANT MANUAL

INFORMATION

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

!

The Safety Alert Symbol means

ATTENTION! BE ALERT! YOUR

SAFETY IS INVOLVED!

WARNING

NOTE :

●

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.

Failure to follow WARNING instructions could result in severe injury or death to the golf car occupants, a bystander, or a person inspecting or repairing the golf car.

● This manual should be considered a permanent part of your golf car and should remain with the car when resold.

CAUTION

This message describes special precautions that must be taken to avoid damage to the golf car.

WARNING

Read and understand this manual completely before operating your golf car.

NOTE :

This message provides additional key information.

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G16A/E

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WARRANTY

IMPORTANT LABELS

OPERATOR SAFETY

MAINTENANCE SAFETY PROGRAM

CONTROLS

PRE-OPERATION CHECKS

OPERATION

MAINTENANCE

CONTENTS

STORAGE

SPECIFICATIONS

WIRING

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WARRANTY

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YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA

G16A, G16E

LIMITED WARRANTY

Yamaha Motor Manufacturing Corporation of America hereby warrants that any new G16 (gas and electric models) Yamaha Golf Car purchased from an authorized

Yamaha dealer in the United States will be free from defects in material and workmanship for the period of time stated herein, subject to the stated limitations.

THE PERIOD OF WARRANTY for any G16 (gas and electric models) will be three years from date of purchase.

The first year of warranty shall cover the entire car except for batteries, battery chargers, tires and rims, which are warranted by their respective manufacturers.

The second year of warranty shall cover the engine assembly, clutch, transmission, axles, electrical system, frame, suspension components, electric motor, control cables, and steering gear.

Parts excluded from the second year of warranty include the body parts, seats, mats, bumper assembly, bag carrier, scorecard holder, and the trim.

The third year of warranty shall cover the engine assembly, clutch, transmission, axles, frame, suspension components, steering gear, and (on the G16E) electronic speed controller.

Parts excluded from the third year of warranty include the second year exclusions and the electrical system

(except electronic speed controller), electric motor, and control cables.

DURING THE PERIOD OF WARRANTY any authorized

Yamaha Golf Car Dealer will, free of charge, repair or replace, at Yamaha’s option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the machine’s warranty period.

All parts replaced under warranty become property of

Yamaha Motor Manufacturing Corporation of America.

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. Modification or alteration that affects 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.)

SPECIFIC EXCLUSIONS from this warranty shall include any parts replaced due to normal wear or routine maintenance; including oil, air filter elements, brake shoes, spark plugs, starter and clutch drive belts. Any charges incurred in transporting a golf car to and from an authorized Yamaha Golf Car Dealer for service or in performing field service is also excluded from this warranty.

THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to:

1. Operate and maintain the golf car as specified in the appropriate Owner’s/Operator’s Manual;

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

WARRANTY TRANSFER: To transfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha

Golf Car Dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee may be charged for this service.

YAMAHA MOTOR MANUFACTURING CORPORA-

TION OF AMERICA 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 DIS-

CLAIMED BY YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA AND EXCLUDED

FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON

HOW LONG AN IMPLIED WARRANTY LASTS, SO

THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

ALSO EXCLUDED FROM THIS WARRANTY ARE

ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO NOT

ALLOW THE EXCLUSION OR LIMITATION OF INCI-

DENTAL 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 MOTOR MANUFACTURING

CORPORATION OF AMERICA

Newnan, Georgia 30265-1320

Effective Date: 2/1/96

LIT-13710-00-96

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G16A/E

WARRANTY

YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA

SPECIALTY VEHICLE ENGINES

EMISSION CONTROL WARRANTY

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YOUR WARRANTY RIGHTS AND OBLIGATIONS

In complance with the California Air Resources

Board, Yamaha Motor Manufacturing Corporation of

America is pleased to explain the emission control system warranty on your 1996 or later specialty vehicle engine.

New Yamaha speciality vehicle engines must be designed, built and equipped to meet stringent anti-smog standards. Yamaha must warrant the emission control system on your speciality vehicle engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your speciality vehicle engine.

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● You are responsible for presenting your specialty vehicle engine to a Yamaha dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable time, not to exceed 30 days.

4

If you have any questions regarding your warranty rights and responsibilities, you should contact the

Yamaha Customer Relations Department at

(770) 254-4164.

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Your emission control system may include parts such as the carburetor or fuel-injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Yamaha Motor Manufacturing Corporation of

America warrants to the ultimate purchaser and each subsequent purchaser thereafter that each new 1996 and later model year specialty vehicle engine certified for sale is:

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Where a warrantable condition exists, Yamaha will repair your specialty vehicle engine at no cost to you including diagnosis, parts and labor.

1.

Designed, built, and equipped so as to conform, at the time of sale, with all applicable regulations adopted by the California Air Resources

Board, and

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MANUFACTURER’S WARRANTY COVERAGE

The 1996 and later specialty vehicle engines are warranted for two years. If any emissions-related part on your engine is defective, the part will be repaired or replaced by Yamaha.

OWNER’S WARRANTY RESPONSIBILITIES

● As the specialty vehicle engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual.

Yamaha recommends that you retain all receipts covering maintenance on your specialty vehicle engine, but Yamaha cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

2.

