2013 - Village Discount Golf Car
Contents
1. 1 MY g Y Hiuva ONS Av 13H dOLS ON3 11 1 JW8 notes notes G9 YAMAHA Printed in U S A YAMAHA GOLF CAR 2012 KCC COMPANY 1000 HWY 34 East Newnan GA 30265 770 254 40002. 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 To keep car from moving while performing pre operation checks e Remove main switch key e Apply parking brake Death or serious personal injury can result from failing to comply with the safety instructions in this manual PRE OPERATION CHECKLIST Before each use check the following V Fuel system w Engine oil level Battery Tire condition w Steering system Reverse alarm V Pedal operation Body and chassis SEAT Open the seat for checking and servicing PRE OPERATION CHECKS FUEL SYSTEM Make sure there is sufficient fuel in the tank and that the fuel shutoff valve is open Also check fuel line and connections for leakage Fuel tank Fuel cap O Fuel shutoff valve D Fuel tank vent WARNING Gasoline and its vapors are highly flammable and explosive To avoid fires and explosions and to reduce the risk of injury when refueling follow these instructions Y 1990b 1 Stop engine and allow it to cool for several minutes before refueling Do not smoke when refueling and keep away from sparks flames or other sources of ignition Refuel in a well ventilated area 2 Take care not to spill gasoline If gasoline spills wipe it up immediately with dry rags
3. Overall width 1200 mm 47 2 in Overall height steering height 1190 mm 46 9 in Height of floor 310 mm 12 2 in Wheelbase 1640 mm 64 6 in Tread Front 870 mm 34 3 in Rear 980 mm 38 6 in Minimum ground clearance 110 mm 4 3 in Weight Dry weight with suntop without battery 276 kg 609 Ib Performance Factory speed setting 19 km h 12 mph Maximum speed 24 km h 15 mph Minimum turning radius 2 8 m 9 2 ft Seating capacity Two occupants per seat four occupants maximum Fuel Tank Capacity 22 0 L 5 8 U S Gallons PAINT CODES Glacier 918519 Emerald 48748 Garnet 701739 Tanzanite 917834 Onyx Metallic 918520 Anthracite Metallic 918522 Sandstone Metallic 918523 10 1 i SPECIFICATIONS ENGINE Description Engine type 4 stroke Gasoline 60 incline OHV Number of cylinders Single Displacement 357 cms Bore x stroke 85 x 63 mm 3 30 x 2 48 in Compression ratio 8 1 1 Rated output 8 5 kw 11 4 hp 3500 rpm Cooling system Forced air cooled Starting system Starter Ignition system TCI Magneto Spark plug type BPR2ES Spark plug gap 0 7 0 8 mm 0 028 0 031 in Lubrication system Splash style positive oil lubrication Engine oil type YAMALUBE 4 cycle oil or 10W30 Engine oil capacity 1 0 L 1000 cc 1 0 US qt Oil change quantity 1 0 L 1000 cc 1 0 US qt TRANSMISSION Transmission Type V belt automatic centrifugal engagement V belt width and outer line length 31 0 x 1010 mm 1 2
4. To remove the drive belt 1 Set the drive select lever halfway between forward and reverse 2 Pull up on the drive belt and push it outward over the edge of the secondary sheave 3 Turn the secondary sheave clockwise and the drive belt will roll off the sheave 4 Remove the drive belt from the primary sheave MAINTENANCE Y 44 45 JW8 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 New 31 0 mm 1 20 in Replace when belt reaches 27 0 mm 1 06 in 5 To install the drive belt reverse the above steps rolling the belt back over the secondary sheave Battery The 12 volt battery that provides starting power to your gas car normally does not require the addition of water If the battery loses its charge have an experienced mechanic charge it 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 imme diately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce exp
5. sions control system warranty on your 2010 or later small off road engine SORE vehicle In California new SORE vehicles must be designed built and equipped to meet the State s stringent anti smog standards Yamaha Golf Car Company must warrant the EECS on your SORE vehicle for the period of time listed below provided there has been no abuse neglect or improper maintenance of your SORE vehicle Your EECS may include parts such as the carburetor fuel injection system the ignition system catalytic converter fuel tanks fuel lines fuel caps valves canisters filters vapor hoses clamps connectors and other associated emission related components Where a warrantable condition exists Yamaha Golf Car Company will repair your SORE vehicle at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE This emissions control system is warranted for two years If any emission related part on your equip ment is defective the part will be repaired or replaced by Yamaha Golf Car Company OWNER S WARRANTY RESPONSIBILITIES As the SORE vehicle owner you are responsible for performance of the required maintenance listed in your owner s manual Yamaha Golf Car Company recom mends that you retain all receipts covering mainte nance on your SORE vehicle but Yamaha Golf Car Company cannot deny warranty solely for the lack of receipts As the SORE vehicle owner you should however be aware that Yam
