LIT_19626_11_07 cover.qxd 9/18/06 8:09 AM Page 1 OWNER’S / OPERATOR’S MANUAL YDRA 4 STROKE GOLF CAR Printed in U.S.
LIT_19626_11_07IFC.qxd 9/18/06 8:09 AM Page 1 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 1 INTRODUCTION Congratulations on your purchase of a Yamaha golf car. This manual contains information you will need for proper operation, maintenance, and care of your golf car. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha. If you have any questions about the operation or maintenance of your golf car, please consult a Yamaha dealer.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 2 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: ! The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the golf car occupants, a bystander, or a person inspecting or repairing the golf car.
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LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 4 WARRANTY YAMAHA LIMITED 3-YEAR GOLF CAR WARRANTY 1 2 3 4 5 6 7 8 9 10 11 Yamaha Golf-Car Company hereby warrants that any new YDRA gas or YDRE electric Yamaha golf car purchased from an authorized Yamaha golf car dealer in the United States will be free from defects in material and workmanship for THREE years from date of purchase, subject to the stated limitations.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 5 IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS 1 4 1 2 3 2 Y-924 Please read the following labels carefully before operating your golf car, and promptly replace any labels which become damaged or removed. 1 3 4 5 6 7 8 Y-500a 9 4 WARNING AVERTISSEMENT Do not tamper with governor to increase speed. Operation at higher speeds can cause loss of control that can result in severe injury or death.
2-2 9 10 11 • Gasoline is extremely flammable. • Keep heat, sparks and open flame away from fuel tank and fuel lines. • Do not add fuel while engine is running or hot. • Do not modify fuel system. Services should be performed by dealer or qualified personnel. 5 6 7 8 3 4 • Maintain oil level between dipstick “MIN” and “MAX” marks. 2 Do not tamper with governor to increase speed. Operation at higher speeds can cause loss of control that can result in severe injury or death.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 7 IMPORTANT LABELS 1 GOLF CAR SERIAL NUMBER 1 JWX-000000 The golf car serial number 1 is identified in the location shown. Y-910b 2 NOTE: The first three digits of the serial number are for model identification; the remaining digits are the unit production number. Keep a record of these numbers for reference when ordering parts from a Yamaha Golf-Car Company dealer. The engine serial number 2 is affixed in the location shown.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 8 ! OPERATOR SAFETY Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following: 1 BEFORE OPERATING THE GOLF CAR 2 ● 3 4 ● ● 5 ● 6 ● 7 8 ● 9 Y-68 Read this Owner’s/Operator’s manual and all safety and instruction labels on the golf car before operating. Perform the pre-operation checks found in Section 6 of this manual.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 9 ! OPERATOR SAFETY ● Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully. ● Avoid starting or stopping abruptly. ● Vary the speed of the golf car to match the terrain of the course. ● Avoid turning the steering wheel too sharply at higher speeds. ● Always drive slowly straight up or straight down slopes – never at an angle. 1 2 3 4 5 Y-921 ● 6 Do not run the engine indoors. Exhaust gas is poisonous.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 10 ! SAFETY CONSIDERATIONS 1 2 3 4 5 6 7 8 9 10 11 Like all machines, golf cars can cause injury if improperly used or maintained. This section contains broad safety practices required for safe golf car operation. Before golf cars are operated, golf course personnel should establish any additional safety practices that may be required for safe operation.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 11 ! SAFETY CONSIDERATIONS ● ● Loose Terrain. Loose terrain may cause a golf car to lose traction and may affect stability. Repair loose terrain, chain or rope off these areas, or identify loose terrain with a suitable warning. Golf Car and Pedestrian Interference. Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent accidents.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 12 ! SAFETY CONSIDERATIONS 1 2 3 4 5 SAFETY PRECAUTIONS DURING MAINTENANCE Record all maintenance performed in a maintenance record log by date, name of person performing maintenance and type of maintenance. Periodically inspect maintenance log to ensure accurate and complete entries. ● Provide operator comment cards to assist in identifying non-periodic maintenance needs for specific golf cars.
