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warranty - Kruizinga
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1. JWX 000000 Y 910b 2 3 GOLF CAR SERIAL NUMBER The golf car serial number 1 is identified 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 Golf Car Company dealer OPERATOR SAFETY Yamaha golf cars are designed to be simple to operate However be sure to observe the following BEFORE OPERATING THE GOLF CAR e Read this Owner s Operator s manual and all safety and instruction labels on the golf car before operating e 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 occupants per seat This golf car is restricted to two occupants unless equipped with a rear seat 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 unless allowed by law or local regulating authority WHILE OPERATING THE GOLF CAR e Keep your entire body inside the golf car remain seated and hold on when the car is in motion e Do not start the golf car until all occupants
2. Jw2 8 5 MAINTENANCE BATTERY INSTALLATION AND WIRE LEAD CONNECTION TO RELAY TO MOTOR CONTROL RECEPTACLE UNIT ASSY RECEPTACLE FORWARD 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 3 The charger will turn off automatically when the batteries reach full charge 4 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 1 Install the battery holddown plates and torque to 7 9 Nm 0 7 0 9 m kg 62 80 in lb as shown Forward Battery O Battery holddown plate 2 Connect the wire leads and torque to 9 10 Nm 0 9 1 0 80 89 6 as shown MAINTENANCE Fuse Type 3 Amp Blade Style Jw2 When installing batteries e Carefully place battery cables and holddowns making sure that cables do not lay across vent caps e Always remove the negative cable to the motor controller first and install it last CAUTION Do not overtighten the battery holddown nuts Excessi
3. 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 Jw2 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 Golf Car Company dealer STORAGE AND BATTERY CHARGING Take the following precautions to ensure maintenance worker safety e Only use battery charging facilities and procedures that are in accordance with applicable ordinances and regulations e Periodically inspect charging facilities and procedures to be certain that applicable safety codes regulations and procedures are being followed 4 3 CONTROLS 5 1 FEATURES 1 Brake pedal 2 Parking brake pedal 3 Accelerator pedal 4 St
4. YAMAHA OVVNER S OPEFBATOB S MANUAL 48 VOLT GOLF CAR Jw2 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 2006 by Yamaha Golf Car Company 1st Edition 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 07 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations AN The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED 4 WARNING 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 CAUTION This message describes special precautions that must be taken to avoid damage to the golf car NOTE This message provides additional key information NOTE e Yamaha continually seeks advancements in product design and quality therefore while th
5. 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 Jw2 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 e Properly immobilize golf car before beginning any maintenance e Properly block chassis before working underneath golf car 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
6. E 23108 2 08299 02 5 S3lLIAVO LINDHID a afl ana au g GASNNN 1459 AVP SI 1 5 LHVd HOLO3NNOO gt SS3NHVH SHIM NOILISOd 92 2 DG SI TVNOIS o WOldAL aauinoau SLOVLNOO IWLAW SnoOlO3Hd E Ma AH X AH 1 AH eiuuw Ppeu NH Ad 7 A H Mu Nu 8 TA E YY sis OO 6 5 u 2 0 WU XU LILON MS NIV 9 AH oj 4 cc Hazzna 30 50 MS LILON MS SOVEOLS MOL 3309 40109 WNOILdO 1 11 NOTES NOTES COYAMAHA Printed U S A YAMAHA GOLF CAR 2006 KCC COMPANY 1000 HWY 34 East Newnan GA 30265 770 254 4000
7. are seated e Keep your hands on the steering wheel and your eyes on the path ahead Jw2 3 1 OPERATOR SAFETY e Use extra care in congested areas or when backing up Always back up slowly and watch carefully e Avoid starting or stopping abruptly e Vary the speed of the golf car to match the terrain of the course e Avoid turning the steering wheel too sharply at higher speeds e Always drive slowly straight up or straight down slopes never at an angle e Do not run the engine indoors Exhaust gas is poisonous e Do not make any modification or addition which affects capacity or safe operation or make any changes not in accordance with the owner s operator s manual 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 pers