6. 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 applicable to passenger cars YAMAHA JUO K7762 00 Y 500a 2 1 LLI 4 lt A 6991 10 2628 WT nb jauuosJad np Jed no alleuuolssaouoo VHVINVA 9 Jed Sagnjoayja JUAAIOP suoisiAgJ sa1e jauuosiad payijenb 10 Jaleap uonejueuipe p 9 sed N e peuuopied aq pinous sea uas e pneu no auno wuajsfs any jou 00 e essay ej 1 Jnalou al anb juepuad jueJnqeo ap Jajnofe sed N e peads 109 6uluum Jnodnalgln691 191942 sed uengues 8SV3JIU 0 10 5 ajuM janp ppe 100 od e d sap 19 JJONaSe sanu Jedure jou 00 e jonj pue jan 19 Sayjaouga p ap e2unos alnol e uado pue syseds e Y1 5391593719 S3AVUD A JrBd Ino 20 JAAS asneo ab
7. 1 mm 0 04 in replace the tire Wear limit PRE OPERATION CHECKS STEERING SYSTEM Check the steering system for exces sive 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 Y 932 hear rattling sounds which may indicate loose steering components consult a Yamaha dealer REVERSE ALARM Check the reverse alarm by moving the drive select lever to R for reverse The alarm should sound 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 Make sure the main switch is in the OFF position Make sure the accelerator pedal operates smoothly Y 20A Accelerator pedal PRE OPERATION CHECKS Y 21a Y 22a JW8 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 is pressed O Parking brake pedal TIP 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
8. 1 oz of stabilizer for each gallon of fuel TIP Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system Consult a Yamaha dealer if the fuel system needs to be drained instead STORAGE ENGINE PREPARATION With the key removed and the spark plug lead disconnected turn the clutch by hand until compression is felt This puts the valves in the closed position CHASSIS PREPARATION 1 Verify the tire pressure is set to 110 kPa 1 1 kgf cm 16 psi 2 Clean exterior of the golf car and apply a rust inhibitor 3 Cover the golf car with a breathable cover and store it a dry well ventilated area BATTERY PREPARATION 1 Remove the battery from the golf car and store it in a cool dry place that stays between 0 C 32 F and 30 C 90 F JW8 2 Have the battery recharged every 60 90 days to keep it fully charged The battery must be kept fully charged to avoid damage 3 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 provid ed by the manufacturer NOTICE Do not allow cleaning solution to enter battery cells Serious bat tery damage can result 4 Clean the top of the battery with a solution of baking soda and water as necessary to remove corrosion SPECIFICATIONS GENERAL SPECIFICATIONS Dimensions Overall length 2395 mm 94 3 in
9. LABELS YEAR OF CONSTRUCTION 20XX MODEL YDRAX YAMAHA MOTOR POWERED PRODUCTS CO LTD MAX POWER X X KW 200 1 SAKAGAWA KAKEGAWA JAPAN DRY WEIGHT XXX kg MAX BATTERY WEIGHT XX kg JXX F4236 XX Y 1607c EMISSION CONTROL INFORMATION YAMAHA MOTOR CO LTD THIS EQUIPMENT CONFORMS TO 2000 CALIFORNIA EVP EXH REGULATIONS AND MEETS U S EPA EVAP STANDARDS FOR SMALL OFF ROAD ENGINE CONFORMS TO PHASE 3 U S EPA Y 1599c Y 1610 JW8 2 3 IMPORTANT LABELS JWX 000000 Y 1539 SM 03 399 GOLF CAR SERIAL NUMBER The golf car serial number 1 is identified in the location shown TIP The first three digits of the serial number are for model identification the remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha Golf Car Company dealer The engine serial number 2 is affixed in the location shown 3 Engine Information IMPORTANT ENGINE INFORMATION ENGINE FAMILY rre REFER OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YAMAHA DISPLACEMENT ee HEF pe IGNITION TIMING amp DLE MIXTURE NO OTHER ADJUSTMENTS NEEDED IDLE SPEED ATNOLOAD FUEL THS ENGINE 5 CERTIFIED TO OPERATE ON UNLEACED GASOLINE ENGINE OL SAE 100830 me 50 THIS ENGINE MEETS CALIFORNIA EMISSION REGULAT
10. 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 to avoid tipping or rolling the golf car e Always drive slowly straight up or straight down slopes never at an angle to avoid tipping or rolling the golf car e Do not run the engine indoors Exhaust gas is poisonous and could result in carbon monoxide poisoning 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 p
11. comply with the safety and warn ing instructions affixed to the golf car or utility vehicle 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 4 1 SAFETY CONSIDERATIONS e Wet Areas Wet grass may cause a golf car to lose traction and may affect stability Golf car operators should reduce speed in wet areas or during periods of inclement weather 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 4 2 e Personnel Allow only qualified train
12. damage can result MAINTENANCE 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 per form maintenance unless otherwise specified If the owner is not familiar with servicing the machine death or serious personal injury can result When in doubt the work should be done by a Yamaha dealer or other qualified mechanic CS CHECK CA CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE 40 Rounds 250 rds 500 rds 1000rds 2000 rds 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks 100 miles 600 mis 1200 mis 2500 mis 5000mis 160 kms 1000 kms 2000 kms 4000 kms 8000 kms Every Every 6 Every Every Every month months year 2 years 4 years Check engine oil CS cs Check air cooling duct cs cs cs cs cs Check fuel lines for leakage cs cs cs cs cs Check fuel level cs cs cs cs CS Check for looseness and corrosion of battery CS CS CS CS CS terminals and hold downs Check brake pedal free play and adjust if necessary CA CA CA CA CA Check steering operation CS CS CS CS Check tire pressure tread depth tire surface for damage CA CA CA CA Check body and chassis for damage CS CS CS CS Check tightness of all bolts nuts screws and rivets cs cs cs cs Check reverse alarm operation cs cs cs c