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LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 14 CONTROLS MAIN SWITCH 1 The main switch controls the following items: 2 OFF ON 3 OFF All electrical circuits are switched off. The key can be removed only in this position. 4 Y-912b 5 OFF ON ON Electrical circuits are switched on. The golf car can be driven. 6 7 Y-913b 8 OIL WARNING LIGHT OFF ON 9 A 10 When the engine oil level falls below an acceptable level, this light comes on.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 15 CONTROLS DRIVE SELECT LEVER The drive select lever is used to shift the golf car into forward or reverse. After coming to a complete stop, move the lever to the desired position. Lever Position Car Movement F FORWARD R REVERSE Y-18 1 2 3 4 NOTE: The back-up buzzer will beep when the drive select lever is turned to “R.” BEEP 5 6 7 Y-920 ACCELERATOR PEDAL A 8 The accelerator pedal controls the golf car’s speed.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 16 CONTROLS PARKING BRAKE PEDAL 1 Press down on the parking brake pedal whenever parking the golf car. 2 ç Parking brake pedal C 3 Y-22a NOTE: Release the parking brake by depressing the accelerator pedal. 4 5 The parking brake will automatically release when the accelerator pedal is depressed. If the main switch is in the “ON” position, depressing the accelerator may suddenly cause the golf car to move.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 17 PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your golf car. Get in the habit of performing the following checks in the same way so that they become second nature. 1 2 3 ● Be sure the main switch key is removed before performing the pre-operation checks to prevent accidental starting, and apply the parking brake to keep the car from moving.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 18 PRE-OPERATION CHECKS 1 FUEL SYSTEM C 2 B 3 A Make sure there is sufficient fuel in the tank and that the fuel shutoff valve is open. Also check fuel line and connections for leakage. Y-514a å Fuel tank ∫ Fuel cap ç Fuel shutoff valve 4 Gasoline and its vapors are highly flammable and explosive. ● Do not smoke when refueling and keep away from sparks, flames, or other sources of ignition.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 19 PRE-OPERATION CHECKS ENGINE OIL 1 With the golf car parked on level ground, remove the dipstick and make sure the engine oil is between the MIN and MAX marks (the crosshatched area on the end of the dipstick). 3 Y-514 å Oil level dipstick ∫ Maximum oil level ç Safe operating range B MIN C 4 If the oil level is below the MIN mark on the dipstick, add oil through the oil filler hole until the oil level is between the MIN and MAX marks.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 20 PRE-OPERATION CHECKS Engine Cooling Inlet Duct 1 Check the engine cooling inlet duct for debris. Remove any debris present. 2 å Engine cooling inlet duct 3 BATTERY A Y-1347 4 5 6 Check that the battery is held securely in place to prevent the battery from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the battery. Check the battery terminals for corrosion.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 21 PRE-OPERATION CHECKS STEERING SYSTEM 1 Check the steering system for excessive free play by: Y-932 ● 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, or hear rattling sounds which may indicate loose steering components, consult a Yamaha dealer. 2 3 4 5 BACK-UP BUZZER Check the back-up buzzer by moving the drive select lever to “R” for reverse.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 22 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 3 Y-21a Parking Brake Pedal Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed. 4 ç Parking brake pedal 5 NOTE: Release the parking brake by depressing the accelerator pedal.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 23 OPERATION STARTING 1 1. With the parking brake applied, turn the drive select lever to “FWD” for forward, or “REV” for reverse. 2 CAUTION Y-18 OFF ON Y-911a Do not shift from “FWD” forward to “REV” reverse while the golf car is moving. 4 2. Turn the main switch to “ON.” Do not depress the accelerator pedal when turning on the main switch or the golf car may suddenly start moving. 3. Pull the choke knob out and hold it while starting.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 24 OPERATION STOPPING 1 To stop the golf car, gradually press down on the brake pedal. 2 å Brake pedal 3 When the car has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.” B ∫ Parking brake pedal 4 CAUTION A Y-65b 5 Do not hold the golf car on an incline with the accelerator – use the brake.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 25 MAINTENANCE PERIODIC MAINTENANCE CHARTS 1 Regular maintenance is required for the best performance and safe operation of your golf car. Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic.
