48 VOLT GOLF CAR YDRE

OWNER’S / OPERATOR’SMANUAL

LI T -19626-21-07 JW2-F8199-10YAMAHA GOLF-CAR

COMPANY 1000 HWY 34 East Newnan, GA 30265

770-254-4000

Printed in U .S. A 2006-KCC

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INTRODUCTIONCongratulations on your purchase of aYamaha golf car. This manual containsinformation you will need for proper operation, maintenance, and care of yourgolf car. A thorough understanding ofthese simple instructions will help you toobtain maximum enjoyment from yournew Yamaha.

If you have any questions about the operation or maintenance of your golfcar, please consult a Yamaha dealer.

YAMAHA GOLF-CAR COMPANY

YDRE OWNER’S/OPERATOR’SMANUAL

© 2006 by Yamaha Golf-Car Company1st Edition

All rights reserved. Any reprintingor unauthorized use without the

written permission ofYamaha Golf-Car Company

is expressly prohibited.Printed in U.S.A.LIT-19626-21-07

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IMPORTANT MANUALINFORMATION

� Yamaha continually seeks advancements in product designand quality; therefore, while thismanual contains the most currentproduct information available at thetime of printing, there may beminor discrepancies between yourgolf car and this manual. If you have any questions concerning thismanual, please consult yourYamaha dealer.

� This manual should be considereda permanent part of your golf carand should remain with the carwhen resold.

Read and understand this manualcompletely before operating yourgolf car.

Particularly important information isdistinguished in this manual by the following notations:

The Safety Alert Symbol meansATTENTION! BE ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNINGinstructions could result in severeinjury or death to the golf car occupants, a bystander, or a person inspecting or repairing the golf car.

This message describes specialprecautions that must be taken toavoid damage to the golf car.

This message provides additionalkey information.

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WARRANTY

CONTENTS

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IMPORTANT LABELS 2

SAFETY CONSIDERATIONS 4

MAINTENANCE 8

STORAGE

SPECIFICATIONS

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WIRING 11

OPERATION 7

PRE-OPERATION CHECKS 6

CONTROLS 5

OPERATOR SAFETY 3

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WARRANTY

Yamaha Golf-Car Company hereby warrants that anynew YDRA gas or YDRE electric Yamaha golf car purchased from an authorized Yamaha golf car dealerin the United States will be free from defects in materialand 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 partadjudged 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 replacedunder warranty become property of Yamaha Golf-CarCompany.

GENERAL EXCLUSIONS from this warranty shallinclude any failures caused by:

a. Abnormal strain, neglect, or abuse, includinglack of proper maintenance, and use contraryto 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 otherthan use as a two-person, golf course vehicle.

f. Damage due to improper transportation.g. Acts of God, i.e. lightning, hail damage,

flooding, fire, etc.

SPECIFIC EXCLUSIONS: The first year of warrantyshall cover the entire car except for the specific exclusions below. Parts excluded from the second yearof warranty include the YDRA battery, body parts,seats, mats, bumper assembly, bag carrier, scorecardholder, and the trim. Parts excluded from the third yearof warranty include the second year exclusions and theelectrical system (except electronic speed controller,battery charger, and electric motor), and control cables.Other specific exclusions from this warranty shallinclude any parts replaced due to normal wear or routine maintenance, including oil and air filter ele-ments, tire wear, spark plugs, starter and clutch drivebelts. Any charges incurred in transporting a golf car orcharger to and from an authorized Yamaha golf cardealer for service or in performing field service is alsoexcluded from this warranty.

THE CUSTOMER’S RESPONSIBILITY under thiswarranty shall be to:1. Operate and maintain the golf car and charger as

specified in the appropriate Owner’s/Operator’sManual;

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

WARRANTY TRANSFER: To transfer any remainingwarranty from the original purchaser to any subsequentpurchaser, it is imperative that the machine be inspectedand registered for warranty by an authorized Yamahagolf car dealer. In order for this warranty to remain ineffect, this inspection and registration must take placewithin ten (10) days after transfer. An inspection andregistration fee will be charged for this service.

