Yamaha G16E, G16A, ULTIMA 36 VOLT ELECTRIC-G16-E User Manual

OWNER’S/
OPERATORS
MANUAL

GOLF CAR

LIT-19626-16-00

G16A

G16E

JN6-F8199-13

The engine exhaust from this product

WARNING

contains chemicals known to the
State of California to cause cancer, birth
defects or other reproductive harm.

YAMAHA

LIT-CALIF-65-01

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.

TECHNICAL SERVICE DEPT

GOLF CAR SALES GROUP

YAMAHA MOTOR

MANUFACTURING CORP OF

AMERICA

G16A, G16E

OWNER’S/OPERATOR’S

MANUAL

© 2000 by Yamaha Motor

Manufacturing Corporation

of America

1st edition

All rights reserved. Any reprinting

or unauthorized use without the

written permission of

Yamaha Motor Manufacturing

Corporation of America
is expressly prohibited.

Printed in U.S.A.

P/N LIT-19626-16-00

G16A/E

i

IMPORTANT MANUAL

WARNING

CAUTION

WARNING

!

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
occupants, a bystander, or a
person inspecting or repairing
the golf car.

to the golf car

● Yamaha continually seeks ad-

vancements in product design and
quality; therefore, while this manual
contains the most current product
information available at the time of
printing, there may be minor
discrepancies between your golf
car and this manual. If you
have any questions concerning this
manual, please consult your
Yamaha dealer.

● This manual should be considered

a permanent part of your golf car
and should remain with the car
when resold.

This message describes special
precautions that must be taken to
avoid damage to the golf car.

This message provides additional key
information.

ii

Read and understand this manual
completely before operating your
golf car.

G16A/E

CONTENTS

WARRANTY

IMPORTANT LABELS 2

OPERATOR SAFETY 3

MAINTENANCE SAFETY PROGRAM 4

CONTROLS 5

PRE-OPERATION CHECKS 6

OPERATION 7

MAINTENANCE 8

1

1

STORAGE

SPECIFICATIONS

WIRING 11

G16A/E

iii

9

10

WARRANTY

1

YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA

2

Yamaha Motor Manufacturing Corporation of America
hereby warrants that any new G16 (gas and electric
models) Yamaha Golf Car purchased from an authorized
Yamaha dealer in the United States will be free from

3

defects in material and workmanship for the period of
time stated herein, subject to the stated limitations.

THE PERIOD OF WARRANTY for any G16 (gas and
electric models) will be three years from date of pur-

4

chase.

The first year of warranty shall cover the entire car
except for batteries, battery chargers, tires and rims,
which are warranted by their respective manufacturers.

The second year of warranty shall cover the engine

5

assembly, clutch, transmission, axles, electrical system,
frame, suspension components, electric motor, control
cables, and steering gear.

Parts excluded from the second year of warranty include

6

the body parts, seats, mats, bumper assembly, bag car­rier, scorecard holder, and the trim.

The third year of warranty shall cover the engine assem­bly, clutch, transmission, axles, frame, suspension com­ponents, steering gear, and (on the G16E) electronic

7

speed controller.

Parts excluded from the third year of warranty include
the second year exclusions and the electrical system
(except electronic speed controller), electric motor, and
control cables.

8

DURING THE PERIOD OF WARRANTY any authorized
Yamaha Golf Car Dealer will, free of charge, repair or
replace, at Yamaha’s option, any part adjudged defective
by Yamaha due to faulty workmanship or material from

9

the factory. Parts used in warranty repairs will be war­ranted for the balance of the machine’s warranty period.
All parts replaced under warranty become property of
Yamaha Motor Manufacturing Corporation of America.

GENERAL EXCLUSIONS from this warranty shall

10

include any failures caused by:
a. Abnormal strain, neglect, or abuse, including lack of

proper maintenance, and use contrary to the
Owner’s/Operator’s Manual instructions.

b. Accident or collision damage.

11

c. Installation of par ts or accessories that are not origi-

nal equipment.

d. Fading, rust, or deterioration due to exposure or ordi-

nary wear and tear.

e. Modification or alteration that affects the car’s condi-

tion, operation, performance, or durability, or which
makes the car serve a purpose other than use as a

two-person, golf course vehicle.
f. Damage due to improper transportation.
g. Acts of God (i.e. lightning, hail damage, flooding,

fire, etc.)

