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MANUAL
YDRE
48 VOLT GOLF CAR
YAMAHA GOLF-CAR
COMPANY
1000 HWY 34 East LIT-19626-21-13 JW9-F8199-21
Newnan, GA 30265
770-254-4000
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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.
YDRE 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-19626-21-13
JW9 i
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IMPORTANT MANUAL
INFORMATION
Particularly important information is TIP
distinguished in this manual by the Yamaha continually seeks
following notations: advancements in product design
and quality; therefore, while this
manual contains the most current
This is the safety alert symbol. It is product information available at the
used to alert you to potential time of printing, there may be minor
personal injury hazards. Obey all discrepancies between your golf car
safety messages that follow this and this manual. If you
symbol to avoid possible injury or have any questions concerning this
death. manual, please consult your
Yamaha dealer.
TIP
A TIP provides key information to
make procedures easier or clearer.
ii JW9
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CONTENTS
WARRANTY 1
IMPORTANT LABELS 2
OPERATOR SAFETY 3
SAFETY CONSIDERATIONS 4
CONTROLS 5
PRE-OPERATION CHECKS 6
OPERATION 7
MAINTENANCE 8
1
STORAGE 9
SPECIFICATIONS 10
WIRING 11
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WARRANTY
LIMITED 4-YEAR GOLF CAR LIMITED WARRANTY
1
Yamaha Golf-Car Company hereby warrants that any • Any charges incurred in transporting a golf car
new YDRA gas or YDRE electric Yamaha golf car or charger to and from an authorized Yamaha
purchased from an authorized Yamaha golf car golf car dealer for service or in performing field
dealer in the United States will be free from defects service are also excluded from this warranty.
2 in material and workmanship for FOUR years from • Gasoline powered golf car starting batteries on
date of purchase, subject to the stated limitations. vehicles equipped with a golf course GPS
device, or any other device with a parasitic
DURING THE PERIOD OF WARRANTY any current draw, unless the vehicle is equipped
authorized Yamaha golf car dealer will, free of from the factory with an optional deep cycle
3 charge, repair or replace, at Yamaha’s option, any
part adjudged defective by Yamaha due to faulty
starting battery.
workmanship or material from the factory. Parts used THE CUSTOMER’S RESPONSIBILITY under this
in warranty repairs will be warranted for the balance warranty shall be to:
of the vehicle’s warranty period. All parts replaced 1. Operate and maintain the golf car and charger as
4 under warranty become property of Yamaha Golf-Car
Company.
specified in the appropriate Owner’s/Operator’s
Manual;
2. Give notice to an authorized Yamaha golf car
GENERAL EXCLUSIONS from this warranty shall dealer of any and all apparent defects within ten
include any failures caused by: (10) days after discovery, and make the vehicle or
5 a. Abnormal strain, neglect, or abuse, including
lack of proper maintenance, and use contrary
charger available at that time for inspection and
repairs by the dealer’s authorized representative.
to the Owner’s/Operator’s Manual instructions.
b. Accident or collision damage. WARRANTY TRANSFER: Any transfer of warranty
c. Installation of parts or accessories that are not must take place within the first three years of the
6 original equipment.
d. Fading, rust, or deterioration due to exposure
original in-service date of the vehicle. The vehicle
must be re-registered by an authorized Yamaha Golf-
or ordinary wear and tear. Car Dealer within 30 days of transfer. A fee may be
e. Modifications or alterations that affect the car’s charged for the transfer of the warranty.
condition, operation, performance, or durability,
7 or which makes the car serve a purpose other
than use as a two-person, golf course vehicle.
YAMAHA GOLF-CAR COMPANY MAKES NO
OTHER WARRANTY OF ANY KIND, EXPRESSED
f. Damage due to improper transportation. OR IMPLIED. ALL IMPLIED WARRANTIES OF
g. Acts of God, i.e. lightning, hail damage, MERCHANTABILITY AND FITNESS FOR A
flooding, fire, etc. PARTICULAR PURPOSE WHICH EXCEED THE
8 WARRANTY COVERAGE:
OBLIGATIONS AND TIME LIMITS STATED IN THIS
WARRANTY ARE HEREBY DISCLAIMED BY
Year 1: The first year of warranty shall cover the entire YAMAHA GOLF-CAR COMPANY AND EXCLUDED
vehicle except for the Specific Exclusions FROM THIS WARRANTY.
below.