YAMAHA GOLF-CAR COMPANY MAKES NOOTHER WARRANTY OF ANY KIND, EXPRESSEDOR IMPLIED. ALL IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FOR APARTICULAR PURPOSE WHICH EXCEED THEOBLIGATIONS AND TIME LIMITS STATED IN THISWARRANTY ARE HEREBY DISCLAIMED BYYAMAHA GOLF-CAR COMPANY AND EXCLUDEDFROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG AN IMPLIED WARRANTY LASTS, SOTHE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTYARE ANY INCIDENTAL OR CONSEQUENTIALDAMAGES INCLUDING LOSS OF USE. SOMESTATES DO NOT ALLOW THE EXCLUSION ORLIMITATION OF INCIDENTAL OR CONSEQUENTIALDAMAGES, SO THE ABOVE EXCLUSION MAY NOTAPPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGALRIGHTS, AND YOU MAY ALSO HAVE OTHERRIGHTS, WHICH VARY, FROM STATE TO STATE.

Yamaha Golf-Car Company, NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 10/01/06LIT-13710-03-06B

YAMAHA LIMITED 3-YEARGOLF CAR WARRANTY

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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 or “1,000 round” limited warranty shall be as follows:

For YDRE golf car 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-(((80-TEMP)/100) x 0.64)).

The customer must notify the Dealer within 10 days that a vehicle has failed to make 36 holes per day. 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 WARRANTY. YAMAHA MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE, EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS LIMITED WARRANTY.

LIMITED WARRANTY EXCLUSIONSWithout 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 chargers 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 LIMITATIONSYamaha 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 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 30265-1320EFFECTIVE DATE: 10/01/06 LIT-13710-EL-16B

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IMPORTANT LABELS

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Y-924

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SAFETY AND INSTRUCTION LABELS

Please read the followinglabels carefully beforeoperating your golf car, and promptly replace anylabels which become damaged or removed.

Y-500a

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Y-844a

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IMPORTANT LABELS

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IMPORTANT LABELS

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GOLF CAR SERIALNUMBERThe golf car serial number 1 isidentified in the location shown.

The first three digits of the serialnumber 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 YamahaGolf-Car Company dealer.Y-910b

JWX

-000

000

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OPERATOR SAFETY

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Y-928

Y-68

Yamaha golf cars are designed to besimple to operate. However, be sureto observe the following:

BEFORE OPERATINGTHE GOLF CAR� Read this Owner’s/Operator’s

manual and all safety and instructionlabels on the golf car before operating.

� Perform the pre-operation checksfound in Section 6 of this manual.

� Only authorized people shoulddrive the golf car, from the driver’sside only, and only in designatedareas.

� Do not allow more than two occupants per seat. This golf car isrestricted to two occupants unlessequipped with a rear seat.

� Do not operate the golf car whileunder the influence of alcohol ordrugs; their affect on vision andjudgment make operating a golfcar dangerous.

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

WHILE OPERATING THEGOLF CAR� Keep your entire body inside the

golf car, remain seated, and holdon when the car is in motion.

� Do not start the golf car until alloccupants are seated.

� Keep your hands on the steeringwheel and your eyes on the pathahead.

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� Use extra care in congested areasor when backing up. Always backup slowly, and watch carefully.

� Avoid starting or stopping abruptly.

� Vary the speed of the golf car tomatch the terrain of the course.

� Avoid turning the steering wheeltoo sharply at higher speeds.

� Always drive slowly straight up orstraight down slopes – never at anangle.

� Do not run the engine indoors.Exhaust gas is poisonous.

� Do not make any modification oraddition which affects capacity orsafe operation, or make anychanges not in accordance withthe owner’s/operator’s manual.

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Y-921

Y-922

Y-923

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SAFETY CONSIDERATIONS

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Like all machines, golf cars cancause injury if improperly used ormaintained. This section containsbroad safety practices required forsafe golf car operation. Before golfcars are operated, golf course personnel should establish any additional safety practices that maybe required for safe operation.

Experience has shown that golf cars are safe when operated inaccordance with the safety warningsaffixed to every golf car. This safeoperation is enhanced when golfcars are used according to the safetyrules and practices established tomeet the terrain and conditions ofthe course they are used on.

The information contained here isintended for golf course personnelresponsible for golf car safety. If youare responsible for the operationand maintenance of this golf car, weencourage you to implement thisgolf car safety program.