13. for inspection and repairs by the dealer s authorized representative WARRANTY TRANSFER Any transfer of warranty must take place within the first three years of the original in service date of the vehicle The vehicle must be re registered by an authorized Yamaha Golf Car Dealer within 30 days of transfer A fee may be charged for the transfer of the warranty YAMAHA GOLF CAR COMPANY MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA GOLF CAR COMPANY AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY IS ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Yamaha Golf Car Company NEWNAN GEORGIA 30265 1320 EFFECTIVE DATE 6 1 11 LIT 13710 01 12 JW8 WARRANTY CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Yamaha Golf Car Company are pleased to explain the emis
14. wire brush The normal electrode color will be tan 2 Check the spark plug type and check the spark plug gap with a feeler gauge Standard spark plug BPR2ES Spark plug gap 0 7 0 8 mm 0 028 0 031 in Gap 3 Clean the gasket and plug surfaces and install the spark plug finger tight before tightening to the following torque Spark plug torque 20 Nm 2 0 m kg 14 5 ft lb JW8 8 4 MAINTENANCE Y 624 Recommended oil YAMALUBE 4 cycle oil or 10W30 Engine oil capacity 1 0 L 1000 cc 1 0 US qt Oil change quantity 1 0 L 1000 cc 1 0 US qt Engine Oil Replacement 1 Warm up the engine for several minutes place the golf on a level surface then stop the engine WARNING Use caution not to touch hot engine oil or hot engine parts during the following procedure Death or serious personal injury can result from failing to comply with the safety instructions in this manual 2 Place an oil pan under the engine drain plug 3 Remove the oil drain plug and let the oil drain completely TIP Dispose of used oil in an environmentally safe way such as taking oil to an oil collection station 4 Install the drain plug along with a new drain plug gasket finger tight before tightening to the following torque Drain plug torque 31 Nm 3 1 m kg 23 16 5 Add the correct qu
15. 0 x 39 76 in V belt wear limit 27 0 mm 1 06 in Governor Type Oil bath flyweight Factory speed setting 19 km h 12 mph Differential reduction gear Differential type Bevel gear Lubricant capacity Yamalube Friction Modified Shaft Drive Gear Oil 1750 mL 1 85 quarts total Alternative lubricant is mixture of 1660 mL 1 75 quarts 80W90 Gear Oil and 90 mL 0 10 quarts API G15 Limited Slip Additive 10 2 SPECIFICATIONS BATTERIES Battery BCI group 24 RC minimum 75 min CCA minimum 400A CHASSIS Steering system Type Steering angle L H Steering angle R H Brakes Brake system Type of brake Brake pedal free play linkage adjustment Brake cable end play Parking brake Type Release timing With pedal segment in second notch Bolt heads round parallel to arm Wheel Tire size Front Rear Rim size Tire pressure 10 3 Rack and Pinion 1 85 turn 1 85 turn Mechanical Maintenance Free internal transaxle disc brake 45 50 mm 1 77 1 96 in 0 1 0 5 mm 0 004 0 02 in Foot type parking brake with automatic release 0 0 0 3 mm 0 000 0 001 in 18 x 8 50 8 00 4 PR 18 x 8 50 8 00 4 PR 7 00 1 8 00 110 kPa 1 1 kgf cm 16 psi JW8 WIRING YDRA WIRING DIAGRAM Ov6 A YOLVYINS YLVIS Div vOL 3503 18 3onv5 13441110 V viaa 01 062 8 avi fore H H H
16. Always dispose of gasoline soaked rags properly 3 Tighten the filler cap securely after refueling WARNING Gasoline is poisonous and can cause injury or death If you swallow gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical i attention Gasoline based fuels containing more than 1096 ethanol are not If any gasoline gets on your skin recommended and may void the immediately wash with soap and warranty water Change clothing if gasoline spills on it Recommended fuel Unleaded gasoline Fuel tank capacity 22 0 L 5 8 US gal JW8 6 2 PRE OPERATION CHECKS Recommended oil YAMALUBE 4 cycle oil or 10W30 Engine oil capacity 1 0 L 1000 cc 1 0 US qt Oil change quantity 1 0 L 1000 cc 1 0 US qt 6 3 NOTICE Avoid using gasoline blended with methyl alcohol which can damage fuel system parts ENGINE OIL With the golf car parked on level ground remove the dipstick and make sure the engine oil is between the MIN and MAX marks the crosshatched area on the end of the dipstick Oil level dipstick Maximum oil level Safe operating range If the oil level is below the MIN mark on the dipstick add oil through the oil filler hole until the oil level is between the MIN and MAX marks Oil filler hole NOTICE Engine damage can result e Use care not to fill past the MAX di