All warranted parts are free from defects in material and workmanship for the warranty period of the specialty vehicle engine or the period prior to the first scheduled replacement point of the warranted part as required by the maintenance schedule, if applicable, whichever is less. A defect exists when a deficiency in material or workmanship is such that an emission-related warranted part does not function as designed.

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The warranty period begins on the date that the specialty vehicle engine is delivered to an ultimate purchaser or on the date it is first placed in service.

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● As the specialty vehicle engine owner, you should also be aware that Yamaha may deny you warranty coverage if your specialty vehicle engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

WARRANTED PARTS INCLUDE the following:

1.

Fuel Metering System

Carburetor and internal parts (or fuel injection)

Air/fuel ratio feedback and control system

Cold start enrichment system

2.

Air Induction System

Controlled hot air intake system

Intake manifold

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WARRANTY

3.

Ignition System

Spark plugs *

Magneto or electronic ignition system

Spark advance/retard system

4.

Exhaust Gas Recirculation (EGR) System

EGR valve body, and carburetor spacer if applicable

EGR rate feedback and control system

5.

Air Injection System

Air pump or pulse valve

Valves affecting distribution of flow

Distribution manifold

6.

Catalyst or Thermal Reactor System

Catalytic converter

Thermal reactor

Exhaust manifold

7.

Particulate Controls

Traps, filters, precipitators, and any other device used to capture particulate emissions

8.

Miscellaneous Items Used in Above Systems

Vacuum, temperature, and time sensitive valves and switches

Electronic controls

Hoses, belts, connectors, and assemblies

9.

Engine components damaged due to a failure under warranty of a warranted part.

* The original spark plug(s) are warranted for the period of replacement indicated in the

Owner’s/Operator’s Manual and not the useful life of the specialty vehicle engine (see your Owner’s

Manual).

DURING THE PERIOD OF THIS WARRANTY


America will repair or replace any warranted part deemed defective by Yamaha during the scope of the warranty without charge to the owner, including parts, labor, and diagnosis. This work must be done at an authorized Yamaha dealer. Give notice to an authorized Yamaha dealer of any apparent defect(s) within a reasonable period of time after discovery.

The specialty vehicle engine must be made available for inspection by an authorized Yamaha dealer.

OWNER’S RESPONSIBILITY: The owner of the specialty vehicle engine is responsible for the performance of required maintenance (see your

Owner’s/Operator’s Manual). Receipts and maintenance records covering the performance of regular maintenance should be retained in the event questions arise concerning maintenance. The receipts should be transferred to each subsequent owner of this specialty vehicle engine.

The emission control systems of your Yamaha specialty vehicle engine were designed, built, tested, and certified as being in conformity with California emission control regulations using genuine Yamaha parts.

Accordingly, it is recommended that any replacement part(s) used for maintenance, replacement, or repair of emission control systems be

Yamaha parts. The owner may elect to have maintenance, replacement, or repair of the emission control devices and systems performed by any repair establishment or individual, and may elect to use parts other than Yamaha parts for such maintenance, replacement, or repair without invalidating this warranty. However, the cost of such service or parts will not be covered under the warranty.

EXCLUSIONS: No warranty coverage will be allowed if the part(s) failure was caused by owner/operator abuse, neglect, tampering, improper adjustment unless performed by a dealer during warranty repair work, modification, misuse, alteration, or improper maintenance (see your Owner’s/

Operator’s Manual).

Use of parts which are not qualitatively equivalent to genuine Yamaha parts, improper service, or lack of required maintenance which causes failure of a warranted part may constitute abuse and/or improper service, thereby invalidating warranty liability hereunder.

This warranty does not cover damage resulting from accidents, acts of nature, or other events or occurrences beyond the control of Yamaha.

Yamaha

Motor Manufacturing Corporation of America expressly disclaims responsibility for any and all consequential damages, such as loss of time, inconvenience, loss of use of the specialty vehicle, or commercial loss.


America

1000 Hwy. 34 East

Newnan, GA 30265

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G16E

G16A

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G16E

G16A

SAFETY AND

INSTRUCTION

LABELS

Y-505

WARNING

Please read the following labels carefully before operating your golf car, and promptly replace any labels which become damaged or removed.

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Y-500

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Y-502

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Y-102a

GOLF CAR SERIAL

NUMBER

The golf car serial number is stamped in the location shown.

NOTE :

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 dealer.

C

ç Engine Information

Y-852A

THIS ENGINE MEETS 2000-2001 CALIFORNIA EMMISSION REGULATIONS FOR OFF-ROAD ENGINES.

THIS ENGINE CONFORMSTO **(*****.******) U.S. EPA REGULATIONS FOR SMALL NONROAD ENGINES.

JR3-2179R-04

Y-851

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OPERATOR SAFETY

Y-8

Y-68

Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following:

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BEFORE OPERATING

THE GOLF CAR

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

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

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

● Do not allow more than two people to ride in the golf car. This golf car is restricted to two occupants.

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

● Do not operate the golf car on public streets, roads or highways. Such use is prohibited by law, and dangerous. Operation on public roads can result in collision with other vehicles.

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WHILE OPERATING THE

GOLF CAR

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

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

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OPERATOR SAFETY

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

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

● Avoid starting or stopping abruptly.

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

● Avoid turning the steering wheel too sharply at higher speeds.

● Always drive slowly straight up or straight down slopes – never at an angle.

Y-10

Y-9

● Do not run the engine indoors

(G16A). Exhaust gas is poisonous.

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

Y-69

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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.