DRIVER QUALIFICATIONSAllow only authorized people tooperate golf cars. It is recommendedthat only people who possess avalid motor vehicle driver’s licensebe allowed to operate golf cars.

Place operation and safety instructions recommended by thegolf car manufacturer, along with the golf course safety rules, in aconspicuous place near the golf carrental area or golf car pick-up area.It is also recommended that the following warning be posted in aconspicuous location:

Do Not Operate Golf Cars WhenUnder The Influence Of AlcoholOr Drugs

GOLF COURSE SAFETYSURVEYPerform safety surveys regularly toidentify hazardous areas where golfcars should not be operated.

GOLF COURSE HAZARDPREVENTIONThe following golf course hazardsmust be made safe:

� Steep Grades. Where steepgrades exist, restrict golf cars todesignated golf car pathwayswhere possible. In addition, identify steep grades with a suitable warning like:

Steep Grade, Descend SlowlyWith Foot On Brake

� Sharp Turns, Blind Corners,Bridge Approaches. Chain orrope off these potentially hazardous areas or identify themwith a suitable warning describingthe nature of the hazard and theproper precautions to be taken toavoid the hazard.

� Wet Areas. Wet grass may causea golf car to lose traction and mayaffect stability. Reduce speed inwet areas or during periods ofinclement weather.

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SAFETY CONSIDERATIONS

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� Loose Terrain. Loose terrain maycause a golf car to lose tractionand may affect stability. Repairloose terrain, chain or rope offthese areas, or identify loose terrain with a suitable warning.

� Golf Car and Pedestrian Interference. Reroute golf car traffic or pedestrian traffic in congested areas wherever possibleto prevent accidents. If it is impractical to reroute traffic, erectwarning signs to warn pedestriansof golf car traffic, and to warn golfcar operators to drive slowly, usecaution, and watch for pedestrians.

MAINTENANCE REQUIRED FOR GOLFCAR SAFETYPractice the following to help ensurethe safety of golf car operators:

� Preventative Maintenance. Perform all scheduled maintenance in accordance withmanufacturer’s recommendationsto provide the golfing patron with asafe, properly operating golf car.

� Personnel. Allow only qualified,trained, and authorized personnelto inspect, adjust, and maintaingolf cars.

� Parts and Materials. Use onlyreplacement parts and materialsrecommended by the manufacturer.

� Ventilation. Properly ventilate allmaintenance and storage areas inaccordance with applicable firecodes and ordinances to avoid firehazards. Ventilation is required toremove flammable vapors andfumes from gasoline powered carstorage areas. Ventilation is alsorequired to remove hydrogen gasfrom the car storage areas duringthe battery charging process.

For electric powered golf cars, theamount of hydrogen gas emittedduring charging depends on anumber of factors, such as thecondition of the batteries, the outputrate of the battery charger, and theamount of time the batteries are oncharge. Because of the highlyvolatile nature of hydrogen gas andits propensity to rise and accumulateat the ceiling in pockets, a minimumof 5 air changes per hour isrecommended. Consult applicablefire and safety codes for the specificventilation levels requirement, aswell as requirements for the use ofexplosion proof electrical apparatus.

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SAFETY CONSIDERATIONS

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SAFETY PRECAUTIONSDURING MAINTENANCEWhen performing maintenance, followall safety instructions contained in themanufacturer’s operation and servicemanuals, as well as the followingsafety procedures:

� Properly immobilize golf car beforebeginning any maintenance.

� Properly block chassis before working underneath golf car.

� Avoid fire hazards, and haveappropriate fire protection equipment available.

� Before working on an electric golfcar, disable the car’s electricalsystem in accordance with themanufacturer’s instructions.

� Use only properly insulated toolswhen working on electricallypowered golf cars or aroundbatteries.

� Maintain all safety devices includingbrakes, steering mechanisms,warning devices, and governors, ina safe operating condition. Do notmodify these safety devices assupplied by the manufacturer.

� After each maintenance or repair,the car must be driven by aqualified, trained, and authorizedperson – in an area free ofpedestrian traffic – to ensure properoperation and adjustment.