G16A, G16E

LIMITED WARRANTY

SPECIFIC EXCLUSIONS from this warranty shall
include any parts replaced due to normal wear or routine
maintenance; including oil, air filter elements, brake
shoes, spark plugs, starter and clutch drive belts. Any
charges incurred in transporting a golf car to and from
an authorized Yamaha Golf Car Dealer for service or in
performing field service is also excluded from this war­ranty.

THE CUSTOMER’S RESPONSIBILITY under this war­ranty shall be to:

1. Operate and maintain the golf car as specified in the
appropriate Owner’s/Operator’s Manual;

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

WARRANTY TRANSFER: To transfer any remaining
warranty from the original purchaser to any subsequent
purchaser, it is imperative that the machine be inspect­ed and registered for warranty by an authorized Yamaha
Golf Car Dealer. In order for this warranty to remain in
effect, this inspection and registration must take place
within ten (10) days after transfer. An inspection and reg­istration fee may be charged for this service.

YAMAHA MOTOR MANUFACTURING CORPORA­TION OF AMERICA MAKES NO OTHER WARRANTY
OF ANY KIND, EXPRESSED OR IMPLIED. ALL
IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE WHICH
EXCEED THE OBLIGATIONS AND TIME LIMITS
STATED IN THIS WARRANTY ARE HEREBY DIS­CLAIMED BY YAMAHA MOTOR MANUFACTURING
CORPORATION OF AMERICA AND EXCLUDED
FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, SO
THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
ALSO EXCLUDED FROM THIS WARRANTY ARE
ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING LOSS OF USE. SOME STATES DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF INCI­DENTAL OR CONSEQUENTIAL DAMAGES, SO THE
ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER
RIGHTS WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR MANUFACTURING
CORPORATION OF AMERICA
Newnan, Georgia 30265-1320

Effective Date: 2/1/96
LIT-13710-00-96

1-1

G16A/E

WARRANTY

YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA

SPECIALTY VEHICLE ENGINES

EMISSION CONTROL WARRANTY

YOUR WARRANTY RIGHTS AND OBLIGATIONS

In complance with the California Air Resources
Board, Yamaha Motor Manufacturing Corporation of
America is pleased to explain the emission control
system warranty on your 1996 or later specialty
vehicle engine. New Yamaha speciality vehicle
engines must be designed, built and equipped to
meet stringent anti-smog standards. Yamaha must
warrant the emission control system on your spe­ciality vehicle engine for the periods of time listed
below provided there has been no abuse, neglect or
improper maintenance of your speciality vehicle
engine.

Your emission control system may include parts
such as the carburetor or fuel-injection system, the
ignition system, and catalytic converter. Also includ­ed may be hoses, belts, connectors and other emis­sion-related assemblies.

Where a warrantable condition exists, Yamaha will
repair your specialty vehicle engine at no cost to you
including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE

The 1996 and later specialty vehicle engines are
warranted for two years. If any emissions-related
part on your engine is defective, the part will be
repaired or replaced by Yamaha.

OWNER’S WARRANTY RESPONSIBILITIES

● As the specialty vehicle engine owner, you are

responsible for the performance of the required
maintenance listed in your owner’s manual.
Yamaha recommends that you retain all receipts
covering maintenance on your specialty vehicle
engine, but Yamaha cannot deny warranty solely
for the lack of receipts or for your failure to ensure
the performance of all scheduled maintenance.

● As the specialty vehicle engine owner, you

should also be aware that Yamaha may deny you
warranty coverage if your specialty vehicle
engine or a part has failed due to abuse, neglect,
improper maintenance or unapproved modifica­tions.

● You are responsible for presenting your specialty

vehicle engine to a Yamaha dealer as soon as a
problem exists. The warranty repairs should be
completed in a reasonable time, not to exceed 30
days.

If you have any questions regarding your warranty
rights and responsibilities, you should contact the
Yamaha Customer Relations Department at
[phone].

Yamaha Motor Manufacturing Corporation of
America warrants to the ultimate purchaser and
each subsequent purchaser thereafter that each
new 1996 and later model year specialty vehicle
engine certified for sale is:

1. Designed, built, and equipped so as to conform,
at the time of sale, with all applicable regula­tions adopted by the California Air Resources
Board, and

2. All warranted parts are free from defects in
material and workmanship for the warranty
period of the specialty vehicle engine or the
period prior to the first scheduled replacement
point of the warranted part as required by the
maintenance schedule, if applicable, whichever
is less. A defect exists when a deficiency in
material or workmanship is such that an emis­sion-related warranted part does not function
as designed.