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LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 27 MAINTENANCE EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS • • • • • Item CARB. ASSY., LH., JT., CARBURETOR 2 & JT., CARBURETOR 1 T.C.I. MAGNETO ASSY. & PLUG, SPARK CRANKCASE 1 & HEAD, CYLINDER 1 AIR FILTER ASSY. MUFF., 2 1 Acronym CARB (Carburetor) 2 El (Electronic Ignition) 3 PCV (Positive Crankcase Ventilation) ACL (Air Cleaner) 4 5 The above items and the corresponding acronyms are provided in accordance with U.S.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 28 MAINTENANCE Spark Plug Inspection 1 2 You should periodically remove and inspect the spark plug. Dirty or worn spark plugs can cause poor performance. B å Spark plug ∫ Spark plug cap 3 A Y-516 4 1. Check for discoloration and remove carbon deposits with a spark plug cleaner or wire brush. The normal electrode color will be tan. 2. Check the spark plug type, and check the spark plug gap with a feeler gauge.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 29 MAINTENANCE Engine Oil Replacement 1. Warm up the engine for several minutes, place the golf car on a level surface, then stop the engine. 1 2 3 Use caution not to touch hot engine oil or hot engine parts, during the following procedure. 4 2. Place an oil pan under the engine drain plug. 3. Remove the oil drain plug and let the oil drain completely. NOTE: Dispose of used oil in an environmentally safe way, such as taking oil to an oil collection station.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 30 MAINTENANCE 1 å Oil filler hole A CAUTION 2 3 Y-515 4 Air Filter To remove the air filter elements: A 5 B A 6 A 7 Y-518 1. Unlatch the air filter cover clips and remove cover. å Air filter cover clips ∫ Air filter cover 2. Lift the air filter and pre-filter out of the air filter case. ç Air filter ∂ Pre-filter 8 9 Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the crankcase.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 31 MAINTENANCE Inspection and cleaning: A 1 3. Wash the foam pre-filter in soap and water. Allow it to dry. B å Soap and water ∫ Foam element 2 4. Check the filter element. If damaged or dirty, replace it. 3 Y-508 CAUTION 4 Do not wring out the foam pre-filter, this could cause it to tear. 5 5. To replace the elements, reverse the above steps. 6 CAUTION The pre-filter has a notch on one side. It will only fit in the case one way.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 32 MAINTENANCE Inspection: 1 To inspect the drive belt, check for frayed edges or tears, and measure drive belt against the following specification. If the belt shows excessive wear or damage, replace the belt with a new one. A 2 B 3 Y-44 4 å New: 1.09 in. (27.6 mm) ∫ Replace when belt reaches: 0.95 in. (24 mm) 5. To install the drive belt, reverse the above steps, rolling the belt back over the secondary sheave.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 33 MAINTENANCE 1 Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 34 MAINTENANCE Fuse Replacement 1 Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and create a fire hazard. 2 3 CAUTION When replacing a fuse, be sure the main switch is turned off to prevent accidental short circuiting. 4 5 1. Locate the in-line fuse holder on the main wire harness adjacent to the battery. 6 2. Pull fuse holder cover off. 3. Pull fuse out, inspect and replace if necessary.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 35 MAINTENANCE Transaxle Oil To check transaxle oil level: 1. Place the golf car on a flat, level surface. 1 3 2. Remove seven plastic rivets 1 and two bolts 2, and remove the bag holder insert. 