� Record all maintenance performedin a maintenance record log bydate, name of person performingmaintenance, and type of

maintenance. Periodically inspectmaintenance log to ensureaccurate and complete entries.

� Provide operator comment cardsto assist in identifying non-periodicmaintenance needs for specificgolf cars.

� Maintain in a legible condition allnameplates, warnings, andinstructions provided by the manufacturer.

� If new nameplates, warnings, orinstructions are needed, contactyour Yamaha Golf-Car Companydealer.

STORAGE AND BATTERY CHARGINGTake the following precautions toensure maintenance worker safety:

� Only use battery charging facilitiesand procedures that are in accordance with applicable ordinances and regulations.

� Periodically inspect charging facilities and procedures to be certain that applicable safetycodes, regulations, and procedures are being followed.

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CONTROLS

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FEATURES1 Brake pedal2 Parking brake pedal3 Accelerator pedal4 Steering wheel5 Main switch6 Receptacle7 Batteries8 Seat9 Front cowla Front tireb Front bumperc Rear cowld Rear tiree Rear bumperf Tow switchg FWD/REV switch

Y-930a

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CONTROLS

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OFFON

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REV FWD

OFFON

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REV FWD

MAIN SWITCHThe main switch controls the following items:

OFFIgnition circuit is switched off.The key can be removed only in thisposition.

ONElectrical circuits are switched on.The golf car can be driven.

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CONTROLS

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DRIVE SELECT SWITCHThe drive select switch is used toshift the golf car into forward orreverse. After coming to a completestop, move the lever to the desired position.

Switch Position Car Movement

FWD FORWARD

REV REVERSE

The back-up buzzer will beep whenthe drive select switch is turned to“REV.”

ACCELERATOR PEDALThe accelerator pedal controls thegolf car’s speed.

Action Car Speed

Depress pedal Increase

Release pedal Decrease

å Accelerator pedal

BRAKE PEDALPress down on the brake pedal tostop the golf car.

∫ Brake pedal

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OFFON

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REV FWD

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CONTROLS

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PARKING BRAKEPEDALPress down on the parking brakepedal whenever parking the golf car.

ç Parking brake pedal

Release the parking brake bydepressing the accelerator pedal.

The parking brake will automaticallyrelease when the accelerator pedalis depressed. If the main switch isin the “ON” position, depressingthe accelerator may suddenlycause the golf car to move.

Y-22a

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CONTROLS

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

å Tow switch

Ensure that the “Drive SelectSwitch” is in the “FWD” positionand then move the “TOW Switch”to “TOW” before towing.

Failure to do so may lead to drivesystem damage.

CAUTION / AVERTISSEMENT

TOW

RUN A

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PRE-OPERATION CHECKS

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Pre-operation checks should bemade each time you use your golfcar. Get in the habit of performingthe following checks in the sameway so that they become secondnature.

� Be sure the main switch key isremoved before performing thepre-operation checks to preventaccidental starting, and applythe parking brake to keep thecar from moving.

PRE-OPERATIONCHECKLISTBefore each use check the following:

� Batteries� Tire condition� Steering system� Back-up buzzer� Pedal operation� Body and chassis

SEATOpen the seat for checking and servicing.

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PRE-OPERATION CHECKS

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BATTERIESCheck that the batteries are heldsecurely in place to prevent themfrom being damaged from vibrationor jarring. Also check that no batterycaps are missing to prevent batteryacid from spilling from the batteries.Check the battery terminals for corrosion.

TIRE CONDITION

Tire Air PressureCheck the tire air pressure beforeoperating the golf car.

Tire pressure:

For JW2: 20 psi(138 kPa, 1.4 kgf/cm2)

Tire Wear LimitCheck the tire surface for damage,cracks or embedded objects. Whentire tread wears down to 0.04 in. (1 mm), replace the tire.

å Wear limit

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STEERING SYSTEMCheck the steering system forexcessive free play by:

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

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

If you feel excessive free play, orhear rattling sounds which may indicate loose steering components,consult a Yamaha dealer.

BACK-UP BUZZERCheck the back-up buzzer by moving the drive select switch to“REV” for reverse. The buzzershould sound.

PEDAL OPERATIONCheck the following pedal controlsfor proper operation. If a pedal doesnot work properly, consult a Yamahadealer.