Year 2: The second year exclusions are the YDRA SOME STATES DO NOT ALLOW LIMITATIONS
9 battery, body parts, seats, mats, bumper ON HOW LONG IMPLIED WARRANTY LASTS,
assembly, bag carrier, scorecard holder, trim, SO THE ABOVE LIMITATION MAY NOT APPLY
and the Specific Exclusions below. TO YOU. ALSO EXCLUDED FROM THIS
Year 3: The third year exclusions include the second WARRANTY IS ANY INCIDENTAL OR
year exclusions, plus the control cables and CONSEQUENTIAL DAMAGES INCLUDING LOSS
10 electrical system (except electronic speed OF USE. SOME STATES DO NOT ALLOW THE
controller, battery charger, and electric motor), EXCLUSION OR LIMITATION OF INCIDENTAL OR
and the Specific Exclusions below. CONSEQUENTIAL DAMAGES, SO THE ABOVE
Year 4: The fourth year of the warranty covers only EXCLUSION MAY NOT APPLY TO YOU.
the electric motor, speed controller, battery
11 charger, and transaxle on the YDRE and the
engine, clutch system (except drive belt), and
THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER
transaxle on the YDRA. RIGHTS, WHICH VARY, FROM STATE TO STATE.
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WARRANTY
YAMAHA FOUR-YEAR LIMITED WARRANTY FOR TROJAN BRAND
ELECTRIC GOLF CAR AND UTILITY VEHICLE BATTERIES WHEN 1
CHARGED WITH A YAMAHA SUPPLIED 48-VOLT CHARGER
YAMAHA Golf-Car Company (herein referred to as “YGC”) hereby • Lack of proper maintenance as outlined in the electric vehicle
warrants to the Original Retail Purchaser or Lessee of a YAMAHA
YDRE golf car or PTV, U-MAX or Adventurer utility vehicle, or
Owner’s/Operator’s Manual. For example, lack of regular
battery watering or adding water to the battery before 2
YAMAHA transportation or specialty vehicle purchased from an charging.
Authorized YGC Dealer, that the Trojan batteries charged with a • Damage caused by improper installation of the battery.
YAMAHA supplied battery charger will be free from defects in • Neglect, breakage, freezing, fire, explosion, wreckage, the
materials and workmanship, and will provide “36-hole performance” for addition of any chemical, or the operation of the battery in an
a period of four-years or “1,000 rounds” from the date of purchase,
whichever event occurs first, subject to the terms and conditions
uncharged condition (below half-charge – 1.200 specific gravity).
• Battery charged by systems other than the original equipment
3
contained herein.
type battery charger.
This limited warranty covers defects in materials and workmanship • On fleet golf cars, the use of any non-YAMAHA supplied
only for a period of four-years or “1,000 rounds”, as applicable, from electrical devices that consume more than one amp-hour per
4
date of purchase, whichever event occurs first. The terms of this round or two amp-hours per day of battery energy. Examples
FOUR-YEAR LIMITED WARRANTY shall be to furnish one or more of these devices include, but are not limited to: heating or
replacement batteries within the four-year period or before 20,000 cooling systems; GPS (global position system) devices;
amp-hours are discharged, whichever event occurs first, as information gathering devices; lights; radios or stereos; or
determined by YGC using the information recorded and stored in the yardage measuring devices.
Genius controller. • Less than one charger per car or inadequate facility electrical
• This warranty only applies to factory installed Trojan battery sets
charged with a Yamaha supplied battery charger.
power to power all chargers. Examples include more than
one charger on a single circuit, circuit rating of less than 15 5
amps, or not enough circuits for the number of cars.
• “1,000 rounds” means 20,000 amp-hours discharged, as recorded
• In fleet applications, less than one battery charger per vehicle.
in the Genius controller.
For example, using only 10 battery chargers to charge a 15
• The customer must perform (or have a contracted Yamaha Dealer car fleet.
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
• The use of any system that does not allow the battery
chargers to shut off automatically. For example, timer
6
systems that are designed to switch battery charger AC power
warranty. Maintenance records must be kept.
on and off during peak demand hours.
• Replacement batteries may be of a different brand or capacity, but
are warranted to provide 36-hole performance for the remainder of THIS BATTERY IS INTENDED TO BE USED BY PERSONS
the warranty term.
• “36-hole performance” is defined as 60-minutes discharge time as
WITH TRAINING AND EXPERIENCE WITH BATTERIES AND
ONLY IN YAMAHA ELECTRIC VEHICLES. ANY OTHER USE 7
tested and recorded using a Lester model #17770 discharge RENDERS THE LIMITED WARRANTIES EXPRESSED HEREIN
machine at an ambient temperature of between 60 and 100 AND ALL IMPLIED WARRANTIES NULL AND VOID AND SAME
degrees F (16 and 38 degrees C). Ambient temperatures ARE HEREBY EXCLUDED.
between 60 and 80 degrees F (16 and 27 degrees C) must be
ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE
corrected using the formula: Adjusted Discharge Time =
(Discharge Minutes) / (1-(((80-TEMP)/100) x 0.64)). ANY AND ALL INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR
8
• The customer must notify the Dealer within 10 days that a vehicle REVENUE, LOSS OF TIME, INCONVENIENCE OR ANY
has failed to make 36 holes per day. YGC reserves the right to OTHER ECONOMIC LOSS.
test and recharge any batteries in question.