17. Bd3Nn VEINIVHLN 1784 S3dnafBdns pinos uoisojdxa 10 aly V S3SS31IA SAC V NOLLVSITLLN 1 36079 13 TTEVIAWY HNI 183 3995537 TIVAN H ATHOIH SI 3NTIOSV9 9091A OO LLEZHONE VHVWVA np JnejjnoJq ins np sel sejnoj eyoedseu ep ejyeoune Jed eD suonsin6ey 3ueuudinb3 eoueJej1ejuj uelpeueo jo Sjueuueuinbeu ujejsAs eds SIUL 00 89Z2M LMr 4 3 N N HVAA VHVIAVA Jd m Suunl ul MOS eplsul poq eunue uonouu ui uo pue paeas pejees sjuednooo UN HEJS JOU 5 Jouoore jo eouenyur y 4epun ees sluednooo om esn ui pue 440 O1 Uollws AlUO epls s JeAuP elolUueA 6ulAeal Bured jos ueu Iuo sedo s umop pue dn Ajmojs eAudg uone4edo uo peleool jeqe au 5 3S3HL AAO TIOH OL SHNTIVS iNOS 110599 NYO AHnnNI TVNOSHd SH3A3S HO HLV3Q ONINHVM V Wa IMPORTANT
18. ER OFF HIGHWAY RECREATIONAL VEHICLES AND ENGINES The abbreviations conform to the latest version of the SAE s recom mended practice document J1930 Diagnostic Acronyms Terms and Definitions For Electrical Electronic System It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic TROUBLESHOOTING If the vehicle s engine won t start use the following chart Fuel System No fuel in tank Fill fuel tank Fuel shutoff valve Open fuel shutoff closed valve Clogged fuel Clean fuel line line Consult Yamaha dealer Foreign matter Clean fuel filter in fuel filter Consult Yamaha dealer Clean carburetor Consult Yamaha dealer Electrical System Spark plug dirty Clean carbon or with carbon or wipe spark plug wet dry Faulty ignition Consult Yamaha System dealer Clogged carburetor MAINTENANCE Spark Plug Inspection You should periodically remove and inspect the spark plug Dirty or worn spark plugs can cause poor performance 4 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 Death or serious personal injury can result from failing to comply with the safety instructions in this manual Spark plug Spark plug cap 1 Check for discoloration and remove carbon deposits with a spark plug cleaner or
19. IONS FOR OFF ROAD ENGINES THIS ENGINE CONFORMS U S EPA REGULATIONS FOR SMALL NONROAD ENGINES YAMAHA MOTOR CO LTD Y 851a Jws OPERATOR SAFETY JW8 Yamaha golf cars are designed to be simple to operate However be sure to observe the following to reduce the risk of serious injury or death due to loss of control and other hazards 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 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 e 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 effect 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 the 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 are seated e Keep your hands on the steering wheel and your eyes on the path ahead 3 1 OPERATOR SAFETY e
20. YAMAHA OWNER S OPERATOR S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information YDRA 4 STROKE GOLF CAR LIT 19626 11 13 JW8 F8199 21 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 JW8 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 YDRA OWNER S OPERATOR S MANUAL 2012 by Yamaha Golf Car Company 3rd Edition All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Golf Car Company is expressly prohibited Printed in U S A LIT 19626 11 13 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations AN This is the safety alert symbol It is used to alert you to potential person al injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death WARNING A WARNING indicates a potentially hazardo
21. aha Golf Car Company may deny you warranty coverage if your SORE vehicle or a part has failed due to abuse neglect or improper maintenance or unapproved modifications You are responsible for presenting your SORE vehicle to Yamaha Golf Car Company s distribution center or service center as soon as the problem exists The war ranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have a question regarding your warranty coverage you should contact YGC Service at 1 866 747 4027 GENERAL EMISSIONS WARRANTY COVERAGE Yamaha Golf Car Company warrants to the ultimate purchaser and each subsequent purchaser that the SORE vehicle is Designed built and equipped so as to conform with all applicable regulations and JW8 Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in Yamaha Golf Car Company s application for certifica tion The warranty period begins on the date the SORE vehicle is delivered to an ultimate purchaser or first placed into service The warranty period is two years Subject to certain conditions and exclusions as stated below the warranty on emission related parts is as fol lows 1 Any warranted part that is not scheduled for replacement as required maintenance in the writ ten instructions supplied is warranted for the war ranty period stated above If the part f
22. ails during the period of warranty coverage the part will be repaired or replaced by Yamaha Golf Car Company according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period 2 Any warranted part that is scheduled only for regu lar inspection in the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining warranty period 3 Any warranted part that is scheduled for replace ment as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first sched uled replacement the part will be repaired or replaced by Yamaha Golf Car Company according to subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part 4 Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner 5 Notwithstanding the provisions herein warranty services or repairs will be provided at all of our dis tribution centers that are franchised to service the subject engines or equipment 6 The SORE vehicle owner will not be charged for diagnostic labor that is direct