8. Areas Wet grass may cause a golf car to lose traction and may affect stability Reduce speed in wet areas or during periods of inclement weather SAFETY CONSIDERATIONS e 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 e 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 MAINTENANCE REQUIRED FOR GOLF CAR SAFETY Practice the following to help ensure the safety of golf car operators e Preventative Maintenance Perform all scheduled maintenance in accordance with manufacturer s recommendations to provide the golfing patron with a safe properly operating golf car e Personnel Allow only qualified trained and authorized personnel to inspect adjust and maintain golf cars 4 2 e Parts and Materials Use only replacement parts and materials recommended by the manufacturer e Ventilation Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards Ventilation is required to remove flammable vapors and
9. O YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Yamaha Golf Car Company NEWNAN GEORGIA 30265 1320 EFFECTIVE DATE 10 01 06 LIT 13710 03 06B Jw2 WARRANTY YAMAHA FOUR YEAR LIMITED WARRANTY FOR TROJAN BRAND ELECTRIC GOLF CAR AND UTILITY VEHICLE BATTERIES WHEN CHARGED WITH A YAMAHA 48 VOLT CHARGER 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 G23E or G27E utility vehicles purchased from an Authorized Yamaha Dealer that the Trojan batteries charged with a Yamaha 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 work manship 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 1 000 round limited warranty shall be as follows For YDRE golf car
10. RANTY 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 JW2 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 TO FAILURE DUE TO Abuse or neglect such as improper fluid levels loose wiring rusted or corroded hardware Lack of proper maintenance as outlined in the electric vehicle Owner s Operator s Manual 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 and a battery charged by systems other than the original equipment type battery charger The golf car facility must have ample electrical power to charge the cars and the charge
11. ad the warning fabel on the beverage holder panel before operating Be sure occupants are seated Select FORWARD or REVERSE Parkin PI then turn main switch to Brake Pedal Press the accelerator pedal to start moving The motor wil Brake Pedal 7 start and the parking brake will release automatically Accelerator 77 To stop release the accelerator Pedal pedal and press the brake pedal Never travel at speeds too fast for the terrain visibility conditions or your experience Drive with extra caution in congested areas when operating in reverse and when driving on wet rough or loose surfaces Come to a complete stop before reversing direction Press the parking broke pedal until it locks and turn the main switch to OFF before leaving the vehicle Read the Owner s Operator s Manual for more information ATTENTION This vehicle was not manufactured for use on public streets and does not comply with federal motor vehicle safety standards opplicable to passenger cars YAMAHA JU0 K7762 00 Y 500a Jw2 IMPORTANT LABELS 00 89ZZy eMe 4 4 A 440 sBnup 40 eouenjur eui Jepun ui ueuM pue 440 O3 U91IMS MEIST IET 195 sedojs umop dn mos VHVIAVA suin ui MOS epi
12. ake noise 8 Install the transaxle servicing plug and tighten to 14 19 Nm 1 4 1 9 mekg 120 168 0 9 Install the bag holder insert 3 and secure with two bolts 2 and seven plastic rivets 1 MAINTENANCE Jw2 NOTE For transaxle oil replacement con sult a Yamaha dealer or other quali fied mechanic CAUTION Before performing wheel or brake maintenance verify that the main switch is in the OFF position Wheel Replacement To remove and install a wheel on your golf car 1 With the wheels blocked to 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 58 ft lb 80 Nm 8 0 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 4 WARNING Consult your Yamaha dealer before using your golf car if you suspect brake problems Brake failure could result in a serious accident 8 9 MAINTENANCE Brake Pedal Free Play Adjustment CAUTION Before adjusting brake pedal free play pump the brake pedal several times to self adjust the brakes To adjust the brake pedal free play 1 Remove the floor mat and service lid from the floor of the g