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:

Do Not Operate Golf Cars When

Under The Influence Of Alcohol Or

Drugs

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GOLF COURSE SAFETY

SURVEY

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

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GOLF COURSE HAZARD

PREVENTION

The following golf course hazards must be made safe:

● 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:

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Warning: Steep Grade, Descend

Slowly With Foot On Brake

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● 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.

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● Wet Areas. Wet grass may cause a golf car to lose traction and may affect stability. Chain or rope off wet areas or identify wet areas with a suitable warning.

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● 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.

● Golf Car and Pedestrian Interfer-

ence. Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent accidents. If it is impractical to reroute traffic, erect warning signs to warn pedestrians of golf car traffic, and to warn golf car operators to drive slowly, use caution, and watch for pedestrians.

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MAINTENANCE

REQUIRED FOR GOLF

CAR SAFETY

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

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

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

●

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

● 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 electric powered car storage areas during the 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.

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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:

● Properly immobilize golf car before beginning any maintenance.

●

Properly block chassis before working underneath golf car.

●

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

● Avoid fire hazards, and have appropriate fire protection equipment available.

● Before working on an electric golf car, disable the car’s electrical system in accordance with the manufacturer’s instructions.

● Use only properly insulated tools when working on electrically powered golf cars or around batteries.

● 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.

● 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.

!


● 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.

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

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

● If new nameplates, warnings, or instructions are needed, contact your Yamaha dealer.

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FUEL HANDLING/

STORAGE AND

BATTERY CHARGING

Take the following precautions to ensure maintenance worker safety:

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Supervise the storage and handling of liquid fuels in accordance with applicable fire and safety requirements.

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● Only use battery changing and charging facilities and procedures that are in accordance with applicable ordinances and regulations.

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● Periodically inspect fueling and charging facilities and procedures to be certain that applicable safety codes, regulations, and procedures are being followed.

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CONTROLS

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Y-506

Y-12

FEATURES

1 Steering wheel

2 Seat

3 Fuel cap (for G16A)

4 Brake pedal

5 Parking brake pedal

6 Accelerator pedal

7 Drive selector lever

8 Main switch

9 Oil warning light (for G16A) a Choke knob (for G16A) b Front cowl c Front tire d Front bumper e Rear cowl f Rear bumper g Rear tire h Battery (for G16A) i Receptacle (for G16E)

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Y-13

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Y-507

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A

OFF

ON

OFF

ON

OFF

ON

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.

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Y-15

ON

Electrical circuits are switched on.

The golf car can be driven.

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Y-16

Y-17

OIL WARNING LIGHT

(G16A)

When the engine oil level falls below an acceptable level, this light comes on. If the light comes on, stop the engine, check the engine oil level, and add oil as necessary. (See page 6-3).

å Oil warning light

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CONTROLS

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Y-18

DRIVE SELECT LEVER

The drive select lever is used to shift the golf car into forward or reverse.

After coming to a complete stop, move the lever to the desired position.

Lever Position

F

R

Car Movement

FORWARD

REVERSE

NOTE :

The back-up buzzer will beep when the drive select lever is turned to “R.”

A

Y-19

Y-20

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.

å Brake pedal

Y-21

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A

CHOKE

A

Y-22

CONTROLS

PARKING BRAKE

PEDAL

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

å Parking brake pedal

NOTE :

Release the parking brake by depressing the accelerator pedal.

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CHOKE KNOB (G16A)

Pull and hold out choke knob when starting a cold engine. Release the knob after the engine starts.

å Choke knob

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Y-23

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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.

WARNING

●

●

Be sure the main switch key is removed before performing the pre-operation checks to prevent accidental starting, and apply the parking brake to keep the car from moving.

For the G16A: During the preoperation checks, avoid touching engine parts or the muffler while they are still hot.

PRE-OPERATION

CHECKLIST

Before each use check the following:

✔ Fuel system (G16A)

✔ Engine oil level (G16A)

✔ Battery

✔ Tire condition

✔ Steering system

✔ Back-up buzzer

✔ Pedal operation

✔ Body and chassis

SEAT

Open the seat for checking and servicing.

Y-512

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Recommended fuel:

Unleaded gasoline

Fuel tank capacity:

6.3 US gal

(24.0 L, 5.3 Imp gal)


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A

Y-513

FUEL SYSTEM (G16A)

Make sure there is sufficient fuel in the tank, and check fuel line and connections for leakage.

å Fuel tank

∫ Fuel cap

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WARNING

Gasoline and its vapors are highly flammable and explosive.

● Do not smoke when refueling and keep away from sparks, flames, or other sources of ignition.

●

●

●

Stop engine and allow it to cool for several minutes before refueling.

Refuel in a well-ventilated area.

Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags. Always dis-

●

●

● pose of gasoline-soaked rags properly.

Tighten the filler cap securely after refueling.

If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.

If any gasoline gets on your skin, immediately wash with soap and water. Change clothing if gasoline spills on it.

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CAUTION

Avoid using gasoline blended with methyl alcohol which can damage fuel system parts.

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11


ENGINE OIL (G16A)

With the golf car parked on level ground, remove the dipstick and make sure the engine oil is between the MIN and MAX marks (the crosshatched area on the end of the dipstick).

Y-514

MIN

C

B

MAX

A

å Oil level dipstick

∫ Maximum oil level

ç Safe operating range

If the oil level is below the MIN mark on the dipstick, add oil through the oil filler hole until the oil level is between the MIN and MAX marks.