23. antity of oil through the oil filler hole TIP Recommended engine oil classification Service SE SF or SG Engine oils labeled Energy Conserving II are recommended MAINTENANCE Oil filler hole NOTICE Use care not to fill past the MAX dipstick mark and be sure no foreign material enters the crankcase Serious engine damage can result After replacing engine oil check for oil leaks around the drain plug If oil leaks are found consult a Yamaha dealer Air Filter To remove the air filter elements 1 Unlatch the air filter cover clips and remove cover Air filter cover clips Air filter cover 2 Lift the air filter and pre filter out of the air filter case Air filter D Pre filter NOTICE Be careful not to drop anything into the air inlet Serious engine damage can result JW8 8 6 MAINTENANCE Inspection and cleaning 3 Wash the foam pre filter in soap and water Allow it to dry A Soap and water Foam element 4 Check the filter element If damaged or dirty replace it NOTICE Do not wring out the foam pre filter this could cause it to tear 5 To replace the elements reverse the above steps NOTICE The pre filter has a notch on one side It will only fit in the case one way Serious engine damage can result from an improperly posi tioned filter Drive Belt
24. asoline and its vapors are highly flammable and explosive Death or serious personal injury can result from failing to comply with the safety instructions in this manual e Do not smoke when draining fuel and keep away from sparks flames or other sources of ignition Stop engine and allow it to cool for several minutes before draining fuel Drain fuel 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 checking fuel level to avoid leaking If you 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 to avoid potential fire hazard 9 1 1 Fill the fuel tank with fresh fuel and add the specified amount of Yamaha Fuel Stabilizer and Conditioner or equivalent product Operate the vehicle for at least five minutes to distribute treated fuel through the fuel system Float bowl drain screw 2 Turn the fuel shutoff valve to the CLOSED position 3 Drain the carburetor float chamber into a clean container by loosening the drain bolt this will help prevent fuel deposits from building up Pour the drained fuel into the fuel tank Specified amount 7 5 cc of stabilizer for each liter of fuel
25. batteries to avoid electrical shock or damage to the electrical system e Maintain all safety devices includ ing brakes steering mechanisms warning devices and governors in a safe operating condition Do not modify these safety devices as supplied by the manufacturer e After each maintenance or repair the car must be driven by a qualified trained and authorized person an area free of pedestrian traffic to ensure proper operation and adjustment JW8 e Record all maintenance performed in a maintenance record log by date name of person performing maintenance and type of maintenance Periodically inspect maintenance log to ensure accurate and complete entries e Provide operator comment cards to assist in identifying non periodic maintenance needs for specific golf cars e Maintain in a legible condition all nameplates warnings and instructions provided by the manufacturer e If new nameplates warnings or instructions are needed contact your Yamaha Golf Car Company dealer FUEL HANDLING STORAGE AND BATTERY CHARGING Take the following precautions to ensure maintenance worker safety e Supervise the storage and handling of liquid fuels in accordance with applicable fire and safety requirements to avoid any fires or explosions e Only use battery charging facilities and procedures that are in accordance with applicable ordinances and regulations to avoid explosions electrical shock or
26. damage to the electrical system e Periodically inspect fueling to be certain that applicable safety codes regulations and procedures are being followed to avoid any fires or explosions 4 3 CONTROLS FEATURES D Brake pedal 2 Parking brake pedal 3 Accelerator pedal Steering wheel 5 Oil warning light 6 Main switch 7 Drive select lever Choke knob 9 Seat Front body Front tire 2 Front bumper 43 Battery Rear body 45 Rear tire Rear bumper 7 Fuel tank Fuel cap Fuel shutoff valve Fuel tank vent California models only Y 1990d CONTROLS OFF Y912bb OFF Y 911aa JW8 MAIN SWITCH The main switch controls the following items OFF All electrical circuits are switched off The key can be removed only in this position ON Electrical circuits are switched on The golf car can be driven OIL WARNING LIGHT When the engine oil level falls below an acceptable level this light comes on NOTICE If the light comes on stop the engine check the engine oil level and add oil as necessary Engine damage can result from low engine oil levels See page 6 3 Oil warning light CONTROLS Y 18 Y 20A Y 21a DRIVE SELECT LEVER The drive select lever is used t