13. ean Lube pedal control area cL EVERY 6 Check all wire insulation for cracks MONTHS and or worn spots Check shock absorbers for oil leaks and damaged springs EVERY Perform a discharge test S YEAR Apply Terminal protectant Check rear axle bearing play E for roughness or freeplay Check steering knuckle bushing freeplay Adjust CA CA CA wheel alignment Check wheel nut tightness front 8 9 wheel bearing play Check transaxle oil level and 8 8 inspect for leakage Check pedal stop operation and adjust if necessary CA CA CA EVERY 4 Replace transaxle oil R YEARS Inspect internal wet brake and CA replace pads if necessary tems without a page number reference shou be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual Jw2 MAINTENANCE Jw2 Battery Care 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 cigar
14. eering wheel 5 Main switch 6 Receptacle 7 Batteries Seat 9 Front cowl Front tire 1 Front bumper 2 Rear cowl 3 Rear tire Rear bumper 5 Tow switch FWD REV switch 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 ON Electrical circuits are switched on REV FWD The golf car can be driven LJ Jw2 5 2 CONTROLS DRIVE SELECT SWITCH wv REV FWD 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 Car Movement 2 FORWARD WD REV REVERSE NOTE The back up buzzer will beep when the drive select switch is turned to REV ACCELERATOR PEDAL The accelerator pedal controls the golf car s speed Depress pedal Increase Release pedal Decrease Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the golf car Brake pedal Jw2 CONTROLS PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the golf car O Parking brake pedal NOTE Release the parking brake by depressing the accelerator pedal 4 WARNING The parking brake will automatically release when the accelerator pedal is depressed If the main switch is in the ON pos
15. ent in second notch Bolt heads round parallel to arm Wheel Tire size Front Rear Rim size Tire pressure Jw2 Rack and Pinion 1 85 turn 1 85 turn Mechanical Internal wet 45 50 mm 1 77 1 96 in 0 004 0 02 in 0 1 0 5 mm Foot type parking brake with automatic release 0 000 0 001 in 0 0 0 3 mm 18 x 8 50 8 00 4 PR 18 x 8 50 8 00 4 PR 7 00 1 8 00 20 psi 138 kPa 1 4 kgf cm 10 2 076 vL3AO3H H39HvHO w2 a L K t H3TIOHINOO tc SB ABB YOSNaS 9 o 370199939 lt 3LIOUHL 3 2 ASSY ul Ju Ass Bi 1081N00 GHvOG 13350 58 2 WY oc a M 11 52 92 2 ay my 02 9
16. ettes 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 CAUTION Do not allow cleaning solution to enter battery cells 2 Check the fluid level before and after charging 8 3 MAINTENANCE e Before charging only add distilled water if fluid is below the top of the plates and then add just enough to cover plates e After charging open the vent caps and look inside the fill wells Add distilled water until the electrolyte level is 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 Fill Well Max Level charged battery M CAUTION Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water Max Level _ discharged battery NON SO NN 3 Using a hydrometer check the specific gravity of the battery fluid in each cell against the readings on the chart bel
17. is manual contains the most current product information available at the time of printing there may be minor discrepancies between your golf car and this manual If you have any questions concerning this manual please consult your Yamaha dealer e This manual should be considered a permanent part of your golf car and should remain with the car when resold WARNING Read and understand this manual completely before operating your golf car CONTENTS WARRANTY IMPORTANT LABELS OPERATOR SAFETY SAFETY CONSIDERATIONS CONTROLS PRE OPERATION CHECKS OPERATION MAINTENANCE STORAGE SPECIFICATIONS E N N 4 Ol WARRANTY YAMAHA LIMITED 3 YEAR GOLF CAR WARRANTY 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 THREE years from date of purchase subject to the stated limitations DURING THE PERIOD OF WARRANTY any authorized Yamaha golf car dealer will free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workman ship 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 prope