Y-28

A

Y-515

å Oil filler hole

CAUTION

●

●

Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the crankcase.

Use care not to get oil on the starter belt.

Recommended oil:

YAMALUBE 4-cycle oil or

SAE 10W-30

Engine oil capacity:

1.16 US qt

(1.0 L, 0.24 Imp gal)

Oil change quantity:

1.0 US qt

(0.9 L, 0.19 Imp gal)

NOTE :

The distance between the dipstick marks represents approx. 1/2 US qt

(1/2 L) of oil.

NOTE :

Recommended engine oil classification: API Service SE, SF, or SG.

Engine oils labeled “Energy Conserving II” are recommended.

6-3

G16A/E

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A


Engine Cooling Inlet Duct

Check the engine cooling inlet duct for debris. Remove any debris present.

å Engine cooling inlet duct

1

2

BATTERY

Charge G16E batteries before each use. See charging steps in chapter 8,

Maintenance.

G16A1

Check that the battery (G16A) or batteries (G16E) are held securely in place to prevent the batteries from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the battery. Check the battery terminals for corrosion.

3

4

5

6

TIRE CONDITION

Tire Air Pressure

Check the tire air pressure before operating the golf car.

7

8

A

Y-30

Y-31

Tire pressure:

For G16A: 16 psi

(108 kPa, 1.1 kgf/cm2)

For G16E: 20 psi

(137 kPa, 1.4 kgf/cm2)

9

10

Tire Wear Limit

Check the tire surface for damage, cracks or embedded objects. When tire tread wears down to 0.04 in. (1 mm), replace the tire.

å Wear limit

6-4

11

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 22

1

2

3

4

5

6


Y-32

STEERING SYSTEM

Check the steering system for excessive freeplay by:

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

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

If you feel excessive freeplay, or hear rattling sounds which may indicate loose steering components, consult a

Yamaha dealer.

BACK-UP BUZZER

Check the back up buzzer by moving the drive select lever to “R” for reverse. The buzzer should sound.

7

Y-33

8

9

10

11

PEDAL OPERATION

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

Brake Pedal

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

å Brake pedal

A

Y-21

6-5

G16A/E

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A


A

Y-22

Parking Brake Pedal

Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed.

å Parking brake pedal

NOTE :

Release the parking brake by depressing the accelerator pedal.

1

2

3

4

Accelerator Pedal

WARNING

Before checking operation of the accelerator pedal, be sure the main switch is in the “OFF” position.

5

6

Make sure the accelerator pedal operates smoothly.


7

8

Y-20

9

BODY AND CHASSIS

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

10

11

6-6

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 24

1

2

3

4

5

6

7

8

9

10

11

OPERATION

7-1

A

CH

OKE

OFF

ON

A

Y-18

STARTING

1. With the parking brake applied, turn the drive select lever to “F” for forward, or “R” for reverse.

CAUTION

Do not shift from “F” forward to

“R” reverse while the golf car is moving.

2. Turn the main switch to “ON.”

WARNING

Do not depress the accelerator pedal when turning on the main switch or the golf car may suddenly start moving.

Y-16

Y-23

Y-20

3. Pull the choke knob out and hold it while starting (G16A). Release the choke knob after the engine starts.

å Choke knob

NOTE :

The choke is not required when the engine is warm.

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


NOTE :

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

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 25

A

B

Y-65

TROUBLESHOOTING

G16A

If G16A’s gas engine won’t start, use the following chart:

Cause Remedy

Fuel System

No fuel in tank Fill fuel tank

Clogged fuel line

Clean fuel line – Consult

Yamaha dealer

Foreign matter Clean fuel in fuel filter fiter – Consult

Yamaha dealer carburetor – Consult

Yamaha dealer

Electrical System

Spark plug dirty Clean carbon with carbon, or or wipe spark wet plug dry

Faulty ignition Consult system Yamaha dealer

G16A/E

OPERATION

STOPPING

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

å Brake pedal

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

∫ Parking brake pedal

1

2

3

4

CAUTION

Do not hold the golf car on an incline with the accelerator – use the brake.

5

6

7-2

7

8

9

10

11

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 26

MAINTENANCE

1

2

PERIODIC MAINTENANCE CHARTS

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

WARNING

Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a

Yamaha dealer or other qualified mechanic.

3

4

5

6

7

8

9

10

11

FOR G16A

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

Remarks

Pre-

20 Rounds

20 hours

Opera100 miles tion 160 kms

(Every month)

125 rds

125 hrs

600 mls

1000 kms

(Every 6 months)

250 rds

250 hrs

1200 mls

2000 kms

(Every year)

500 rds

500 hrs

2500 mls

4000 kms

(Every

2 years)

1000 rds

1000 hrs

5000mls

8000 kms

(Every

4 years) Page

PRE-

OPER-

ATION

Check engine oil

Check air cooling duct

Check fuel lines for leakage

CHECKS Check fuel level

Check for looseness and corrosion of battery terminals and hold downs

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

C

C

C

C

C

C

C

C

C

C

C

C

C

C

CA

C

CA

C

C

C

C

C

C

CA

C

CA

C

C

C

C

C

CA

C

CA

C

C

C

C

C

CA

C

CA

C

C

C

C

C

CA

CA

C

6-3

*

6-2

6-2

6-4

8-18

6-5

6-4

6-6

Check tightness of all bolts, nuts, and screws

Check reverse buzzer operation

EVERY Check fuel filter for clogging

MONTH Check wear of drive belt

Check operation of

Forward / Reverse shifting

Clean / Lube pedal control area

EVERY 6 Wash pre-filter, check air

MONTHS cleaner element

Check spark plug and plug cap condition** / Check compression

Check shock absorbers for oil leaks and damaged springs

C

C

C

C

C

C

C

CL

C

C

C

C

C

S

C

C

C

C

C

C

C

S

C

C

C

C

C

C

C

S

C

C

C

C

C

C

C

S

C

*

6-5

*

8-9

—

—

8-7

8-5/*

*

* Items with out a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does not contain these procedures. They are contained in the Service Manual.