Some states do not allow limitation on the duration of an implied
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE SHALL BE VOID AND EXCLUDED
warranty, exclusions or limitations of incidental or consequential
damages. Therefore, the above limitations or exclusions may not
9
SUBSEQUENT TO ONE YEAR FROM THE DATE OF PURCHASE. apply to you.
THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE
REMEDY UNDER THIS WRITTEN WARRANTY OR ANY IMPLIED WARRANTY LIMITATIONS
WARRANTY. YAMAHA MAKES NO OTHER REPRESENTATION Yamaha Golf-Car Company’s and Trojan Battery Company’s limit
OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE,
EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA HAS THE
of liability shall be to replace a defective battery. Replacement
shall mean furnishing a new battery or used battery with sufficient 10
AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, life to complete the remainder of the warranty term, which is
PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE identical or reasonably equivalent to the warranted product at no
TERMS OF THIS LIMITED WARRANTY. cost to the purchaser during the limited warranty period, except
for labor or transportation expenses.
LIMITED WARRANTY EXCLUSIONS
Without limiting the generality of the foregoing in any way, and as Damage not resulting from a defect in materials or workmanship
or which occurs due to abuse or neglect (including failure to
11
part of its limited warranty exclusion, YAMAHA does not warrant
that its battery is suitable for use in any application other than in a provide reasonable and necessary maintenance), accident,
golf car or utility vehicle. As in the use of any battery, a prudent alteration or acts of God is excluded from this limited warranty.
owner will read and study the charger owner’s manual, the vehicle This warranty gives you specific legal rights, and you may also
owner’s manual, the operator’s instructions, and the battery warning have other rights, which vary from state to state.
labels; and will exercise due care in working on or around batteries.
For further information or to submit a warranty claim, contact your
THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT local Yamaha Golf-Car Dealer or contact Yamaha Golf-Car
APPLY IF BATTERIES ARE SUBJECTED TO ANY OF THE Company toll free at (877) 811-8250.
FOLLOWING CONDITIONS:
• Abuse or neglect such as improper fluid levels, loose wiring, Yamaha Golf-Car Company,
rusted or corroded hardware. NEWNAN, GEORGIA 30265-1320
EFFECTIVE DATE: 06/01/11 LIT-13710-EL-11
JW9 1-2
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IMPORTANT LABELS
2 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 comply with the safety
and warning instructions affixed to the golf car or utility vehicle.
3
4 1
3 4 5
5 2
7
Y-924ff
9 1
10
11
Y-500c
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JW9
2
3
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NOTICE / NOTIFICATION
Move switch to the “TOW” position before Mettre l’interrupteur a position “TOW” avant de remorquer
towing or storage. Failure to do so may lead to:
TOW SWITCH ou avant l’entreposage. Non-observation pourrait:
• Drive system damage when towing. • Dommages de système d’entrainement en remourquant.
• Complete battery discharge and battery • Causer une decharge totale de la batterie et endommager
damage when storing long term. la batterie pendant l’entreposage a long terme.
• After moving switch from “RUN” to “TOW”, wait • Apres avoir change l’interrupteur de position “RUN” a
15 seconds minimum before switching again. position “TOW”, attendre un minimum de 15 seconds
avant de le remettre.
JW9-K8298-10
IMPORTANT LABELS
2-2
9
8
7
6
5
4
3
2
1
11
10
9
8
7
6
5
4
3
2
1
11
10
2-3
5
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IMPORTANT LABELS
1 GOLF CAR SERIAL
1
NUMBER
The golf car serial number 1 is
identified in the location shown.
2
TIP
The first three digits of the serial
number are for model identification; 3
the remaining digits are the unit
JWX-000000 production number. Keep a record
of these numbers for reference
when ordering parts from a Yamaha 4
Y-1539B Golf-Car Company dealer.
10
11
JW9 2-4
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! OPERATOR SAFETY
Yamaha golf cars are designed to be
1 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:
2
BEFORE OPERATING
3 THE GOLF CAR
● Read this Owner’s/Operator’s
manual and all safety and instruction
labels on the golf car before
4 operating.
● Perform the pre-operation checks
found in Section 6 of this manual.
5 ● Only authorized people should
drive the golf car, from the driver’s
side only, and only in designated
areas.
6
● Do not allow more than two
occupants per seat. This golf car is
restricted to two occupants unless
7 equipped with a rear seat.
● Do not operate the golf car while
under the influence of alcohol or
8 drugs; their effect on vision and
judgment make operating a golf
car dangerous.
Do not operate the golf car on
9
●
Y-68
public streets, roads or highways
unless allowed by law or local
regulating authority.
10
WHILE OPERATING THE
GOLF CAR
11
● Keep your entire body inside the
golf car, remain seated, and hold
on when the car is in motion.
Y-928 ● Do not start the golf car until all
occupants are seated.
● Keep your hands on the steering
wheel and your eyes on the path
ahead.
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! OPERATOR SAFETY
● Use extra care in congested areas
or when backing up. Always back 1
up slowly, and watch carefully.
Y-922
9
● Do not make any modification or
addition which affects capacity or
safe operation, or make any 10
changes not in accordance with
the owner’s/operator’s manual.
