golf car g e

GOLF CAR G22E

OWNER'S / OPERATOR,S

MANUAL

LIT-19626-00-79 JU2-F8199-12YAMAHA MOTOR

MANUFACTURING CORP.OF AMERICA

1000 HWY 34 East Newnan, GA 30265

770-254-4000

Printed in U.S.A2004-KCC

LIT_19626_00_79 cover.qxd 5/28/04 6:39 AM

INTRODUCTIONCongratulations on your purchase of aYamaha golf car. This manual containsinformation you will need for proper oper-ation, maintenance, and care of your golfcar. A thorough understanding of thesesimple instructions will help you to obtainmaximum enjoyment from your newYamaha.

If you have any questions about the oper-ation or maintenance of your golf car,please consult a Yamaha dealer.

YAMAHA MOTOR MANUFACTURINGCORP OF AMERICA

G22EOWNER’S/OPERATOR’S

MANUAL© 2004 by Yamaha Motor

Manufacturing Corporationof America1st edition

All rights reserved. Any reprintingor unauthorized use without the

written permission ofYamaha Motor Manufacturing

Corporation of Americais expressly prohibited.

Printed in U.S.A.P/N LIT-19626-00-79

iG22E

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IMPORTANT MANUALINFORMATION

Yamaha continually seeks ad-vancements in product design andquality; therefore, while this manualcontains the most current productinformation available at the time ofprinting, there may be minor discrepancies between your golf 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.

WARNING

NOTE:Particularly important information isdistinguished in this manual by thefollowing notations:

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

Failure to follow WARNING instruc-tions could result in severe injuryor 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 additional keyinformation.

NOTE:

CAUTION

WARNING

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iiiG22E

1

WARRANTY

CONTENTS

1

IMPORTANT LABELS 2

MAINTENANCE SAFETY PROGRAM 4

MAINTENANCE 8

STORAGE

SPECIFICATIONS

9

WIRING 11

OPERATION 7

PRE-OPERATION CHECKS 6

CONTROLS 5

OPERATOR SAFETY 3

10

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WARRANTY

Yamaha Motor Manufacturing of America hereby war-rants that any new Yamaha Golf Car (gas and electricmodels) purchased from an authorized Yamaha dealerin the United States will be free from defects in materialand workmanship for THREE years from date of pur-chase, subject to the stated limitations.

DURING THE PERIOD OF WARRANTY any autho-rized Yamaha Golf Car Dealer will, free of charge, repairor replace, at Yamaha’s option, any part adjudgeddefective by Yamaha due to faulty workmanship ormaterial from the factory. Parts used in warranty repairswill be warranted for the balance of the machine’s war-ranty period. All parts replaced under warranty becomeproperty of Yamaha Motor Manufacturing Corporation ofAmerica.

GENERAL EXCLUSIONS from this warranty shallinclude any failures caused by:a. Abnormal strain, neglect, or abuse, including lack of

proper maintenance, and use contrary to theOwner’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 alteration that affects the car’s

condition, operation, performance, or durability, orwhich makes the car serve a purpose other than useas a two-person, golf course vehicle.

f. Damage due to improper transportation.g. Acts of God, ie: lightning, hail damage, flooding, fire,

etc.

SPECIFIC EXCLUSIONS: The first year of warrantyshall cover the entire car except for batteries, batterychargers, tires and rims, which are warranted by theirrespective manufacturers. Parts excluded from the sec-ond year of warranty include the body parts, seats,mats, bumper assembly, bag carrier, scorecard holder,and the trim. Parts excluded from the third year of war-ranty include the second year exclusions, the electricalsystem (except electronic speed controller and electricmotor) and control cables. Other specific exclusionsfrom this warranty shall include any parts replaced dueto normal wear or routine maintenance, including oil, airfilter elements, brake shoes, spark plugs, starter andclutch drive belts. Any charges incurred in transportinga golf car to and from an authorized Yamaha Golf CarDealer for service or in performing field service are alsoexcluded from this warranty.