The warranty period begins on the date that the
specialty vehicle engine is delivered to an ultimate
purchaser or on the date it is first placed in service.

WARRANTED PARTS INCLUDE the following:

1. Fuel Metering System
Carburetor and internal parts (or fuel injection)
Air/fuel ratio feedback and control system
Cold start enrichment system

2. Air Induction System
Controlled hot air intake system
Intake manifold

1

2

3

4

5

6

7

8

9

10

11

G16A/E

1-2

WARRANTY

1

2

3

4

5

6

7

8

9

10

11

3. Ignition System
Spark plugs *
Magneto or electronic ignition system
Spark advance/retard system

4. Exhaust Gas Recirculation (EGR) System
EGR valve body, and carburetor spacer if
applicable
EGR rate feedback and control system

5. Air Injection System
Air pump or pulse valve
Valves affecting distribution of flow
Distribution manifold

6. Catalyst or Thermal Reactor System
Catalytic converter
Thermal reactor
Exhaust manifold

7. Particulate Controls
Traps, filters, precipitators, and any other
device used to capture particulate emissions

8. Miscellaneous Items Used in Above Systems
Vacuum, temperature, and time sensitive
valves and switches
Electronic controls
Hoses, belts, connectors, and assemblies

9. Engine components damaged due to a failure
under warranty of a warranted part.

* The original spark plug(s) are warranted for the
period of replacement indicated in the
Owner’s/Operator’s Manual and not the useful life of
the specialty vehicle engine (see your Owner’s
Manual).

DURING THE PERIOD OF THIS WARRANTY

Yamaha Motor Manufacturing Corporation of
America will repair or replace any warranted part
deemed defective by Yamaha during the scope of
the warranty without charge to the owner, including
parts, labor, and diagnosis. This work must be done
at an authorized Yamaha dealer. Give notice to an
authorized Yamaha dealer of any apparent defect(s)
within a reasonable period of time after discovery.
The specialty vehicle engine must be made avail­able for inspection by an authorized Yamaha dealer.

OWNER’S RESPONSIBILITY: The owner of the
specialty vehicle engine is responsible for the per­formance of required maintenance (see your
Owner’s/Operator’s Manual). Receipts and mainte­nance records covering the performance of regular
maintenance should be retained in the event ques­tions arise concerning maintenance. The receipts
should be transferred to each subsequent owner of
this specialty vehicle engine.

The emission control systems of your Yamaha spe­cialty vehicle engine were designed, built, tested,
and certified as being in conformity with California
emission control regulations using genuine Yamaha
parts. Accordingly, it is recommended that any
replacement part(s) used for maintenance, replace­ment, or repair of emission control systems be
Yamaha parts. The owner may elect to have main­tenance, replacement, or repair of the emission
control devices and systems performed by any
repair establishment or individual, and may elect to
use parts other than Yamaha parts for such mainte­nance, replacement, or repair without invalidating
this warranty. However, the cost of such service or
parts will not be covered under the warranty.

EXCLUSIONS: No warranty coverage will be
allowed if the part(s) failure was caused by
owner/operator abuse, neglect, tampering, improper
adjustment unless performed by a dealer during
warranty repair work, modification, misuse, alter­ation, or improper maintenance (see your Owner’s/
Operator’s Manual).

Use of parts which are not qualitatively equivalent to
genuine Yamaha parts, improper service, or lack of
required maintenance which causes failure of a
warranted part may constitute abuse and/or improp­er service, thereby invalidating warranty liability
hereunder.

This warranty does not cover damage resulting from
accidents, acts of nature, or other events or occur­rences beyond the control of Yamaha. Yamaha
Motor Manufacturing Corporation of America
expressly disclaims responsibility for any and all
consequential damages, such as loss of time,
inconvenience, loss of use of the specialty vehicle,
or commercial loss.

Yamaha Motor Manufacturing Corporation of
America
1000 Hwy. 34 East
Newnan, GA 30265

1-3

G16A/E

IMPORTANT LABELS

WARNING

1

4

1

6

G16E

4

5

G16A

3

G16E

G16A

SAFETY AND
INSTRUCTION
LABELS

1

2

2

Y-505

Please read the following
labels carefully before
operating your golf car,
and promptly replace any
labels which become dam­aged or removed.