27. direct cause of the need for repair or replacement of the part That notwithstanding any adjustment of a component that has a factory installed and properly operating adjustment limiting device is still eligible for warranty coverage The following emission warranty parts are covered Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps Control Valves Control Solenoids Electronic Controls Control Cables 10 Control Linkages 11 Vapor Hoses 12 Carbon Cannister 13 Cannister Mounting Brackets JW8 IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS A WARNING Read the following labels carefully before operating your golf car and promptly replace any labels which become damaged or removed Death or serious personal injury can result from failing to read and comply with the safety labels in this manual JW8 OPERATING INSTRUCTIONS Read the warning label on the beverage holder panel before operating Be sure occupants are seated Select FORWARD or REVERSE Parkin PI then turn main switch to ON Brake eda Press the accelerator pedal to start moving The motor will Brake Pedal start and the parking brake will release automatically Accelerator 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
28. ed 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 the car storage areas during the battery charging process Jws N 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 to avoid any unexpected vehicle movement e Properly block chassis before working underneath golf car to avoid any unexpected vehicle movement e Before disconnecting any part of the fuel system drain the applicable part of the system to prevent fuel leaks e When working on the fuel system or the battery do not smoke or allow any sparks or open flames near the vehicle to avoid any fires or explosions e Before performing any maintenance disable the car s electrical system in accordance with the manufacturer s instructions e Use only properly insulated tools when working around
29. ersonnel 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 JW8 WARNING Do not operate golf cars or utility vehicles when under the influence of alcohol or drugs Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle 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 WARNING Descend steep grades slowly with foot on brake Death or serious per sonal injury can result from failing to
30. ing play cs cs cs for roughness or freeplay Check steering knuckle bushing free play Adjust CA CA CA wheel alignment Check wheel nut tightness front wheel bearing play cs cs cs Check transaxle oil level and inspect for leakage Check operation and adjust pedal stop if necessary cs cs cs CA CA Check brushes for wear and commutator for dirt Replace transaxle oil Replace fuel filter and fuel hoses Check tightness of cylinder head Adjust valves Inspect internal wet brake and replace pads if necessary Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual Related to emission control system JW8 8 2 MAINTENANCE EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS tem sd Abbreviation CARB ASSY LH JT CARBURETOR 2 amp JT CARBURETOR 1 T C l MAGNETO ASSY amp PLUG SPARK CRANKCASE 1 amp HEAD CYLINDER 1 CARB Carburetor Electronic Ignition PCV Positive Crankcase Ventilation AIR FILTER ASSY ACL Air Cleaner MUFF ASSY 1 MUFF 2 __ CANISTER The above items and the corresponding abbreviations are provided in accordance with U S EPA REGULATIONS FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULATIONS FOR NEW 1995 AND LAT
31. losive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN MAINTENANCE 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 Death or serious personal injury can result from failing to comply with the safety instructions in this manual NOTICE When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting and electrical system damage 1 Locate the in line fuse holder on the main wire harness adjacent to the battery 2 Pull fuse holder cover off 3 Pull fuse out inspect and replace if necessary A Fuse holder Fuse Fuse Type 10 Amp Blade Style MAINTENANCE Y 1994 JW8 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 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
32. ly associated with diagnosis of a defective emission related warrant ed part provided that such diagnostic work is per formed at a warranty station 7 Yamaha Golf Car Company is liable for damages to other engine or equipment components proxi mately caused by a failure under warranty of any warranted part WARRANTY 8 Throughout the SORE vehicle warranty period stated above Yamaha Golf Car Company will maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the perfor mance of any warranty maintenance or repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of Yamaha Golf Car Company 10 Add on or modified parts that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disal lowing a warranty claims Yamaha Golf Car Company will not be liable to warrant failures of warranted parts caused by the use of a non exempted add on or modified part WARRANTED PARTS The repair or replacement of any warranted part other wise eligible for warranty coverage may be excluded from such warranty coverage if Yamaha Golf Car Company demonstrates that the SORE vehicle has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the