YAMAHA MOTOR MANUFACTURINGCORPORATION OF AMERICA

LIMITED 3-YEARGOLF CAR WARRANTY

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Y-843

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2-1G22E

IMPORTANT LABELS

Y-654a

1

2

3

5

4

Y-500 Y-655

Y-656

13

4

Y-844

5

SAFETY AND INSTRUCTION LABELS

Please read the followinglabels carefully beforeoperating your golf car, andpromptly replace any labelswhich become damaged orremoved.

WARNING

2

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2-2 G22E

IMPORTANT LABELS

Y-102b

JU2

GOLF CAR SERIALNUMBERThe golf car serial number is stampedin the location shown.

The first three digits of the serial num-ber are for model identification; theremaining digits are the unit produc-tion number. Keep a record of thesenumbers for reference when orderingparts from a Yamaha dealer.

NOTE:

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3-1G22E

OPERATOR SAFETY!

Y-67

Y-68

Y-8

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 man-

ual and all safety and instructionlabels on the golf car before operat-ing.

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 peopleto ride in the golf car. This golf car isrestricted to two occupants.

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

Do not operate the golf car on pub-lic streets, roads or highways. Suchuse is prohibited by law, and dan-gerous. Operation on public roadscan result in collision with othervehicles.

WHILE OPERATING THEGOLF CAR Keep your entire body inside the

golf car, remain seated, and hold onwhen the car is in motion.

Do not start the golf car until alloccupants are seated.

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3-2 G22E

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

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 wheel toosharply at higher speeds.

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

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

OPERATOR SAFETY!

Y-10

Y-69

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GOLF COURSE SAFETY PROGRAM!

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 per-sonnel should establish any addition-al safety practices that may berequired for safe operation.

Experience has shown that golf carsare safe when operated in accor-dance with the safety warningsaffixed to every golf car. This safeoperation is enhanced when golf carsare used according to the safety rulesand practices established to meet theterrain and conditions of the coursethey are used on.

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

DRIVER QUALIFICATIONSAllow only authorized people to oper-ate golf cars. It is recommended thatonly people who possess a validmotor vehicle driver’s license beallowed to operate golf cars.

Place operation and safety instruc-tions recommended by the golf carmanufacturer, along with the golfcourse safety rules, in a conspicuousplace near the golf car rental area orgolf car pick-up area. It is also rec-ommended that the following warningbe posted in a conspicuous location:

Do Not Operate Golf Cars WhenUnder The Influence Of Alcohol OrDrugs

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, identifysteep grades with a suitable warn-ing like:

Warning: Steep Grade, DescendSlowly With Foot On Brake

Sharp Turns, Blind Corners,Bridge Approaches. Chain orrope off these potentially haz-ardous areas or identify them witha suitable warning describing thenature of the hazard and the prop-er precautions to be taken to avoidthe hazard.

Wet Areas. Wet grass may causea golf car to lose traction and mayaffect stability. Chain or rope off wetareas or identify wet areas with asuitable warning.

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4-2 G22E

GOLF COURSE SAFETY PROGRAM

Loose Terrain. Loose terrain maycause a golf car to lose traction andmay affect stability. Repair looseterrain, chain or rope off theseareas, or identify loose terrain witha suitable warning.

Golf Car and Pedestrian Interfer-ence. Reroute golf car traffic orpedestrian traffic in congestedareas wherever possible to preventaccidents. If it is impractical toreroute traffic, erect warning signsto warn pedestrians of golf car traf-fic, and to warn golf car operators todrive slowly, use caution, and watchfor pedestrians.

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

Preventative Maintenance. Per-form all scheduled maintenance inaccordance with manufacturer’srecommendations to provide thegolfing patron with a safe, properlyoperating golf car.

Personnel. Allow only qualified,trained, and authorized personnelto inspect, adjust, and maintain golfcars.

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 hydrogen gas from electricpowered car storage areas duringthe charging process.