11
Y-923
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! SAFETY CONSIDERATIONS
Like all machines, golf cars can
1 cause injury if improperly used or
maintained. This section contains Do not operate golf cars when
broad safety practices required for under the influence of alcohol or
safe golf car operation. Before golf drugs. Death or serious personal
2 cars are operated, golf course injury can result from failing to
personnel should establish any comply with the safety and warning
additional safety practices that may instructions affixed to the golf car
3 be required for safe operation. or utility vehicle.
9 QUALIFICATIONS
Allow only authorized people to
Descend steep grades slowly with
operate golf cars. It is recommended
foot on brake. Death or serious
that only people who possess a
10 valid motor vehicle driver’s license
personal injury can result from
failing to comply with the safety
be allowed to operate golf cars.
and warning instructions affixed to
the golf car or utility vehicle.
Place operation and safety
11 instructions recommended by the
golf car manufacturer, along with ● Sharp Turns, Blind Corners,
the golf course safety rules, in a Bridge Approaches. Chain or rope
conspicuous place near the golf car off these potentially
rental area or golf car pick-up area. hazardous areas or identify them
It is also recommended that the with a suitable warning describing
following warning be posted in a the nature of the hazard and the
conspicuous location: proper precautions to be taken to
avoid the hazard.
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! SAFETY CONSIDERATIONS
● Wet Areas. Wet grass may cause ● Parts and Materials. Use only
a golf car to lose traction and may replacement parts and materials 1
affect stability. Golf car operators recommended by the manufacturer.
should reduce speed in wet areas ● Ventilation. Properly ventilate all
or during periods of inclement
weather.
maintenance and storage areas in 2
accordance with applicable fire
● Loose Terrain. Loose terrain may codes and ordinances to avoid fire
cause a golf car to lose traction hazards. Ventilation is required to
and may affect stability. Repair remove flammable vapors and 3
loose terrain, chain or rope off fumes from gasoline powered car
these areas, or identify loose storage areas. Ventilation is also
terrain with a suitable warning. required to remove hydrogen gas
from the car storage areas during 4
● Golf Car and Pedestrian
Interference. Reroute golf car the battery charging process.
traffic or pedestrian traffic in
For electric powered golf cars, the
congested areas wherever possible
amount of hydrogen gas emitted
5
to prevent accidents. If it is
impractical to reroute traffic, erect during charging depends on a
warning signs to warn pedestrians number of factors, such as the
of golf car traffic, and to warn golf condition of the batteries, the output 6
car operators to drive slowly, use rate of the battery charger, and the
caution, and watch for pedestrians. amount of time the batteries are on
charge. Because of the highly
volatile nature of hydrogen gas and 7
its propensity to rise and accumulate
MAINTENANCE at the ceiling in pockets, a minimum
REQUIRED FOR GOLF of 5 air changes per hour is
8
recommended. Consult applicable
CAR SAFETY fire and safety codes for the specific
Practice the following to help ensure ventilation levels requirement, as
the safety of golf car operators: well as requirements for the use of 9
explosion proof electrical apparatus.
● Preventative Maintenance.
Perform all scheduled
maintenance in accordance with 10
manufacturer’s recommendations
to provide the golfing patron with a
safe, properly operating golf car.
11
● Personnel. Allow only qualified,
trained, and authorized personnel
to inspect, adjust, and maintain
golf cars.
JW9 4-2
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! SAFETY CONSIDERATIONS
SAFETY PRECAUTIONS ● Record all maintenance performed
1 in a maintenance record log by
DURING MAINTENANCE date, name of person performing
When performing maintenance, follow maintenance, and type of
maintenance. Periodically inspect
2 all safety instructions contained in the
maintenance log to ensure
manufacturer’s operation and service
manuals, as well as the following accurate and complete entries.
safety procedures: ● Provide operator comment cards
3 to assist in identifying non-periodic
● Properly immobilize golf car before maintenance needs for specific
beginning any maintenance to avoid golf cars.
any unexpected vehicle movement.
4 ● Maintain in a legible condition all
● Properly block chassis before nameplates, warnings, and
working underneath golf car to instructions provided by the
avoid any unexpected vehicle manufacturer.
5 movement.
● If new nameplates, warnings, or
● When working on the fuel system or instructions are needed, contact
the battery, do not smoke, or allow your Yamaha Golf-Car Company
6 any sparks or open flames near the dealer.
vehicle, to avoid any fires or
explosions.
Before working on an electric golf
STORAGE AND
7 ●
car, disable the car’s electrical BATTERY CHARGING
system in accordance with the
manufacturer’s instructions to avoid Take the following precautions to
ensure maintenance worker safety:
8 electrical shock or damage to the
electrical system.