33. missing parts 6 6 OPERATION Y 18 Y 911aa Y 20B 7 1 STARTING 1 With the parking brake applied turn the drive select lever to F for forward or R for reverse NOTICE Do not shift from F forward to R reverse while the golf car is moving Transmission damage can result 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 start moving unexpectedly Death or serious personal injury can result from failing to comply with the safety instructions in this manual 3 Pull the choke knob out and hold it while starting Release the choke knob after the engine starts Choke knob TIP 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 slow ly depress the accelerator pedal The golf car will start to move Accelerator pedal TIP The parking brake automatically releases when the accelerator pedal is depressed JW8 OPERATION Y 65c JW8 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 NOTICE Do not hold the golf car on an incline with the accelerator use the brake Transmission
34. o shift the golf car into forward or reverse After coming to a complete stop move the lever to the desired position Lever Position Car Movement FORWARD REVERSE TIP The reverse alarm will sound when the drive select lever is turned to R 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 JW8 CONTROLS Y 22a Clockwise closed Counterclockwise open Y 1572 JW8 PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the golf car O Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal WARNING The parking brake will automatically release when the accelerator pedal is depressed If the main switch is in the ON position depressing the accelerator may suddenly cause the golf car to move Death or serious personal injury can result from failing to comply with the safety instructions in this manual CHOKE KNOB Pull and hold out choke knob when starting a cold engine Release the knob after the engine starts A Choke knob FUEL SHUTOFF VALVE Ensure the fuel shutoff valve is in the OPEN position for normal operation Fuel shutoff valve 5 4 PRE OPERATION CHECKS
35. of hole NOTICE Do not allow foreign material to enter transaxle Serious transaxle damage can result 7 If needed add Yamalube Friction Modified Shaft Drive Gear Oil until it is at the top of the plug hole or just beginning to run out of servic ing hole TIP The YDRA Golf Car is equipped with an internal wet brake Use of oil other than Yamalube Friction Modified Shaft Drive Gear Oil will cause brake noise 8 Install the transaxle servicing plug and tighten to 14 19 Nm 1 4 1 9 m kg 120 168 in lb 9 Install the bag holder insert 3 and secure with two bolts 2 and seven plastic rivets 1 8 10 MAINTENANCE 8 11 TIP For transaxle oil replacement con sult a Yamaha dealer or other quali fied mechanic NOTICE Before performing wheel or brake maintenance verify that the main switch is in the OFF position Serious transaxle damage can result Wheel Replacement To remove and install a wheel on your golf car 1 With the wheels blocked to prevent the golf car from moving loosen the wheel nuts 2 Elevate the golf car with a jack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 88 Nm 8 8 m kg 65 ft lb Brake Adjustment The brakes on your golf car are self adjusting Before you operate the car press down on the brake pedal several times to make sure the b
36. pstick mark and be sure no foreign material enters the crankcase e Use care not to get oil on the starter belt TIP The distance between the dipstick marks represents approx 1 2 1 2 US qt of oil TIP Recommended engine oil classification API Service SE SF or SG Engine oils labeled Energy Conserving are recommended PRE OPERATION CHECKS Y 1347 JW8 Engine Cooling Inlet Duct Check the engine cooling inlet duct for debris Remove any debris present Engine cooling inlet duct BATTERY Check that the battery is held securely in place to prevent the battery 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 WARNING Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Ventilate when charg ing or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the golf car Tire pressure 110 kPa 1 1 kgf cm 16 psi Tire Wear Limit Check the tire surface for damage cracks or embedded objects When tire tread wears down to
37. r will free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty work manship or material from the factory Parts used in warranty repairs will be warranted for the balance of the vehicle s warranty period All parts replaced under warranty become property of Yamaha Golf Car Company GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Abnormal strain neglect or abuse including lack of proper maintenance and use contrary to the Owner s Operator s Manual instructions b Accident or collision damage c Installation of parts or accessories that are not original equipment d Fading rust or deterioration due to exposure or ordinary wear and tear e Modifications or alterations that affect the car s condition operation performance or durability or which makes the car serve a purpose other than use as a two person golf course vehicle f Damage due to improper transportation g Acts of God i e lightning hail damage flooding fire etc WARRANTY COVERAGE Year 1 The first year of warranty shall cover the entire vehicle except for the Specific Exclusions below Year 2 The second year exclusions are the YDRA battery body parts seats mats bumper assembly bag carrier scorecard holder trim and the Specific Exclusions below The third year exclusions include the second year exclusions plus the control cables and electrical sy