Accelerator Pedal

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

Make sure the accelerator pedaloperates smoothly.

å Accelerator pedal

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PRE-OPERATION CHECKS

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Brake PedalMake sure the brake pedal feels firmwhen pressed and returns to its original position when released.

∫ Brake pedal

Parking Brake PedalMake sure the parking brake pedallocks in place with a positive click,and releases when the acceleratorpedal is pressed.

ç Parking brake pedal

Release the parking brake bydepressing the accelerator pedal.

BODY AND CHASSISBefore each use, visually inspect the golf car body and chassis fordamage and/or missing parts.

Y-22a

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OPERATION

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OFFON

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STARTING1. With the parking brake applied,

turn the drive select switch to“FWD” for forward, or “REV” forreverse.

Do not shift from “FWD” forwardto “REV” reverse while the golfcar is moving.

2. Turn the main switch to “ON.”

Do not depress the acceleratorpedal when turning on the mainswitch or the golf car may suddenly start moving.

3. Check that your path is clear inthe direction you plan to go, andslowly depress the acceleratorpedal. The golf car will start tomove.

å Accelerator pedal

The parking brake automaticallyreleases when the accelerator pedalis depressed.

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OPERATION

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STOPPINGTo stop the golf car, gradually pressdown on the brake pedal.

å Brake pedal

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

∫ Parking brake pedal

Do not hold the golf car on anincline with the accelerator – usethe brake.

Y-65bA

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MAINTENANCE

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PERIODIC MAINTENANCE CHARTSRegular maintenance is required for the best performance and safe operation ofyour golf car.

Be sure to turn off the main switch and apply the parking brake when you performmaintenance unless otherwise specified. If the owner is not familiar with machineservicing, this work should be done by a Yamaha dealer or other qualified mechanic.

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MAINTENANCE

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8-2 JW2

DailyPre-

Opera-tion

20 hours100 miles160 kms(EveryMonth)

125 hrs600 mls

1000 kms(Every 6months)

250 hrs1200 mls2000 kms

(EveryYear)

500 hrs2500 mls4000 kms(Every 2years)

1000 hrs5000 mls8000 kms(Every 4years)

PageRemarks

40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds

ChargePRE-OP

EVERYMONTH

EVERY 6MONTHS

EVERYYEAR

EVERY 4YEARS

8-5

6-28-3/

8-9/8-10

*

8-9/*

*

*

*

*

*

*

—

—

6-3

6-3

6-2

6-4

8-3/8-4

8-8

*

* Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual doesnot contain these procedures. They are contained in the Service Manual.

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

FOR JW2

Clean battery tops, check fortightness of hold-down screws andterminals

Check brake pedal freeplay andadjust if necessary

Check steering operation

Check tire pressure, tread depth,tire surface for damage

Check body and chassis for damage

Check tightness of all bolts, nuts,screws and rivets

Check for loose or brokenconnections

Check all wire insulation for cracksand/or worn spots

Check wheel nut tightness, frontwheel bearing play

Check transaxle oil level andinspect for leakage

Check shock absorbers for oil leaksand damaged springs

Clean/Lube pedal control area

Check reverse buzzer operation

Check electrolyte level

Perform a discharge test

Apply Terminal protectant

Check pedal stop operation and adjust if necessary

Inspect internal wet brake andreplace pads if necessary

Replace transaxle oil

S

S

C

C

C

C

C

C

S

S

CA

CA

CL

C

C

C

C

C

C

S

S

CA

CA

C

C

C

C

C

C

C

C

S

S

S

S

CA

CA

CA

C

C

C

C

C

C

C

C

C

C

S

S

S

S

CA

CA

CA

C

C

C

C

C

C

C

C

C

C

S

S

S

S

CA

CA

CA

CA

C

C

C

C

C

C

C

C

C

C

*

*

Check rear axle bearing playfor roughness or freeplay

C

CA

C

CA

C

CA

R

Check steering knucklebushing freeplay / Adjustwheel alignment

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MAINTENANCE

8-3JW2

Battery Care

Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuric acid.Avoid contact with skin, eyes, orclothing.Antidote:EXTERNAL: Flush with water. INTERNAL: Drink large quantities ofwater or milk. Follow with milk ofmagnesia, beaten egg, or vegetableoil. Call physician immediately.EYES: Flush with water for 15 minutes and get prompt medical attention.Batteries produce explosive gases.Keep sparks, flame, cigarettes, etc.,away.Ventilate when charging or using inenclosed space. Always shield eyeswhen working near batteries.KEEP OUT OF REACH OFCHILDREN.