● Only use battery charging facilities
● Use only properly insulated tools and procedures that are in
when working on electrically
9 powered golf cars or around
accordance with applicable
ordinances and regulations to
batteries to avoid electrical shock or avoid explosions, electrical shock
damage to the electrical system. or damage to the electrical
10 ● Maintain all safety devices including system.
brakes, steering mechanisms, ● Periodically inspect charging
warning devices, and governors, in facilities and procedures to be
a safe operating condition. Do not
11 modify these safety devices as
certain that applicable safety
codes, regulations, and
supplied by the manufacturer. procedures are being followed to
● After each maintenance or repair, avoid any fires or explosions.
the car must be driven by a
qualified, trained, and authorized
person – in an area free of
pedestrian traffic – to ensure proper
operation and adjustment.
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CONTROLS
4 FEATURES
1
6 1 Brake pedal
5 2 Parking brake pedal
3 Accelerator pedal 2
3 4 Steering wheel
5 Main switch
6 Drive select switch
7 Batteries 3
8 Seat
2 1
Y-916ee 9 Front body
a Front tire 4
b Front bumper
c Rear body
d Rear tire
e Rear bumper 5
f Tow switch
g Receptacle
7
6
Y-935
7
8
9 12 8
9
16
14 13
10
11 Y-918dd Y-919a 10
15
11
Y-930a
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CONTROLS
MAIN SWITCH
1
The main switch controls the
following items:
2 OFF “OFF”
ON
REV FWD All electrical control circuits are
switched off (controller remains
3 energized). The golf car cannot be
operated. The key can be removed
only in this position.
4 Y-912
5 OFF
ON
REV FWD
“ON”
Electrical circuits are switched on.
6 The golf car can be driven.
7 Y-913
10
11
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CONTROLS
OFF DRIVE SELECT SWITCH
REV FWD
ON 1
The drive select switch is used to
shift the golf car into forward or
reverse. After coming to a complete
stop, move the lever to the desired 2
position.
Y-920
A ACCELERATOR PEDAL
8
The accelerator pedal controls the
golf car’s speed.
BRAKE PEDAL 11
Press down on the brake pedal to
stop the golf car.
B
∫ Brake pedal
Y-21a
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CONTROLS
PARKING BRAKE
1 PEDAL
Press down on the parking brake
2 pedal whenever parking the golf car.
C
ç Parking brake pedal
Y-22a
3 TIP
Release the parking brake by
depressing the accelerator pedal.
4
10
11
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CONTROLS
TOW SWITCH
A
1
Before operating the car, make
sure the tow switch is in the “RUN”
position.
2
å Tow switch
TOW
RUN
NOTICE 3
Ensure that the “Drive Select
Switch” is in the “FWD” position
and then move the “TOW Switch” 4
Y-1995
to “TOW” before towing.
10
11
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PRE-OPERATION CHECKS
Pre-operation checks should be
1 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
2 nature.
3
To keep car from moving while
performing pre-operation checks:
● Remove main switch key.
4 ● Apply parking brake.
Death or serious personal injury
can result from failing to comply
5 with the safety and warning
instructions affixed to the golf car
or utility vehicle.
6 PRE-OPERATION
CHECKLIST
7 Before each use check the following:
✔ Batteries
✔ Tire condition
8
✔ Steering system
✔ Reverse alarm
9 ✔ Pedal operation
✔ Body and chassis
10 SEAT
Open the seat for checking and
servicing.
11
Y-905
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PRE-OPERATION CHECKS
BATTERIES
1
Check that the batteries are held
securely in place to prevent them
from being damaged from vibration
or jarring. Also check that no battery 2
caps are missing to prevent battery
acid from spilling from the batteries.
Check the battery terminals for
corrosion.
3
4
Battery electrolyte is poisonous
and dangerous, causing severe
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes 5
or clothing. Ventilate when
charging or using in enclosed
space. Always shield eyes when
working near batteries. KEEP OUT 6
OF REACH OF CHILDREN.
TIRE CONDITION 7
Tire Air Pressure
Check the tire air pressure before 8
operating the golf car.
Tire pressure:
9
138 kPa, 1.4 kgf/cm2 (20 psi)
Y-30
Tire Wear Limit 10
Check the tire surface for damage,
cracks or embedded objects. When
A tire tread wears down to 1 mm
(0.04 in.), replace the tire.
11
å Wear limit
Y-31
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PRE-OPERATION CHECKS
STEERING SYSTEM
1
Check the steering system for
excessive free play by:
2 ● moving the steering wheel up and
down, and back and forth.
5 OFF
REV FWD
ON
REVERSE ALARM
Check the reverse alarm by moving
6 the drive select switch to “REV” for
reverse. The alarm should sound.
7 Y-911b
PEDAL OPERATION
Check the following pedal controls
for proper operation. If a pedal does
8 not work properly, consult a Yamaha
dealer.
9 Accelerator Pedal
1. WARNING! Make sure the
A main switch is in the “OFF”
10 position.
2. Make sure the accelerator pedal
operates smoothly.
11
å Accelerator pedal
Y-20A
6-3 JW9
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PRE-OPERATION CHECKS
Brake Pedal
1
Make sure the brake pedal feels firm
when pressed and returns to its
original position when released.