38. rakes are functioning properly 4 WARNING Consult your Yamaha dealer before using your golf car if you suspect brake problems Death or serious personal injury can result from fail ing to comply with the safety instructions in this manual MAINTENANCE Brake Pedal Free Play Adjustment NOTICE Before adjusting brake pedal free play pump the brake pedal several times to self adjust the brakes To adjust the brake pedal free play 1 Remove the floor mat and service lid from the floor of the golf car 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 Y 62b 3 If the free play distance needs adjusting loosen the lock nut under rubber boot and turn the adjusting nut in or out until the free play specification is met Then tighten the lock nut in place NOTICE Do over tighten the brake cables Over tightening will Y909D increase brake wear and affect overall performance of car Premature brake wear can result swe 8 12 STORAGE Perform the following preparations when storing your golf car for extended periods of time TIP Turn main switch key to OFF position remove key and store key in a safe place DRAINING FUEL G
39. s Check fuel filter for clogging cs cs cs cs Check wear of drive belt cs cs cs cs Check operation of Forward Reverse shifting cs Clean Lube pedal control area CL 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 Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual Related to emission control system 8 1 JW8 MAINTENANCE CS CHECK CA CHECK AND ADJUST R REPLACE 5 5 CL CLEAN AND LUBRICATE L LUBRICATE 40 Rounds 250 rds 500 rds 1000rds 2000 rds 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks 100 miles 600 mls 1200 mis 2500 mis 5000mis 160 kms 1000 kms 2000 kms 4000 kms 8000 kms Every Every 6 Every Every Every month months year 2 years 4 years Replace engine oil R R R Adjust throttle cables choke cable check carburetor CA CA CA throttle shaft for wear Check starter V belt for damage and tension cs cs cs Check drive belt for slippage wear or scratches cs cs cs Check operation of speed limiter cs cs cs Apply battery terminal protectant S S S Check wiring connections and insulation CS CS CS Check rear axle bear
40. stem except electronic speed controller battery charger and electric motor and the Specific Exclusions below Year 4 The fourth year of the warranty covers only the electric motor speed controller battery charger and transaxle on the YDRE and the engine clutch system except drive belt and transaxle on the YDRA Year 3 SPECIFIC EXCLUSIONS Specific exclusions from this warranty shall include the following Electric car batteries which are covered under a separate warranty Any parts replaced due to normal wear or routine maintenance including oil and air filter elements tire wear spark plugs starter and clutch drive belts 1 1 Any charges incurred in transporting a golf car or charger to and from an authorized Yamaha golf car dealer for service or in performing field service are also excluded from this warranty Gasoline powered golf car starting batteries on vehicles equipped with a golf course GPS device or any other device with a parasitic current draw unless the vehicle is equipped from the factory with an optional deep cycle starting battery THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the golf car and charger as specified in the appropriate Owner s Operator s Manual 2 Give notice to an authorized Yamaha golf car deal er of any and all apparent defects within ten 10 days after discovery and make the vehicle or charger available at that time
41. us situation which if not avoided could result in death or serious injury NOTICE A NOTICE indicates special pre cautions that must be taken to avoid damage to the vehicle or other property TIP ATIP provides key information to make procedures easier or clearer TIP Yamaha continually seeks advancements in product design and quality therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your golf car and this manual If you have any questions concerning this manual please consult your Yamaha dealer WARNING Read and understand this manual completely before operating your golf car This manual should be considered a permanent part of your golf car and should remain with the car when resold CONTENTS amp WARRANTY IMPORTANT LABELS OPERATOR SAFETY SAFETY CONSIDERATIONS CONTROLS PRE OPERATION CHECKS OPERATION MAINTENANCE STORAGE SPECIFICATIONS c 11 WARRANTY LIMITED 4 YEAR GOLF CAR LIMITED 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 deal er in the United States will be free from defects in material and workmanship for FOUR years from date of purchase subject to the stated limitations DURING THE PERIOD OF WARRANTY any autho rized Yamaha golf car deale
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