**Related to emission control system.

8-1

G16A/E

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MAINTENANCE

FOR G16A (continued)

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

Remarks

Pre-

20 Rounds

20 hours

Opera100 miles tion 160 kms

(Every month)

125 rds

125 hrs

250 rds

250 hrs

500 rds

500 hrs

1000 rds

1000 hrs

600 mls 1200 mls 2500 mls 5000mls

1000 kms 2000 kms 4000 kms 8000 kms


(Every year)

(Every

2 years)

(Every

4 years) Page

R R R 8-6 EVERY Replace engine oil

YEAR Adjust throttle cables,** choke cable, check carburetor throttle shaft for wear**

Check starter V-belt for damage and tension

Check drive belt for slippage, wear or scratches

Check sliding sheave and ramp shoes; Grease secondary sheave bearing.

Grease primary sheave

Check operation of speed limiter

Apply battery terminal protectant

Check wiring connections and insulation

Check shoe lining thickness and rear axle bearing play

Check kingpin play, seal, and cap / Adjust wheel alignment

Check wheel nut tightness, front wheel bearing play

Check gear box oil level and leakage

Check operation and adjust pedal stop if necessary

CA

C

C

CL

L

C

S

C

C

CA

C

C

CA

CA

C

C

CL

L

C

S

C

C

CA

C

C

CA

CA

C

C

CL

L

C

S

C

C

CA

C

C

CA

*

*

8-8

*

*

*

—

—

*

*

*

8-16

*

C S *

2 YEARS commutator for dirt

EVERY Replace fuel filter and

4 YEARS fuel hoses

Check tightness of cylinder head / Adjust valves

Replace gear box oil

Check for grease leakage; adjust gearbox if necessary

R

CA

R

CA

*

*

*

*

1

2

3

4

5

6

7

8

9

10

11

* Items with out a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does not contain these procedures. They are contained in the Service Manual.

**Related to emission control system.

8-2

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 28

MAINTENANCE

1

2

3

4

5

6

7

8

9

10

11

FOR 16E

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

PRE-OP

Charge

Remarks

Pre-

Operation

S

20 rounds 125 rds

20 hours

100 miles

125 hrs

600 mls

160 kms

(Every

Month)

1000 kms


S S

250 rds

250 hrs

1200 mls

2000 kms

(Every

Year)

S

500 rds

500 hrs

2500 mls

4000 kms

(Every 2 years)

S

1000 rds

1000 hrs

5000 mls

8000 kms

(Every 4 years)

S

Page

8-13

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

S S S S S S

8-11

Check brake pedal freeplay and adjust if necessary

C CA CA CA CA CA 8-18

C C C C C C 6-5 Check steering operation

Check tire pressure, tread depth, tire surface for damage

C CA CA CA CA CA 6-4

Check body and chassis for damage

C C C C C C

6-6

Check tightness of all bolts, nuts, and screws

Check reverse buzzer operation

Check electrolyte level EVERY

MONTH

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

EVERY

YEAR

Perform a discharge test

Apply Terminal protectant

Check shoe lining thickness and rear axle bearing play

Check kingpin play, seal, and cap / Adjust wheel alignment

Check wheel nut tightness, front wheel bearing play

Check gear box oil level and leakage

Check operation and adjust pedal stop if necessary

EVERY 4

YEARS

Replace gear box oil

Check for grease leakage; adjust gear box if necassry

C

C

C

C

C

C

CL

C

C

C

C

C

C

C

C

C

C

C

C

S

S

C

CA

C

C

CA

C

C

C

C

C

C

S

S

C

CA

C

C

CA

C

C

C

C

C

C

S

S

C

CA

C

C

CA

R

CA

*

6-5

8-12

*

*

*

*

*

*

*

8-16

*

*

*

* 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.

8-3

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 29

MAINTENANCE

EXHAUST EMISSION CONTROL SYSTEM

AND COMPONENTS

Item

• CARB. ASSY., LH., JT.,

CARBURETOR 2 & JT.,

CARBURETOR 1

• T.C.I. MAGNETO ASSY. &

PLUG, SPARK

• CRANKCASE 1 & HEAD,

CYLINDER 1

• AIR FILTER ASSY.

• MUFF., 2

Acronym

CARB (Carburetor)

El (Electronic Ignition)

PCV (Positive Crankcase

Ventilation)

ACL (Air Cleaner)

1

2

3

4

5

The above items and the corresponding acronyms are provided in accordance with U.S. EPA REGULATIONS

FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULA-

TIONS FOR NEW 1995 AND LATER

OFF-HIGHWAY RECREATIONAL

VEHICLES AND ENGINES.