Four 12-volt deep cycle batteriesprovide power for your electric golfcar and must be properly maintainedand recharged for maximumperformance and service life.

To maintain your batteries:

1. Clean the tops of the batterieswith a solution of baking sodaand water, as necessary, toremove corrosion.

Do not allow cleaning solution toenter battery cells.

2. Check the fluid level before andafter charging.

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MAINTENANCE

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8-4 JW2

� Before charging: only add distilledwater if fluid is below the top of theplates, and then add just enough tocover plates.

� After charging: open the vent capsand look inside the fill wells. Adddistilled water until the electrolytelevel is 1/8" below the bottom of thefill well. A piece of rubber can beused safely as a dipstick to helpdetermine this level. Clean, replaceand tighten all vent caps.

Normal tap water containsminerals which are harmful to abattery; therefore, refill only withdistilled water.

3. Using a hydrometer, check thespecific gravity of the battery fluidin each cell against the readingson the chart below. Consult aYamaha dealer if any low readingsare found, or if readings vary morethan one point between cells.

Temperature Satisfactory Uncorrected

˚F ˚C 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

Y-936

POS

NEG

1/8”

Electrolyte 1/8” BelowBottom of Fill Well

Max. Level - discharged battery

Max. Level - charged battery

Fill Well

Electrolyte

Y-937

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MAINTENANCE

8-5JW2

Battery Charging

Read and understand the owner’smanual provided with your golfcar’s battery charger beforecharging batteries.

Explosive hydrogen gas is produced while batteries arebeing charged. Only charge batteries in well ventilated areas(a minimum of five air changesper hour is recommended).

To charge the batteries in your golf car, follow the instructions con-tained in your battery charger’sowner’s manual.The following is a summary of thecharging steps.

Do not attempt to recharge yourgolf car’s batteries without thor-oughly reading and understandingthe owner’s manual provided withyour charger.

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

2. With the charger properly connected and grounded (seecharger’s owner’s manual), insertthe DC output plug into the golfcar receptacle.

Use only battery chargers that arerated for use with 48-volt YamahaGolf Cars. Thoroughly read andunderstand the user manual supplied with your 48-volt charger.

CAUTION

OFFON

Y-912

REV FWD

Y-669

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MAINTENANCE

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8-6 JW2

Do not disconnect the DC outputcord from the battery receptaclewhen the charger is on or an arccould occur that may cause anexplosion.

3. The charger will turn offautomatically when the batteriesreach full charge.

4. After the charger has turned off,disconnect the DC output plugfrom the golf car receptacle bygrasping the plug body andpulling the plug straight out ofthe receptacle.

Battery Installation

When working with batteries, donot put wrenches or other metalobjects across the batteryterminals. An arc can occurcausing explosion of the battery.

1. Install the battery holddownplates and torque to 7-9 Nm(0.7-0.9 m•kg, 62-80 in•lb) asshown.

å Forward∫ Batteryç Battery holddown plate

2. Connect the wire leads andtorque to 9-10 Nm (0.9-1.0 m•kg,80-89 in•lb) as shown.

PO

S

PO

SN

EG

NE

G

PO

S

PO

SN

EG

NE

G

Y-751B

B C

A

Y-672b

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MAINTENANCE

8-7JW2

When installing batteries:� Carefully place battery cables

and holddowns making sure thatcables do not lay across ventcaps.

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

Do not overtighten the batteryholddown nuts. Excessive forcewill damage the battery casing.

Fuse Replacement

Be sure to use the specified fuse.Using a wrong fuse can causeelectrical system damage andcreate a fire hazard.

When replacing a fuse be surethe main switch is turned off toprevent accidental short-circuiting.