2
∫ Brake pedal
B
Y-21a 3
Parking Brake Pedal
Make sure the parking brake pedal
locks in place with a positive click, 4
and releases when the accelerator
pedal is pressed.
7
BODY AND CHASSIS
Before each use, visually inspect
the golf car body and chassis for 8
damage and/or missing parts.
10
11
JW9 6-4
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OPERATION
OFF STARTING
1 REV
ON
FWD 1. With the parking brake applied,
turn the drive select switch to
“FWD” for forward, or “REV” for
2 reverse.
NOTICE
3 Y-933
Do not shift from “FWD” forward
to “REV” reverse while the golf
car is moving. Transmission
damage can result.
4 OFF
ON
REV FWD 2. Turn the main switch to “ON.”
5
Do not depress the accelerator
pedal when turning on the main
switch or the golf car may start
6 Y-911b moving unexpectedly. Death or
serious personal injury can result
from failing to comply with the
7 safety and warning instructions
affixed to the golf car or utility
vehicle.
å Accelerator pedal
10 Y-20A
TIP
The parking brake automatically
11 releases when the accelerator pedal
is depressed.
7-1 JW9
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OPERATION
STOPPING
1
To stop the golf car, gradually press
down on the brake pedal.
å Brake pedal 2
B
NOTICE
3
Do not hold the golf car on an
incline with the accelerator – use
the brake. Transmission damage
A
Y-65c
can result. 4
10
11
JW9 7-2
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MAINTENANCE
PERIODIC MAINTENANCE CHARTS
1
Regular maintenance is required for the best performance and safe operation of
your golf car.
2
Be sure to turn off the main switch and apply the parking brake when you
perform maintenance, unless otherwise specified. If the owner is not familiar
with servicing the machine, death or serious personal injury can result. When in
3 doubt the work should be done by a Yamaha dealer or other qualified mechanic.
4 CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds
Daily 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs
Remarks Pre- 100 miles 600 mls 1200 mls 2500 mls 5000 mls Page
Opera- 160 kms 1000 kms 2000 kms 4000 kms 8000 kms
tion (Every (Every 6 (Every (Every 2 (Every 4
5 PRE-OP
Month) months) Year) years) years)
4-3/
Charge S S S S S S 8-5
9
MONTH
Check for loose or broken
connections
CS CS CS CS CS *
Clean/Lube pedal control area CL —
EVERY 6 Check all wire insulation for cracks
10 *
MONTHS and/or worn spots CS CS CS CS
* Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does
11 not contain these procedures. They are contained in the Service Manual.
8-1 JW9
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MAINTENANCE
CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
Daily
40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds
20 hours 125 hrs 250 hrs 500 hrs 1000 hrs
1
Remarks Pre- 100 miles 600 mls 1200 mls 2500 mls 5000 mls Page
Opera- 160 kms 1000 kms 2000 kms 4000 kms 8000 kms
tion (Every (Every 6 (Every (Every 2 (Every 4
Month) months) Year) years) years)
10
11
JW9 8-2
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MAINTENANCE
Battery Care
1
MAINTENANCE
● Before charging: only add distilled
water if fluid is below the top of the 1
plates, and then add just enough to
cover plates.
2
Fill Well
● After charging: open the vent caps
Electrolyte 1/8” Below and look inside the fill wells. Add
Bottom of Fill Well Electrolyte distilled water until the electrolyte
level is 3 mm (1/8") below the
bottom of the fill well. A piece of 3
rubber can be used safely as a
dipstick to help determine this level.
Clean, replace and tighten all vent
Max. Level -
1/8”
(3 mm) caps. 4
charged battery
Max. Level -
discharged battery NOTICE 5
Normal tap water contains
minerals which are harmful to a
battery; therefore, refill only with 6
distilled water.
Y-937c
3. Using a hydrometer, check the
specific gravity of the battery fluid 7
in each cell against the readings
on the chart below. Consult a
Yamaha dealer if any low readings
are found, or if readings vary more 8
than one point between cells.
Temperature Satisfactory Uncorrected
°C °F Hydrometer Reading 9
48.9 120 1.244
43.3 110 1.248
37.8 100 1.252 10
32.2 90 1.256
26.7 80 1.260
21.1 70 1.264
11
15.6 60 1.268
10.0 50 1.272
4.4 40 1.276
-1.1 30 1.280
Y-936a
JW9 8-4
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MAINTENANCE
Battery Charging
1
8-5 JW9
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MAINTENANCE
NOTICE 1
Use only battery chargers that are
rated for use with 48-volt Yamaha
Golf Cars. Serious battery damage
can result. Thoroughly read and
2
understand the user manual
supplied with your 48-volt charger.
3
3. With the charger properly
connected and grounded (see
charger’s owner’s manual), insert
the DC output into the golf car 4
receptacle.