6

7

The acronyms conform to the latest version of the SAE’s recommended practice document J1930, “Diagnostic

Acronyms, Terms, and Definitions For

Electrical/Electronic System”.

8

9

It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.

10

11

8-4

G16A/E

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1

2

3

4

5

6

7

8

9

10

B

MAINTENANCE - G16A

A

Y-516

Spark Plug Inspection

You should periodically remove and inspect the spark plug. Dirty or worn spark plugs can cause poor performance.

å Spark plug

∫ Spark plug cap

1.

Check for discoloration and remove carbon deposits with a spark plug cleaner or wire brush.

The normal electrode color will be tan.

2.

Check the spark plug type, and check the spark plug gap with a feeler gauge.

A

Y-37

Standard spark plug:

BPR2ES

Spark plug gap:

0.028 ˜ 0.031 in (0.7 ˜ 0.8 mm)

å Gap

3. Clean the gasket and plug surfaces and install the spark plug finger tight before tightening to the following torque:

Spark plug torque:

14.5 ft.lb

(20 Nm, 2.0 m.kg)

11

WARNING

When removing or installing the spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire.

8-5

G16A/E

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Engine Oil Replacement

1. Warm up the engine for several minutes, place the golf car on a level surface, then stop the engine.

1

2

Recommended oil:

YAMALUBE 4-cycle oil or

SAE 10W-30

Engine oil capacity:

1.16 US qt

(1.0 L, 0.24 Imp gal)

Oil change quantity:

1.0 US qt

(0.9 L, 0.19 Imp gal)

Y-624

WARNING

Use caution not to touch hot engine oil or hot engine parts, during the following procedure.

3

4

2. Place an oil pan under the engine drain plug.

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

5

NOTE :

Dispose of used oil in an environmentally safe way, such as taking oil to an oil collection station.

6

7

4. Install the drain plug, along with a new drain plug gasket, finger tight before tightening to the following torque:

8

Drain plug torque:

23 ft.lb

(31 Nm, 3.1 m.kg)

9

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

10

NOTE :

Recommended engine oil classification: API Service SE, SF, or SG.

Engine oils labeled “Energy Conserving II” are recommended.

11

8-6

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 32

1

2

3

4

5

6

7

8

9

10


å Oil filler hole

A

Y-515

CAUTION

Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the crankcase. After replacing engine oil, check for oil leaks around the drain plug. If oil leaks are found, consult a Yamaha dealer.

B

A

A

A

Y-518

Air Filter

To remove the air filter elements:

1. Unlatch the air filter cover clips and remove cover.

å Air filter cover clips

∫ Air filter cover

2. Lift the air filter and pre-filter out of the air filter case.

å Air filter

∫ Pre-filter

A

CAUTION

Be careful not to drop anything into the air inlet.

B

Y-519

11

8-7

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 33

B


Inspection and cleaning:

1

3.

Wash the foam pre-filter in soap and water. Allow it to dry.

å Soap and water

∫ Foam element

2

4.

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

3

Y-508

CAUTION

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

4

5

5.

To replace the elements, reverse the above steps.

6

CAUTION

The pre-filter has a notch on one side. It will only fit in the case one way.

7

Y-60

Drive Belt

To remove the drive belt:

8

1. Set the drive select lever halfway between forward and reverse.

9

2. Pull up on the drive belt and push it outward over the edge of the secondary sheave.

10

3. Turn the secondary sheave clockwise and the drive belt will roll off the sheave.

11

4. Remove the drive belt from the primary sheave.

8-8

G16A/E

A

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 34

1

2

3

4

5

6

7

8

9

10

11


A

B

Y-44

Inspection:

To inspect the drive belt, check for frayed edges or tears, and measure drive belt against the following specification. If the belt shows excessive wear or damage, replace the belt with a new one.

å New: 1.22 in. (31.0 mm)

∫ Replace when belt reaches:

1.06 in. (27 mm)

5. To install the drive belt, reverse the above steps, rolling the belt back over the secondary sheave.

Battery

WARNING

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 CHIL-

DREN.

8-9

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 35

– –

B

A

G16A/E

D C

+ +


Y-45

Y-522

The 12-volt battery that provides starting power to your gas car normally doesn’t require the addition of water during the one year period provided by the battery manufacturer. If the battery loses its charge, have an experienced mechanic charge it.

1

2

3

Fuse Replacement

WARNING

Be sure to use the specified fuse.

Using a wrong fuse can cause electrical system damage and create a fire hazard.

4

5

CAUTION

When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting.

6

7

1. Remove cap screw on cover. Pull fuse case cover forward.

å Cap screw

∫ Fuse case cover

8

9

NOTE :

You do not have to remove the cover.

10

2. Pull cap off fuse. Pull fuse out and replace if necessary.

ç Fuse cap

∂ Fuse

11

Replacement Fuse:

10 Amp, Blade Style

Y-523

8-10

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1

2

3

4

5

6

7

8

9

10

11

MAINTENANCE - G16E

Battery Care

WARNING

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, ciga-rettes, etc., away.

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

KEEP OUT OF REACH OF CHIL-

DREN.

Six 6-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.

CAUTION

Do not allow cleaning solution to enter battery cells.

2. Check the fluid level before and after charging.

8-11

G16A/E

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G16A/E

D

A

C

B


Y-829

Y-47

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

● After charging: check that the fluid level is approximately 1/4 to 1/2 inch above the plates and 1/4 to 3/8 inch below the level indicator. If the fluid level is low, carefully add distilled water. Adding distilled water

after charging prevents boil over.