3. Place an oil pan under the transaxle case. 2 4. Clean area around servicing plug 4. Y-1215 4 1 2 3 4 5. Using an 8 mm hex wrench, remove transaxle oil servicing plug located on the rear of the transaxle case. 5 6.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 36 MAINTENANCE NOTE: For transaxle oil replacement, consult a Yamaha dealer or other qualified mechanic. 1 2 CAUTION 3 Before performing wheel or brake maintenance, verify that the main switch is in the “OFF” position. 4 Wheel Replacement Y-57 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.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 37 MAINTENANCE Brake Pedal Free Play Adjustment CAUTION 1 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: 1. Remove the floor mat and service lid from the floor of the golf car. 4 5 6 Y-61c a 8 9 10 11 12 13 14 15 16 17 18 2.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 38 STORAGE 1 2 3 Perform the following preparations when storing your golf car for extended periods of time: NOTE: Turn main switch key to “OFF” position, remove key, and store key in a safe place. å Float bowl drain screw DRAINING FUEL 4 Gasoline and its vapors are highly flammable and explosive. 5 ● 6 ● 7 ● ● 8 ● 9 ● 10 ● 11 1.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 39 STORAGE ENGINE PREPARATION With the key removed and the spark plug lead disconnected, turn the clutch by hand until compression is felt. This puts the valves in the closed position. CHASSIS PREPARATION 1. Verify the tire pressure is set to 16 psi (110 kPa, 1.1 kgf/cm2). 2. Have the battery recharged every 60-90 days to keep it fully charged. The battery must be kept fully charged to avoid damage.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 40 SPECIFICATIONS 1 2 3 4 GENERAL SPECIFICATIONS Items Dimensions: Overall length Overall width Overall height (steering height) Height of floor Wheelbase Tread: Front Rear Minimum ground clearance YDRA 94.3 in. (2395 mm) 47.2 in. (1200 mm) 46.9 in. (1190 mm) 12.2 in. (310 mm) 64.6 in. (1640 mm) 34.3 in. (870 mm) 38.6 in. (980 mm) 4.3 in.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 41 SPECIFICATIONS ENGINE 1 Items Description: Engine type Number of cylinders Displacement Bore x stroke Compression ratio Rated output Cooling system Starting system Ignition system Spark plug type Spark plug gap Lubrication system Engine oil type Engine oil capacity Oil change quantity YDRA 4-stroke, Gasoline, OHV Single 357 cm3 3.30 x 2.48 in. (85 x 63 mm) 8.1:1 11.4 hp (8.5 kw)/3500 rpm Forced air-cooled Starter TCI Magneto BPR2ES 0.028-0.031 in. (0.7-0.
LIT_19626_11_07.qxd 10/5/06 10:42 AM Page 42 SPECIFICATIONS 1 CHASSIS Items 2 3 4 5 6 7 8 9 Steering system: Type Steering angle (L.H.) Steering angle (R.H.) Brakes: Brake system Type of brake Brake pedal free play linkage adjustment (Brake cable end play) Parking brake: Type Release timing (With pedal segment in second notch) (Bolt heads round parallel to arm) Wheel: Tire size: Front Rear Rim size: Tire pressure: YDRA Rack and Pinion 1.85 turn 1.85 turn Mechanical Internal wet 45-50 mm (1.77-1.
Y BR G G B RY G BR RW Br Br R Br RW RG BY BY RG RY B Br R B ....................Black L ......................Blue G ...................Green Y...................Yellow R ......................Red P ......................Pink Br ..................Brown W ...................White B/R .........Black/Red Y/B .....Yellow/Black R/Y .......Red/Yellow R/W ........Red/White COLOR CODE PILOT LAMP (12V3.
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LIT_19626_11_07 cover.qxd 9/18/06 8:09 AM Page 1 OWNER’S / OPERATOR’S MANUAL YDRA 4 STROKE GOLF CAR Printed in U.S.