18. ition depressing the accelerator may suddenly cause the golf car to move Jw2 5 4 CONTROLS TOW SWITCH Before operating the car make sure the tow switch is in the RUN position Tow switch CAUTION Ensure that the Drive Select Switch is in the FWD position and then move the TOW Switch to TOW before towing Failure to do so may lead to drive system damage 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 WARNING e Be sure the main switch key is removed before performing the pre operation checks to prevent accidental starting and apply the parking brake to keep the car from moving PRE OPERATION CHECKLIST Before each use check the following Batteries Tire condition Steering system Back up buzzer V Pedal operation Body and chassis SEAT Open the seat for checking and servicing Jw2 6 1 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 TIRE CONDITION Tire Air Pressure Check the tire air pressure befo
19. lf 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 Jw2 8 1 MAINTENANCE FOR JW2 C CHECK AND ADJUST R REPLACE S SERV CE CLEAN AND LUBRICATE L LUBRICATE 40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds Daily 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks Pre 100 miles 600 mis 1200 mis 2500 mis 5000 mls Page Opera 160 kms 1000 kms 2000 kms 4000 kms 8000 kms tion Every Every 6 Every Every 2 Every 4 Month months Year years years PRE OP Charge 8 5 Clean battery tops check for 8 3 tightness of hold down screws and 5 5 5 6 2 terminals Check brake pedal freeplay and 8 9 adjust if necessary 8 10 Check steering operation 6 3 tire pressure tread depth 6 2 tire surface for damage Check body and chassis for 64 damage Check tightness of all bolts nuts x screws and rivets Check reverse buzzer operation c 6 3 EVERY Check electrolyte level c 8 3 8 4 Check for loose or broken connections Cl
20. n transporting a golf car or charger to and from an authorized Yamaha golf car dealer for service or in performing field service is also excluded from this warranty 1 1 THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the golf car and charger as specified in the appropriate Owner s Operator s Manual 2 notice to an authorized Yamaha golf car dealer of any and all apparent defects within ten 10 days after discovery and make the machine or charger available at that time for inspection and repairs by the dealer s authorized representative WARRANTY TRANSFER To transfer any remaining warranty from the original purchaser to any subsequent purchaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha golf car dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service YAMAHA GOLF CAR COMPANY MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA GOLF CAR COMPANY AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY T
21. olf car 2 Check the brake pedal free play by pressing against the pedal with two fingers using light force and measuring the distance the pedal travels before resistance is felt Brake pedal free play 8 45 50 mm 1 77 1 96 in 3 If the free play distance needs adjusting loosen the lock nut A and turn the adjusting nut B in or out until the free play specification is met Then tighten the lock nut in place Do not over tighten the brake cables Over tightening will increase brake wear and affect overall performance of car STORAGE Perform the following preparations 2 Have the batteries recharged when storing your golf car for every 60 90 days to keep them extended periods of time fully charged The batteries must be kept fully charged to avoid NOTE damage Turn main switch key to OFF position remove key and store key CAUTION in a safe place Do not allow cleaning solution to enter battery cells CHASSIS PREPARATION 3 Clean the top of the batteries with a solution of baking soda 1 Verify the tire pressure is set to and water as necessary to 20 psi 138 kPa 1 4 kgf cm remove corrosion 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 1 Remove the batteries from the golf car and
22. onnel 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 conspicuous location Jw2 Do Not Operate Golf Cars When Under The Influence Of Alcohol Or Drugs GOLF COURSE SAFETY SURVEY Perform safety surveys regularly to identify hazardous areas where golf cars should not be operated GOLF COURSE HAZARD PREVENTION The following golf course hazards must be made safe e 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 4 WARNING Steep Grade Descend Slowly With Foot On Brake e 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 Wet