ERROR2 C
fl
9
CHARGING D 4. When the charger is plugged into
90% the AC power, the Power ON
CHARGED E
Light illuminates continuously. 10
5. If Error 1 or Error 2 light is
blinking, there is a problem with
the batteries or the charger. 11
Contact your Yamaha Dealer.
6. During normal charging, the
Y-1559
Charging Light blinks or
continually illuminates.
7. The charger turns off
automatically when the batteries
reach full charge.
JW9 8-6
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MAINTENANCE
8. After the charger has turned off,
1 disconnect the DC output plug
from the golf car receptacle by
grasping the plug body and
pulling the plug straight out of
2 the receptacle.
Battery Installation
3
When working with batteries, do
not put wrenches or other metal
4 objects across the battery
terminals. An arc can occur
causing an explosion or fire at the
battery. Death or serious personal
5 injury can result from failing to
comply with the safety and warning
instructions affixed to the golf car
or utility vehicle.
6
1. Install the battery holddown
B C
A
plates and torque to 7-9 Nm, 0.7-
Y-751D 0.9 m•kg (62-80 in•lb) as shown.
7 å Forward
∫ Battery
ç Battery holddown plate
8 2. Connect the wire leads and
torque to 9-10 Nm, 0.9-1.0 m•kg
(80-89 in•lb) as shown.
9
When installing batteries:
● Carefully place battery cables
10 and hold-downs making sure
Y-672h that cables do not lay across
vent caps.
● Always remove the negative (–)
11 cable to the motor controller
first, and install it last. A spark
can occur causing an explosion
or fire at the battery. 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.
8-7 JW9
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MAINTENANCE
NOTICE 1
Do not overtighten the battery
holddown nuts. Excessive force
will damage the battery casing.
2
Fuse Replacement
3
Be sure to use the specified fuse.
Using a wrong fuse can cause
electrical system damage and 4
create a fire hazard. Death or
serious personal injury can result
B A Y-523a from failing to comply with the 5
safety and warning instructions
affixed to the golf car or utility
vehicle.
Fuse Type: 6
3 Amp, Blade Style
NOTICE
When replacing a fuse be sure 7
the main switch is turned off to
prevent accidental short-
circuiting and electrical system
damage. 8
1. Locate the in-line fuse holder on
the main wire harness adjacent 9
to the tow switch.
å Fuse holder 11
∫ Fuse
JW9 8-8
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MAINTENANCE
Transaxle Oil
1
To check transaxle oil level:
1. Place the golf car on a flat, level
2 surface.
2. Remove seven plastic rivets 1
and two bolts 2, and remove the
1 3 bag holder insert 3.
3 3. Place an oil pan under the
2 transaxle case.
4. Clean area around servicing plug 4.
4
5. Using an 8 mm hex wrench,
remove transaxle oil servicing
plug located on the rear of the
5 Y-1994
transaxle case.
6. Transaxle oil should be at the top
of the oil servicing hole or just
6 beginning to run out of hole.
4 NOTICE
Do not allow foreign material to
7 enter transaxle. Serious transaxle
damage can result.
8-9 JW9
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MAINTENANCE
TIP
For transaxle oil replacement, 1
consult a Yamaha dealer or other
qualified mechanic.
2
NOTICE
Before performing wheel or brake
maintenance, verify that the main 3
switch is in the “OFF” position.
Serious transaxle damage can
result.
4
Y-57
Wheel Replacement
To remove and install a wheel on
your golf car: 5
1. With the wheels blocked to
prevent the golf car from moving,
loosen the wheel nuts. 6
2. Elevate the golf car with a jack
and remove the wheel nuts and
the wheel.
3. Reverse the removal steps when
7
installing the wheel.
Wheel nut tightening torque:
80 Nm, 8.0 m.kg (58 ft.lb) 8
Brake Adjustment
The brakes on your golf car are 9
self-adjusting.
Before you operate the car, press
down on the brake pedal several
times to make sure the brakes are 10
functioning properly.
11
Consult your Yamaha dealer before
using your golf car if you suspect
brake problems. 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.
JW9 8-10
JW9-F8199-21_LIT_19626_16_05.qxd 5/3/12 9:56 AM Page 36
MAINTENANCE
Brake Pedal Free Play
1
Adjustment
NOTICE
2
Before adjusting brake pedal free
play, pump the brake pedal several
times to self-adjust the brakes.
3
To adjust the brake pedal free play:
8
16
15
14
13
12
11
9
3. If the free play distance needs
Y-62b adjusting, loosen the lock nut å
(under rubber bushing) and turn
10 the adjusting nut ∫ in or out
A B until free play specification is
met. Then tighten the lock nut in
place.
11
NOTICE
Do not over-tighten the brake
cables. Over-tightening will
Y-909D
increase brake wear and affect
overall performance of car.
Premature brake wear can result.
8-11 JW9
JW9-F8199-21_LIT_19626_16_05.qxd 5/3/12 9:56 AM Page 37
STORAGE
Perform the following preparations 2. Have the batteries recharged
when storing your golf car for every 60-90 days to keep them 1
extended periods of time: fully charged. The batteries must
be kept fully charged to avoid
TIP damage.