For electric powered golf cars, theamount of hydrogen gas emitted dur-ing charging depends on a number offactors, such as the condition of thebatteries, the output rate of the bat-tery charger, and the amount of timethe batteries are on charge. Becauseof the highly volatile nature of hydro-gen gas and its propensity to rise andaccumulate at the ceiling in pockets, aminimum of 5 air changes per hour isrecommended. Consult applicablefire and safety codes for the specificventilation levels requirement, as wellas requirements for the use of explo-sion proof electrical apparatus.

!

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GOLF COURSE SAFETY PROGRAM

SAFETY PRECAUTIONSDURING MAINTENANCEWhen performing maintenance, fol-low all safety instructions containedin the manufacturer’s operation andservice manuals, as well as the fol-lowing safety procedures:

Properly immobilize golf car beforebeginning any maintenance.

Properly block chassis beforeworking underneath golf car.

Avoid fire hazards, and haveappropriate fire protection equip-ment available.

Before working on an electric golfcar, disable the car’s electrical sys-tem in accordance with the manu-facturer’s instructions.

Use only properly insulated toolswhen working on electrically pow-ered golf cars or around batteries.

Maintain all safety devices includ-ing brakes, 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 a quali-fied, trained, and authorized per-son – in an area free of pedestriantraffic – to ensure proper operationand adjustment.

Record all maintenance performedin a maintenance record log bydate, name of person performingmaintenance, and type of mainte-nance. Periodically inspect mainte-nance log to ensure accurate andcomplete entries.

Provide operator comment cards toassist in identifying non-periodicmaintenance needs for specific golfcars.

Maintain in a legible condition allnameplates, warnings, and instruc-tions provided by the manufacturer.

If new nameplates, warnings, orinstructions are needed, contactyour Yamaha dealer.

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

Only use battery changing andcharging facilities and proceduresthat are in accordance with applic-able ordinances and regulations.

Periodically inspect charging facili-ties and procedures to be certainthat applicable safety codes, regu-lations, and procedures are beingfollowed.

!

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5-1 G22E

CONTROLS

Y-65816 3

Y-659a

18 7

6

5

4

P

Y-661

15

13

14

Y-66012

10

2

11

FEATURES1 Steering wheel2 Seat3 Batteries4 Brake pedal5 Parking brake pedal6 Accelerator pedal7 Main switch8 Drive selector switch9 Tow switcha Front cowlb Front tirec Front bumperd Rear cowle Rear bumperf Rear tireg Receptacle

CAUTION / AVERTISSEMENT

Y-662a

9

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5-2G22E

CONTROLS

REV FWD

OFF

ON

Y-663

REV FWD

OFF

ON

Y-664

MAIN SWITCHThe main switch controls the follow-ing 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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5-3 G22E

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

Switch Position Car Movement

FWD FORWARD

REV REVERSE

The back-up buzzer will beep whenthe drive select switch is depressedto the “REV” position.

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

NOTE:

CONTROLS

Y-19

Y-20A

A

REV FWD

OFF

ON

Y-665

Y-21a

B

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5-4G22E

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 is inthe “ON” position, depressing theaccelerator may suddenly cause thegolf car to move.

TOW SWITCHBefore operating the car, make surethe tow switch is in the “RUN” posi-tion.

å Tow switch

Anytime the tow switch is moved fromthe “RUN” position to the “TOW” posi-tion and immediately moved back to“RUN”, there is a delay of approxi-mately 30 seconds before the car willrun.

Make sure the tow switch is in the“TOW” position if towing this vehicle.

NOTE:

WARNING

NOTE:

CONTROLS

Y-22a

C

A1

F2

CAUTION / AVERTISSEMENT

TOW

RUN

A

Y-666a

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6-1 G22E

PRE-OPERATION CHECKS

Y-512

Pre-operation checks should bemade each time you use your golfcar. Get in the habit of performing thefollowing checks in the same way sothat they become second nature.

Be sure the main switch key isremoved before performing thepre-operation checks to preventaccidental starting, and applythe parking brake to keep the carfrom 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 ser-vicing.

WARNING

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G22E 6-2

BATTERYCharge batteries before each use.See charging steps in chapter 8,Maintenance.