23. or PTV G23E or G27E utility vehicles free replacement within four years or 20 000 amp hours discharged or 500 hours elapsed time usage whichever event occurs first as determined by YGC using the information recorded and stored in the Genius controller This warranty only applies to Trojan battery sets charged with a Yamaha brand battery charger supplied by YGC 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 Thirty six 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 BO 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 Yamaha 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 WAR
24. ow Consult a Yamaha dealer if any low readings are found or if readings vary more than one point between cells Temperature Satisfactory Uncorrected F Hydrometer Reading 120 48 9 1 244 110 43 3 1 248 100 37 8 1 252 90 32 2 1 256 80 26 7 1 260 70 21 1 1 264 60 15 6 1 268 50 10 0 1 272 40 4 4 1 276 30 1 1 1 280 8 4 Jw2 MAINTENANCE Battery Charging Read and understand the owner s manual provided with your golf car s battery charger before charging batteries WARNING 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 To charge the batteries in your golf car follow the instructions con tained in your battery charger s owner s manual The following is a summary of the charging steps WARNING Do not attempt to recharge your golf car s batteries without thor oughly reading and understanding the owner s manual provided with your charger REV FWD 1 Turn main switch key to OFF position 2 With the charger properly connected and grounded see charger s owner s manual insert the DC output plug into the golf car receptacle CAUTION Use only battery chargers that are rated for use with 48 volt Yamaha Golf Cars Thoroughly read and understand the user manual supplied with your 48 volt charger
25. re operating the golf car Tire pressure For JW2 20 psi 138 kPa 1 4 kgf cm 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 Wear limit PRE OPERATION CHECKS STEERING SYSTEM Check the steering system for excessive free play by e moving the steering wheel up and down and back and forth e turning the steering wheel slightly to the right and left If you feel excessive free play 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 switch to C REV for reverse The buzzer should sound REV FWD PEDAL OPERATION Check the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha dealer Accelerator Pedal 4 WARNING Before checking operation of the accelerator pedal be sure the main switch is in the OFF position Make sure the accelerator pedal operates smoothly Accelerator pedal Jw2 6 3 PRE OPERATION CHECKS Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its original position when released Brake pedal Parking Brake Pedal Make sure the parking brake pedal locks in place with a positive click and releases when the accelerator pedal i
26. rs must be allowed to shut off automatically 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 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 WARRANTY LIMITATIONS Yamaha Golf Car Company and Trojan Battery Company s 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 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 This warranty gives you specific legal rights and
27. rty 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 9 Acts of God i e lightning hail damage flooding fire etc SPECIFIC EXCLUSIONS The first year of warranty shall cover the entire car except for the specific exclusions below Parts excluded from the second year of warranty include the YDRA battery body parts seats mats bumper assembly bag carrier scorecard holder and the trim Parts excluded from the third year of warranty include the second year exclusions and the electrical system except electronic speed controller battery charger and electric motor and control cables Other specific exclusions from this warranty shall include any parts replaced due to normal wear or routine maintenance including oil and air filter ele ments tire wear spark plugs starter and clutch drive belts Any charges incurred i