å Battery cap

∫ Plates

ç Maximum fluid level

∂ Minimum fluid level

1

2

3

4

5

CAUTION

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.

6

7

8

9

Temperature

90

80

70

60

˚F

120

110

100

50

40

30

˚C

48.9

43.3

37.8

32.2

26.7

21.1

15.6

10.0

4.4

-1.1

Satisfactory Uncorrected

Hydrometer Reading

1.244

1.248

1.252

1.256

1.260

1.264

1.268

1.272

1.276

1.280

8-12

10

11

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 38

1

2

3

4

5

6

7

8

9


Battery Charging

WARNING

Read and understand the owner’s manual provided with your golf car’s battery charger before charging batteries.

OFF

ON

WARNING

Explosive hydrogen gas is produced while batteries are being charged. Only charge batteries in well ventilated areas (a minimum of 5 air changes per hour is recommended).

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. Do not attempt to recharge your golf car’s batteries without thoroughly reading and understanding the owner’s manual provided with your charger.

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

10

Y-15

11

8-13

Y-49

2. With the charger properly connected and grounded (see charger’s owner’s manual), insert the

DC output plug into the golf car receptacle.

3. Monitor the ammeter on the charger according to instructions found in the charger’s owner’s manual.

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 39

B

C

A


WARNING

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.

1

2

4. The charger will turn off automatically when the batteries reach full charge.

3

5. 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

WARNING

When working with batteries, do not put wrenches or other metal objects across the battery terminals. An arc can occur causing explosion of the battery.

4

5

6

7

8

1. Install the battery holddown plates as shown.

å Forward

∫ Battery

ç Battery fitting plate

9

10

Y-50

11

8-14

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 40

1

2

3

4

5

6

7


C

A

B

D

2. Connect the wire leads as shown.

å Forward

∫ To relay

ç To controller

∂ Between batteries

D

D

Y-51

WARNING

When installing batteries:

● Carefully place battery cables

● and holddowns making sure that cables don’t lie across vent caps.

Always remove the negative (–) cable to the motor controller first, and install it last.

Y-52

CAUTION

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

8

9

10

A

B

11

Fuse Type:

10 Amp, Blade Style

8-15

Y-653

Fuse Replacement

WARNING

Be sure to use the specified fuse.

Using a wrong fuse can cause electrical system damage and create a fire hazard.

CAUTION

When replacing a fuse be sure the main switch is turned off to prevent accidental short-circuiting.

å Fuse case

∫ Fuse

G16A/E

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B

MAINTENANCE - G16A & G16E

Gear Box Oil

To check gear box oil level:

1. Place the golf car on a level surface.

2. Remove the access panel by removing the screws in the two lower corners of the panel and pulling the panel from the car.

1

2

3

4

Y-48

Recommended oil:

SAE 90 gear oil

Gearcase capacity:

G16A: 0.44 US qt

(0.42 L, 0.09 Imp gal)

G16E: 0.32 US qt

(0.3 L, 0.06 Imp gal)

A

Y-520

5

3. For G16A and G16E

●

●

Remove the oil level plug (A).

Add gear oil little by little until oil flows from the level plug hole (B).

4. Allow excess gear oil to flow out until it stops.

6

7

CAUTION

Do not allow foreign material to enter the gear box.

8

9

5. Reinstall the oil level plug.

NOTE :

For gear oil replacement, consult a

Yamaha dealer or other qualified mechanic.

10

11

8-16

G16A/E

95%

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1

2

3

4


Y-57

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.

5

Wheel nut tightening torque:

58 ft.lb (80 Nm, 8.0 m.kg)

6

7

8

9

10

Brake Adjustment

The brakes on your golf car are selfadjusting.

Before you operate the car, press down on the brake pedal several times to make sure the brakes are functioning properly.

WARNING

Consult your Yamaha dealer before using your golf car if you suspect brake problems. Brake failure could result in a serious accident.

11

8-17

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 43

25-30 mm


Brake Pedal Free Play

Adjustment

1

CAUTION

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

To adjust the brake pedal free play:

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

2

3

4

7

8

9

10

11

12

13

14

15

16

17

18

5

Y-61

Y-63

Y-62

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:

25-30 mm (0.98-1.18 in.)

9

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

10

11

WARNING

Do not overtighten the brake cables. The self adjusters may not operate properly, reducing braking performance.

8-18

G16A/E

95%

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 44

7

8

9

5

6

10

11

3

4

1

2

A

STORAGE

9-1

Y-521

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

NOTE :

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

DRAINING FUEL

(G16A GAS CAR)

WARNING

Gasoline and its vapors are highly flammable and explosive.

●

●

●

●

●

●

●

Do not smoke when refueling and keep away from sparks, flames, or other sources of ignition.

Stop engine and allow it to cool for several minutes before refueling.

Refuel in a well-ventilated area.

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

Tighten the filler cap securely after refueling.

If you swallow gasoline, inhale a lot of gasoline vapor, or get gasoline in your eyes, get immediate medical attention.

If any gasoline gets on your skin, immediately wash with soap and water. Change clothing if gasoline spills on it.

1. Fill the fuel tank.

å Float bowl drain screw

2. Drain the carburetor float bowl into a suitable container by turning the screw located on the bottom of the carburetor.