Check that the batteries are held securelyin place to prevent the batteries frombeing damaged from vibration or jarring.Also check that no battery caps aremissing to prevent battery acid fromspilling from the battery. Check the battery terminals for corrosion.

TIRE CONDITION

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

Tire pressure:

20 psi(137 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. (1mm), replace the tire.

å Wear limit

Y-30

A

Y-31

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G22E6-3

Y-667

REV FWD

OFFON

Y-668

Y-21a

B


STEERING SYSTEMCheck the steering system for exces-sive freeplay by:

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

turning the steering wheel slightly to the right and left.

If you feel excessive freeplay, or hearrattling sounds which may indicateloose steering components, consult aYamaha dealer.

BACK-UP BUZZERCheck the back up buzzer by movingthe drive select switch to “REV” forreverse. The buzzer should sound.

PEDAL OPERATIONCheck the following pedal controls forproper operation. If a pedal does notwork properly, consult a Yamahadealer.

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

∫ Brake pedal

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G22E 6-4


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


Release the parking brake bydepressing the accelerator pedal.

Accelerator Pedal

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

Make sure the accelerator pedaloperates smoothly.


BODY AND CHASSISBefore each use, visually inspect thegolf car body and chassis for damageand/or missing parts.

WARNING

NOTE:Y-22a

C

Y-20A

A

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G22E7-1

REV FWD

OFF

ON

Y-664

REV FWD

OFF

ON

Y-665

Y-20A

A

OPERATION

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 golf caris moving.

2. Turn the main switch to “ON.”

Do not depress the acceleratorpedal when turning on the mainswitch or the golf car may sudden-ly 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.


The parking brake automaticallyreleases when the accelerator pedalis depressed.

NOTE:

WARNING

CAUTION

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G22E 7-2

OPERATION

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

∫ Brake pedal

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


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

CAUTION

Y-65aB

C

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G22E8-1

MAINTENANCE

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 qualifiedmechanic.

WARNING

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G22E 8-2

MAINTENANCE

Pre-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

20 rounds 125 rounds 250 rounds 500 rounds 1000 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

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 G22E

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,and screws

Check for loose or brokenconnections

Check all wire insulation for cracksand/or worn spots

Check wheel nut tightness, frontwheel bearing play

Check gear box oil level andleakage

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 operation and adjust pedal stop if necessary

Check for grease leakage; adjustgear box if necassry

Replace gear box 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 shoe lining thickness andrear axle bearing play

C

CA

C

CA

C

CA

R

Check steering knucklebushing freeplay / Adjustwheel alignment

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8-3 G22E

MAINTENANCE

Battery Care

Battery electrolyte is poisonous anddangerous, causing severe burns,etc. It contains sulfuric acid. Avoidcontact with skin, eyes, or clothing.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 OF CHIL-DREN.

Six 8-volt deep cycle batteries providepower for your electric golf car andmust be properly maintained andrecharged for maximum performanceand service life.

To maintain your batteries:

1. Clean the tops of the batterieswith a solution of baking soda andwater, as necessary, to removecorrosion.

Do not allow cleaning solution toenter battery cells.

2. Check the fluid level before andafter charging.

CAUTION

WARNING

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MAINTENANCE

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

After charging: check that the fluidlevel is approximately 1/4 to 1/2 inchabove the plates and 1/4 to 3/8 inchbelow the level indicator. If the fluidlevel is low, carefully add distilledwater. Adding distilled water aftercharging helps prevent boil over.

å Battery cap∫ Platesç Maximum fluid level∂ Minimum fluid level

Normal tap water contains miner-als which are harmful to a battery;therefore, refill only with distilledwater.

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

CAUTION

Y-47

Y-829

D A

C

B

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8-5 G22E

MAINTENANCE

Battery Charging

Read and understand the owner’smanual provided with your golfcar’s battery charger before charg-ing batteries.

Explosive hydrogen gas is pro-duced while batteries are beingcharged. Only charge batteries inwell ventilated areas (a minimumof 5 air changes per hour is rec-ommended).