1. Locate the in-line fuse holder onthe main wire harness adjacentto the tow switch.

2. Pull fuse holder cover off.

3. Pull fuse out, inspect and replaceif necessary.

å Fuse holder∫ Fuse

Fuse Type:3 Amp, Blade Style

Y-523aAB

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MAINTENANCE

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8-8JW2

Transaxle OilTo check transaxle oil level:

1. Place the golf car on a flat, levelsurface.

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

3. Place an oil pan under thetransaxle case.

4. Clean area around servicing plug 4.

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

6. Transaxle oil should be at the topof the oil servicing hole or justbeginning to run out of hole.

Do not allow foreign material toenter transaxle.

7. If needed, add SAE80 W90 APIGL-5 limited slip high perfor-mance gear oil until it is at thetop of the plug hole or just begin-ning to run out of servicing hole.

The YDRE Golf Car is equipped withan internal wet brake. Use of oil otherthan SAE80 W90 API GL-5 limitedslip high performance gear oil willcause brake noise.

8. Install the transaxle servicingplug and tighten to 14-19 Nm(1.4-1.9 m•kg, 120-168 in•lb).

9. Install the bag holder insert 3and secure with two bolts 2 andseven plastic rivets 1.

4

Y-1214

Y-1215

1

2

3

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MAINTENANCE

8-9JW2

For transaxle oil replacement, con-sult a Yamaha dealer or other quali-fied mechanic.

Before performing wheel or brakemaintenance, verify that the mainswitch is in the “OFF” position.

Wheel ReplacementTo remove and install a wheel onyour 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 jackand remove the wheel nuts andthe wheel.

3. Reverse the removal steps wheninstalling the wheel.

Wheel nut tightening torque:58 ft.lb (80 Nm, 8.0 m.kg)

Brake AdjustmentThe brakes on your golf car are self-adjusting.

Before you operate the car, pressdown on the brake pedal severaltimes to make sure the brakes arefunctioning properly.

Consult your Yamaha dealerbefore using your golf car if yoususpect brake problems. Brakefailure could result in a seriousaccident.

Y-57

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MAINTENANCE

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8-10 JW2

Brake Pedal Free PlayAdjustment

Before adjusting brake pedal freeplay, pump the brake pedal severaltimes to self-adjust the brakes.

To adjust the brake pedal free play:

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

2. Check the brake pedal free playby pressing against the pedalwith two fingers (using lightforce) and measuring the distance the pedal travels beforeresistance is felt.

Brake pedal free play Å:45-50 mm (1.77-1.96 in.)

3. If the free play distance needsadjusting, loosen the lock nut åand turn the adjusting nut ∫ in or out until the free play specification is met. Then tightenthe lock nut in place.

Do not over-tighten the brakecables. Over-tightening willincrease brake wear and affectoverall performance of car.

Y-61c

Y-909A

A B

Y-62b

7

1817

1615

1413

1211

109

8

a

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STORAGE

9-1JW2

2. Have the batteries rechargedevery 60-90 days to keep themfully charged. The batteries mustbe kept fully charged to avoid damage.

Do not allow cleaning solution toenter battery cells.

3. Clean the top of the batterieswith a solution of baking sodaand water, as necessary, toremove corrosion.

Perform the following preparationswhen storing your golf car forextended periods of time:

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

CHASSIS PREPARATION1. Verify the tire pressure is set to

20 psi (138 kPa, 1.4 kgf/cm2).

2. Clean exterior of the golf car andapply a rust inhibitor.

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

BATTERYPREPARATION1. Remove the batteries from the

golf car and store them in a cool,dry place that stays between 32˚F (0˚C) and 90˚F (30˚C).