G16A/E

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ENGINE PREPARATION

(G16A GAS CAR)

With the key removed and the spark plug lead disconnected, turn the clutch by hand until compression is felt. This puts the valves in the closed position.

CHASSIS

PREPARATION

1. Increase the tire pressure to 20 psi (137 kPa, 1.4 kgf/cm2).

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.

BATTERY

PREPARATION

For G16A:

1. Remove the battery from the golf car and store it in a cool, dry place that stays between 32˚F

(0˚C) and 90˚F (30˚C).

STORAGE

2. Have the battery recharged every

60-90 days to keep it fully charged. The battery must be kept fully charged to avoid damage.

1

2

NOTE :

Batteries like the one supplied with your car normally do not require you to check the water level inside the battery for the one year warranty period provided by the manufacturer.

For G16E:

1.

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

3

4

5

6

CAUTION

Do not allow cleaning solution to enter battery cells.

7

2. Recharge the batteries and check the fluid levels at least once a month.

8

9

10

11

9-2

G16A/E

95%

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 46

10

11

1

2

3

4

5

6

7

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)

Performance:

Maximum speed

G16A G16E

93.9 in. (2385 mm)

47.2 in. (1200 mm)

46.8 in. (1190 mm)

11.8 in. (300 mm)

64.0 in. (1629 mm)

34.3 in. (870 mm)

38.6 in. (980 mm)

3.8 in. (97 mm)

653 lb (296 kg) 560 lb (254 kg)

Minimum turning radius

Seating capacity

Hill climbing ability

12 mph

(19 km/h)

113.0 in. (2.8 m)

2 persons

27˚ (50% grade) on pavement

12-15 mph

(19-24 km/h)

113.0 in. (2.8 m)

2 persons

20˚ (38% grade) on pavement

8

9

10-1

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 47

SPECIFICATIONS

ENGINE

Items

Description:

Engine type

Number of cylinders

Displacement

Bore x stroke

Compression ratio

Rated output

Cooling system

Starting system

Ignition system

Spark plug type

Spark plug gap

Lubrication system

Engine oil type

Engine oil capacity

Oil change quantity

TRANSMISSION

Items

Transmission:

Type

V-belt width and outer line length

V-belt wear limit

Governor:

Type

Factory speed setting

Differential/reduction gear:

Differential type

Lubricant/capacity

G16A

4-stroke, Gasoline, OHV

Single

301 cm

3

3.07 x 2.48 in. (78 x 63 mm)

8.1:1

9.5 hp (7.1 kw)/4000 rpm

Forced air cooled

Starter

TCI Magneto

BPR2ES

0.028-0.031 in. (0.7-0.8 mm)

Splash

YAMALUBE 4 cycle oil or SAE 10W30

1.16 US qt (1.0 L, 0.24 Imp gal)

1.0 US qt (0.9 L, 0.19 Imp gal)

1

2

3

4

5

6

7

G16A

V-belt automatic centrifugal engagement

1.22 x 39.76 in. (31 x 1010 mm)

1.06 in. (27 mm)

Oil bath flyweight

12 mph (19 km/h)

G16A

Bevel gear

SAE 90 gear oil/

0.44 US qt (0.42 L,

0.09 Imp qt)

G16E

Bevel gear

SAE 90 gear oil/

0.32 US qt (0.3 L,

0.26 Imp qt)

8

9

10

11

BATTERIES

Items

Battery:

G16A/E

G16A

BCI group 24,

RC: minimum 75 min

CCA: minimum 400A

G16E

BCI group GC-2

RC: minimum 105 min

10-2

95%

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 48

SPECIFICATIONS

1

2

3

4

5

6

CHASSIS

Items

Steering system:

Type

Steering angle (L.H.)

Steering angle (R.H.)

Lubricant/capacity

Brakes:

Brake system

Type of brake

Brake pedal freeplay linkage adjustment

(Brake cable end play)

Parking brake:

Type

7

8

Release timing

(Bolt heads round parallel to arm)

Wheel:

Tire size:

Front

Rear

Rim size:

Tire pressure:

9

G16A and G16E

Worm and pin

1.5 turn

1.5 turn

Grease/3.0 US oz (0.09 L, 3.17 Imp oz)

Mechanical drum brake on each rear wheel with self-adjusters.

Dual internal expanding shoe.

Leading/trailing shoes (self-adjusting)

25-30 mm

0.004-0.02 in. (0.1-0.5 mm)

Foot type; parking brake with automatic release.

0.04 in. (1 mm)

18 x 8.50–8.00/4 PR

18 x 8.50–8.00/4 PR

7.00–I–8.00

For G16A:

16 psi (108 kPa, 1.1 kgf/cm2)

For G16E:

20 psi (137 kPa, 1.4 kgf/cm2)

10

11

10-3

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 49

G16A WIRING DIAGRAM

WIRING

7

8

9

5

6

10

11

3

4

1

2

11-1

G16A/E

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 50

7

8

9

5

6

10

11

3

4

1

2

WIRING

G16E WIRING DIAGRAM

+

+ + + +

11-2

G16A/E

OWNER’S/

OPERATORS

MANUAL

GOLF CAR

07/12/0 1

1PC - G16A/E O/M

LIT196261600

*LIT196261600*

USA Yamaha Motor Corp., USA

Cypress, California made in

YAMAHA MOTOR

MANUFACTURING CORP.

OF AMERICA


KCC

LIT-19626-16-00

G16A

G16E

JN6-F8199-13

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