To charge the batteries in your golfcar, follow the instructions containedin your battery charger’s owner’smanual.

The following is a summary of thecharging steps. Do not attempt torecharge your golf car’s batterieswithout thoroughly reading andunderstanding the owner’s manualprovided with your charger.

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

2. With the charger properly con-nected and grounded (see charg-er’s owner’s manual), insert theDC output plug into the golf carreceptacle.

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

WARNING

WARNING

REV FWD

OFF

ON

Y-663

Y-669

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8-6G22E

MAINTENANCE

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 off automat-ically when the batteries reachfull 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 of thereceptacle.

Battery Installation

When working with batteries, donot put wrenches or other metalobjects across the battery termi-nals. An arc can occur causingexplosion of the battery.

1. Install the battery holddownplates as shown.

å Forward∫ Batteryç Battery fitting plate

WARNING

WARNING

A

C

B

Y-751a

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Fuse Type:3 Amp, Blade Style

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8-7 G22E

MAINTENANCE

2. Connect the wire leads as shown.

å Forward∫ To receptacleç To motor control unit∂ Between batteries

To relay

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 controller first,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 and cre-ate a fire hazard.

When replacing a fuse be sure themain switch is turned off to pre-vent accidental short-circuiting.

å Fuse case∫ Fuse

CAUTION

WARNING

CAUTION

WARNINGB

A

Y-672a

-

+

-

+

-

+

-

+

-

+

-

+

DC C

FORWARD

Y-653

BA

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8-8G22E

MAINTENANCE

Gear Box OilTo check gear box oil level:

1. Place the golf car on a level sur-face.

2. Remove the access panel byremoving the rivets in the twolower corners of the panel andpulling the panel from the car.

3. Remove the oil level plug å.

4. Add gear oil little by little until oilflows from the level plug hole ∫.

Recommended oil:SAE 90 gear oil

Gearcase capacity:0.32 US qt(300 mL, 300 cc)

5. Allow excess gear oil to flow outuntil it stops.

Do not allow foreign material toenter the gear box.

6. Reinstall the oil level plug.

For gear oil replacement, consult aYamaha dealer or other qualifiedmechanic.

NOTE:

CAUTION

Y-48

Y-520AAB

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8-9 G22E

MAINTENANCE

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 pre-vent 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.

WARNING

CAUTION

Y-57

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8-10G22E

MAINTENANCE

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 service lid from thefloor of the golf car.

2. Check the brake pedal free playby pressing against the pedalwith two fingers (using light force)and measuring the distance thepedal travels before resistance isfelt.

Brake pedal free play Å:20-25 mm (0.79-0.98 in.)

3. If the free play distance needsadjusting, loosen the lock nut andturn the adjusting nut in or outuntil the free play specification ismet. Then tighten the lock nut inplace.

Do not overtighten the brakecables. The self adjusters may notoperate properly, reducing brakingperformance.

WARNING

CAUTION

Y-61a

Y-63

Y-62b

7

1817

1615

1413

1211

109

8

a

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9-1 G22E

STORAGE

Perform the following preparationswhen storing your golf car for extend-ed periods of time:

Turn main switch key to “OFF” posi-tion, remove key, and store key in asafe place. Move the tow switch intothe “TOW” position.

CHASSIS PREPARATION1. Verify the tire pressure is set to

20 psi (137 kPa, 1.4 kgf/cm2).

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

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

NOTE:

BATTERYPREPARATION

1. Recharge the batteries and checkthe fluid levels at least once amonth.

Do not allow cleaning solution toenter battery cells.