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SPECIFICATIONS

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10-1 JW2

GENERAL SPECIFICATIONS

Items YDREDimensions:

Overall length 93.4 in. (2395 mm)Overall width 47.2 in. (1200 mm)Overall height (steering height) 46.9 in. (1190 mm)Height of floor 12.2 in. (310 mm)Wheelbase 64.6 in. (1640 mm)Tread:Front 34.3 in. (870 mm)Rear 38.6 in. (980 mm)

Min. ground clearance 4.3 in. (110 mm)

Weight:

Dry weight (without battery) 535 lb (243 kg)

Vibration Level:

Vibration on seat (EN1032,

ISO5008) (for Europe Will not exceed 0.5 m/s2

Vibration on steering wheel

(EN1032, ISO5008) (for Europe) Will not exceed 2.5 m/s2

Performance:

Factory speed setting 12 mph (19 km/h)

Maximum speed 15 mph (24 km/h)

Minimum turning radius 114.2 in. (2.9 m)

Seating capacity 2 persons per seat

TRANSMISSION

Items YDRE

Differential/reduction gear:Differential type Bevel gearLubricant/capacity SAE80 W90 API GL-5 limited slip

high performance gear oil/1.43 US quarts

(1350 mL, 1350 cc)

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SPECIFICATIONS

10-2JW2

BATTERIES

Items YDRE

Battery: Trojan - Golf Car Type T-1275 (4x12-volt)RC: minimum 102 min

CHASSISItems YDRE

Steering system:Type Rack and PinionSteering angle (L.H.) 1.85 turnSteering angle (R.H.) 1.85 turn

Brakes:Brake system MechanicalType of brake Internal wetBrake pedal freeplay linkageadjustment 45-50 mm

(1.77-1.96 in.)

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

Parking brake:Type Foot type; parking brake with automatic

release.

Release timing(With pedal segment in second notch)(Bolt heads round parallel to arm) 0.000 ~ 0.001 in. (0.0 ~ 0.3 mm)

Wheel:Tire size:Front 18 x 8.50–8.00/4 PRRear 18 x 8.50–8.00/4 PRRim size: 7.00–I–8.00Tire pressure: 20 psi (138 kPa, 1.4 kgf/cm2)

LIT_19626_21_07.qxd 9/20/06 10:04 AM Page 37

WIRING

1

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11-1 JW2

YDRE WIRING DIAGRAM

1. P

RE

CIO

US

ME

TAL

CO

NTA

CT

S

A

RE

RE

QU

IRE

D. T

YP

ICA

L

SIG

NA

L IS

10m

A.

2. T

HE

26

PO

SIT

ION

WIR

E H

AR

NE

SS

C

ON

NE

CT

OR

PLU

G P

AR

T N

UM

BE

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AE

MX

23A

26S

F1.

UN

US

ED

C

IRC

UIT

CA

VIT

IES

RE

QU

IRE

DU

MM

Y

PLU

GS

P/N

M12

0-55

780.

L

BL

B

LO

B

(NO

TE 2

)

RW

RY

RY

RW

OF

F

ON

RW

BO

L

RY

TH

RO

TT

LEP

OS

ITIO

NS

EN

SO

R

B

BB

W RW

W

YR

Y

RY

Y

W

BR

G

GATE DRIVER CIRCUITPWM OUTPUT

RB

PB

PB

PB

BU

ZZ

ER

RW

Br

RW

Br

WRY Y

BA

TT

ER

Y(4

x12v

)

RE

CE

PTA

CLE

CO

NT

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R

3 5 6 7

13

2

YR

G

CH

AR

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ATA

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CE

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14

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2625

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VF

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(N

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TACH

A1F

1

(A2)

(A1)

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(F2)

(F1)

(P)

(N)

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SF

ET

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Y.CO

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L BOA

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MA

IN S

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(NO

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)

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ON

R RY

RWR

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r

OFF

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Br RW

(N

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SW

.

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RB

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RR G B

R G B

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22 21 20 19

BW

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Y-94

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lack

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enY

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low

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......

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P...

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.Pin

kB

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......

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......

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w/B

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......

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1211

84

109

LIT_19626_21_07.qxd 9/18/06 9:24 AM Page 38

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JW2

NOTES

LIT_19626_21_07.qxd 9/18/06 9:24 AM Page 39

NOTES

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JW2

LIT_19626_21_07.qxd 9/18/06 9:24 AM Page 40

48 VOLT GOLF CAR YDRE

OWNER’S / OPERATOR’SMANUAL

LI T -19626-21-07 JW2-F8199-10YAMAHA GOLF-CAR

COMPANY 1000 HWY 34 East Newnan, GA 30265

770-254-4000

Printed in U .S. A 2006-KCC

LIT_19626_21_07 cover.qxd 9/18/06 8:10 AM Page 1