2
Turn main switch key to “OFF”
position, lift seat and switch tow NOTICE
switch in the “TOW” position. Do not allow cleaning solution to
Remove key from main key switch, enter battery cells. Serious
3
and store key in a safe place. battery damage can result.
BATTERY
PREPARATION 8
1. Remove the batteries from the
golf car and store them in a cool,
dry place that stays between 9
0°C (32°F) and 30°C (90°F).
10
11
JW9 9-1
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SPECIFICATIONS
GENERAL SPECIFICATIONS
1
Items YDRE
Dimensions:
2 Overall length 2395 mm (93.4 in.)
Overall width 1200 mm (47.2 in.)
Overall height (steering height) 1190 mm (46.9 in.)
3 Height of floor 310 mm (12.2 in.)
Wheelbase 1640 mm (64.6 in.)
Tread:
4 Front 870 mm (34.3 in.)
Rear 980 mm (38.6 in.)
Min. ground clearance 110 mm (4.3 in.)
5 Weight:
Dry weight (with suntop,
without battery) 270 kg (595 lb)
6
Performance:
Factory speed setting 19 km/h (12 mph)
7 Maximum speed 24 km/h (15 mph)
Turning radius 2.8 m (9.2 ft)
Seating capacity 2 persons per seat
8
PAINT CODES
9 Name Ditzler Number
Glacier 918519
Emerald 48748
10 Garnet 701739
Tanzanite 917834
Onyx Metallic 918520
Anthracite Metallic 918522
11 Sandstone Metallic 918523
10-1 JW9
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SPECIFICATIONS
BATTERIES 1
Items YDRE
Battery: Trojan - Golf Car Type T-875 (6x8-volt)
RC: minimum 117 min 2
CHASSIS
Items YDRE
3
Steering system:
Type Rack and Pinion
Steering angle (L.H.) 1.85 turn 4
Steering angle (R.H.) 1.85 turn
Brakes:
Brake system Mechanical
Type of brake Maintenance-Free internal transaxle disc brake 5
Brake pedal freeplay linkage
adjustment 45-50 mm
(1.77-1.96 in.) 6
(Brake cable end play) 0.1-0.5 mm (0.004-0.02 in.)
Parking brake:
Type Foot type; parking brake with automatic
release. 7
Release timing
(With pedal segment in second notch)
(Bolt heads round parallel to arm) 0.0 ~ 0.3 mm (0.000 ~ 0.001 in.) 8
Wheel:
Tire size:
Front 18 x 8.50–8.00/4 PR
Rear 18 x 8.50–8.00/4 PR
9
Rim size: 7.00–I–8.00
Tire pressure: 138 kPa, 1.4 kgf/cm2 (20 psi)
10
TRANSMISSION
Items YDRE 11
Differential/reduction gear:
Differential type Bevel gear
Lubricant/capacity Yamalube Friction Modified Shaft Drive Gear
Oil / 1350 mL (1.45 quarts total). Alternative
lubricant is mixture of 1280 mL (1.35 quarts)
80W90 Gear Oil and 70 mL (0.10 quarts)
API G15 Limited Slip Additive.
JW9 10-2
JW9-F8199-21_LIT_19626_16_05.qxd 5/3/12 9:56 AM Page 40
10
11
1
OPTIONAL
OPTIONAL
11-1
BATTERY GAUGE CONNECTOR SUPPLIED
ON JW2-H2590-10 DIRECTIONAL SW.
WIRE HARNESS ONLY
WIRING
GAUGE PIN-OUT
REV FWD
COLOR CODE TOW/
STORAGE SW.
1 BATTERY +
2 BATTERY - RY
I.R.
TRANSCEIVER
B ....................Black 3 NOT USED
4 KEY SW.
ACCEL. SW.
Y
OFF ON
L ......................Blue R Br
OFF ON BUZZER W
W B BR
G ...................Green RY RW W
Y...................Yellow MAIN SW.
W
W R
R ......................Red OFF
RY RW
RY R 1 Y RY
P ......................Pink ON
RW B RY
P B
Y RY
B BW
Br ..................Brown RW Br
P B W
W ...................White RW B RW Br B BW
B/R .........Black/Red RW RY RY RW P B
W R
Y/B .....Yellow/Black RW RW Br
B W
R/Y .......Red/Yellow RY RY
RY RY
R/W ........Red/White RY W
Y
RY BW
RW
R
D.C. MOTOR
R B R R B R F1 F2
RB
TACH
G G G G
B B
A1 A2
13 12 11 8 4 10 9
3 22
RY RB 5 21
6 20
7 19
RW RB 2 24 26 25
(P) (A1)
L BO
L B O
BATTERY L B O
(6x8v) (F2)
Gy Gy
JW9
OWNER’S /
MANUAL
READ TH
! It contain
YDR
48 VOLT