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

CAUTION

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10-1G22E

SPECIFICATIONS

GENERAL SPECIFICATIONS

Items G22EDimensions:

Overall length 93.9 in. (2385 mm)Overall width 47.2 in. (1200 mm)Overall height (steering height) 46.9 in. (1190 mm)Height of floor 11.8 in. (300 mm)Wheelbase 64.3 in. (1632 mm)Tread:Front 34.3 in. (870 mm)Rear 38.6 in. (980 mm)

Min. ground clearance 3.8 in. (97 mm)

Weight:

Dry weight (without battery) 549 lb (249 kg)

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

Hill climbing ability 20°on pavement

TRANSMISSION

Items G22E

Differential/reduction gear:Differential type Bevel gearLubricant/capacity SAE 90 gear oil/

0.32 US qt (300 mL,300 cc)

BATTERIES

Items G22E

Battery: BCI group GC-2HRC: minimum 105 min

LIT_19626_00_79.qxd 5/28/04 7:01 AM Page 33

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10-2 G22E

SPECIFICATIONS

CHASSISItems G22E

Steering system:Type Rack and PinionSteering angle (L.H.) 1.55 turnSteering angle (R.H.) 1.55 turn

Brakes:Brake system Mechanical drum brake on each rear wheel

with self-adjusters.Type of brake Dual internal expanding shoe.

Leading/trailing shoes (self-adjusting)Brake pedal freeplay linkageadjustment 20-25 mm

(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 (137 kPa, 1.4 kgf/cm2)

LIT_19626_00_79.qxd 5/28/04 7:01 AM Page 34

95%

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WIRING

11-1G22E

G22E WIRING DIAGRAM

OF

FO

N

RR

/WR

W RY

R/W

R

OF

FO

N

R/WBr

OF

FO

N

R/YR

Br

Br

R/W

R/W

A1

A2

TRA

NS

CE

IVE

R

BU

ZZE

R

F1

F2

PB

PB

WR

/Y

RR

B/W

B

B

B

B/W

B

B/

W

RW

W

W

W

W

Y YR

/YP

B

R/B

Y

R/Y

R/BR

/B

R/W R

R

RR

B5KΩ

111

23

1

9 8 7

23

64

5

1518 19 20 21

1416

10 CO

NT

RO

LB

OA

RD

AS

SY

MO

SF

ET

BO

AR

DA

SS

Y

(N)

(P)

(A1)

(A2)

(F2)

(F1)

3/4

RE

C

RE

VF

WD

YR/Y W

R/W

R/W

R/Y

R/Y

R

R/Y

R/Y

WR

/YY

WR

/YY

Br

32

1

Y-6

71

T A C H

R/W R/Y

54

3

2

1

8

9

7

6

10

11 12

Mai

n sw

itch

Tow

/sto

rage

sw

itch

Acc

eler

ator

sto

p sw

itch

Buz

zer

Dire

ctio

nal s

witc

hD

C m

otor

C

ontr

olle

rT

hrot

tle s

enso

rR

elay

Rec

epta

cle

Fus

e (3

A)

Bat

terie

s (6

x 8

V)

1 2 3 4 5 6 7 8 9 10 11 12

CO

LO

R C

OD

EB

......

......

......

...B

lack

L....

......

......

......

.Blu

eG

......

......

......

.Gre

enY

......

......

......

.Yel

low

R...

......

......

......

..Red

P...

......

......

......

..Pin

kB

r....

......

......

...B

row

nW

......

......

......

..Whi

teB

/R...

......

.Bla

ck/R

edY

/B...

...Y

ello

w/B

lack

R/Y

......

..Red

/Yel

low

R/W

....

....

Red

/Whi

teB

/W..

....

Bla

ck/W

hite

BO

BL

LL

OO

BOL B

GG

GR

RR

BB

BGR B

LIT_19626_00_79.qxd 6/11/04 12:01 PM Page 35

NOTES

G22E

LIT_19626_00_79.qxd 5/28/04 7:01 AM Page 36

GOLF CAR G22E

OWNER'S / OPERATOR,S

MANUAL

LIT-19626-00-79 JU2-F8199-12YAMAHA MOTOR

MANUFACTURING CORP.OF AMERICA

1000 HWY 34 East Newnan, GA 30265

770-254-4000

Printed in U.S.A2004-KCC

LIT_19626_00_79 cover.qxd 5/28/04 6:39 AM Page 1

golf car g e

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