28. s pressed O Parking brake pedal NOTE Release the parking brake by depressing the accelerator pedal BODY AND CHASSIS Before each use visually inspect the golf car body and chassis for damage and or missing parts 6 4 Jw2 OPERATION STARTING 1 With the parking brake applied turn the drive select switch to FWD for forward or REV for reverse CAUTION Do not shift from FWD forward to REV reverse while the golf car is moving 3 Jw2 2 A WARNING Do not depress the accelerator pedal when turning on the main switch or the golf car may suddenly start moving Turn the main switch to ON 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 Accelerator pedal NOTE The parking brake automatically releases when the accelerator pedal is depressed 7 1 OPERATION 7 2 STOPPING To stop the golf car gradually press down on the brake pedal Brake pedal When the car has come to a stop apply the parking brake pedal and turn the main switch to OFF Parking brake pedal CAUTION Do not hold the golf car on an incline with the accelerator use the brake Jw2 MAINTENANCE PERIODIC MAINTENANCE CHARTS Regular maintenance is required for the best performance and safe operation of your go
29. store them in a cool dry place that stays between 32 F 0 C and 90 F 30 C Jw2 9 1 SPECIFICATIONS GENERAL SPECIFICATIONS 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 1505008 for Europe Vibration on steering wheel EN1032 1505008 for Europe Performance Factory speed setting Maximum speed Minimum turning radius Seating capacity TRANSMISSION Differential reduction gear Differential type Lubricant capacity 10 1 93 4 in 2395 mm 47 2 in 1200 mm 46 9 in 1190 mm 12 2 in 310 mm 64 6 in 1640 mm 34 3 in 870 mm 38 6 in 980 mm 4 3 in 110 mm 535 Ib 243 kg Will not exceed 0 5 m s Will not exceed 2 5 m s 12 mph 19 km h 15 mph 24 km h 114 2 in 2 9 m 2 persons per seat Bevel gear SAE80 W90 API GL 5 limited slip high performance gear oil 1 43 US quarts 1350 mL 1350 cc Jw2 SPECIFICATIONS BATTERIES Items Battery YDRE Trojan Golf Car Type T 1275 4x12 volt RC minimum 102 min CHASSIS Steering system Type Steering angle L H Steering angle R H Brakes Brake system Type of brake Brake pedal freeplay linkage adjustment Brake cable end play Parking brake Type Release timing With pedal segm
30. sui deax uonouu ui uaym pjou pue paeas peyees sjuednooo un 14 3 jees sjuednooo uey apis sese poyeubisap ui Ajuo pue uoneJedo eui uo jeqe eui SNOILONYLSNI 5 1 MOT1IOS OL SYNTIVA LINSSY NYO TVNOSH3d 3Ha as HO Hlivad ONINHVM V 00 2628 ZMf s euiuuo 2 pue Aunful jo eu pue sdeo E jou oq suang dn i ut ynse1 jou og pue S1HOHS iji 47 7291319573 alov ormnnains ONINHVM 77 Buom pieius pue sowey syieds peiejnuea d y peBaeuosip 10 s n yeq i S3SV9 3AISO dX3 t ASSV LINN 1041 02 319 19393 3194193934 OL OL NOLLO3NNOO QV3 133IM NOILVTIVLSNI AH3 LIVG D 2 2 JW IMPORTANT LABELS
31. ve force will damage the battery casing Fuse Replacement 4 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 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 Fuse holder Fuse 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 CAUTION Do not allow foreign material to enter transaxle 7 If needed add SAE80 W90 GL 5 limited slip high perfor mance gear oil until it is at the top of the plug hole or just begin ning to run out of servicing hole NOTE The YDRE Golf Car is equipped with an internal wet brake Use of oil other than SAE80 W90 API GL 5 limited slip high performance gear oil will cause br
32. 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 Yamaha Golf Car Company NEWNAN GEORGIA 30265 1320 EFFECTIVE DATE 10 01 06 LIT 13710 EL 16B 1 2 2 AVERTISSEMENT SAFETY AND INSTRUCTION LABELS 4 WARNIN Please read the following labels carefully before operating your golf car and promptly replace any labels which become damaged or removed Move switch to the TOW position before towing or storage Fallure to do so lead to Drive system damage or electrical fire when towin Complete battery discharge and battery damage when storing long term NOTE After moving switch from RUN to TOW wait 15 seconds minimum before switching again Mettre l interrupteur position TOW avant de remorquer ou avant l entreposage TOW Non observation pourrait e endommager le syst me d actionnement causer un incendie lectrique pendant la remorque e causer une d charge totale de la batterie et la batterie pendant l entreposage long terme NOTE Apr s avoir chang l interrupteur de RUN position RUN position TOW attendre un minimum de 15 seconds avant de le remettre YAMAHA UA 829600 844 OPERATING INSTRUCTIONS Re
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