6

3

4

5

6

7

Y-500

8

2

3

G16A/E

5

9

10

11

Y-502

2-1

IMPORTANT LABELS

1

GOLF CAR SERIAL
NUMBER

The golf car serial number is stamped

2

3

Y-102a

4

in the location shown.

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 dealer.

5

C

ç Engine Information

6

7

THIS ENGINE MEETS 2000-2001 CALIFORNIA EMMISSION REGULATIONS FOR OFF-ROAD ENGINES.

Y-852A

8

THIS ENGINE CONFORMSTO **(*****.******) U.S. EPA REGULATIONS FOR SMALL NONROAD ENGINES.

JR3-2179R-04

Y-851

9

10

11

2-2

G16A/E

OPERATOR SAFETY

!

Y-67

Y-8

Y-68

Yamaha golf cars are designed to be
simple to operate. However, be sure
to observe the following:

BEFORE OPERATING
THE GOLF CAR

● Read this Owner’s/Operator’s man-

ual and all safety and instruction
labels on the golf car before operat­ing.

● Perform the pre-operation checks

found in Section 6 of this manual.

● Only authorized people should

drive the golf car, from the driver’s
side only, and only in designated
areas.

● Do not allow more than two people

to ride in the golf car.This golf car is
restricted to two occupants.

● Do not operate the golf car while

under the influence of alcohol or
drugs; their affect on vision and
judgment make operating a golf car
dangerous.

● Do not operate the golf car on pub-

lic streets, roads or highways. Such
use is prohibited by law, and dan­gerous. Operation on public roads
can result in collision with other
vehicles.

WHILE OPERATING THE
GOLF CAR

● Keep your entire body inside the

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

1

2

3

4

5

6

7

8

9

10

11

● Do not start the golf car until all

occupants are seated.

G16A/E

3-1

OPERATOR SAFETY

!

1

2

3

● Keep your hands on the steering

wheel and your eyes on the path
ahead.

● 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.

4

● Avoid turning the steering wheel too

sharply at higher speeds.

5

● Always drive slowly straight up or

straight down slopes – never at an
angle.

6

7

Y-10

● Do not run the engine indoors

(G16A). Exhaust gas is poisonous.

8

9

10

11

3-2

Y-9

● Do not make any modification or

addition which affects capacity or
safe operation, or make any
changes not in accordance with the
owner’s/operator’s manual.

Y-69

G16A/E

MAINTENANCE SAFETY PROGRAM

!

Like all machines, golf cars can
cause injury if improperly used or
maintained. This section contains
broad safety practices required for
safe golf car operation. Before golf
cars are operated, golf course per­sonnel should establish any addition­al safety practices that may be
required for safe operation.

Experience has shown that golf cars
are safe when operated in accor­dance with the safety warnings
affixed to every golf car. This safe
operation is enhanced when golf cars
are used according to the safety rules
and practices established to meet the
terrain and conditions of the course
they are used on.

The information contained here is
intended for golf course personnel
responsible for golf car safety. If you
are responsible for the operation and
maintenance of this golf car, we
encourage you to implement this golf
car safety program.

Do Not Operate Golf Cars When
Under The Influence Of Alcohol Or
Drugs

GOLF COURSE SAFETY
SURVEY

Perform safety surveys regularly to
identify hazardous areas where golf
cars should not be operated.

GOLF COURSE HAZARD
PREVENTION

The following golf course hazards
must be made safe:

● Steep Grades. Where steep

grades exist, restrict golf cars to
designated golf car pathways
where possible. In addition, identify
steep grades with a suitable warn­ing like:

Warning: Steep Grade, Descend
Slowly With Foot On Brake

1

2

3

4

5

6

7

8

DRIVER
QUALIFICATIONS

Allow only authorized people to oper­ate golf cars. It is recommended that
only people who possess a valid
motor vehicle driver’s license be
allowed to operate golf cars.

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

G16A/E

● Sharp Turns, Blind Corners,

Bridge Approaches. Chain or
rope off these potentially haz­ardous areas or identify them with
a suitable warning describing the
nature of the hazard and the prop­er precautions to be taken to avoid
the hazard.

● Wet Areas.Wet grass may cause a

golf car to lose traction and may
affect stability. Chain or rope off wet
areas or identify wet areas with a
suitable warning.

4-1

9

10

11

MAINTENANCE SAFETY PROGRAM

!

● Loose Terrain. Loose terrain may

1

2

3

4

5

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 Interfer-

ence. Reroute golf car traffic or
pedestrian traffic in congested
areas wherever possible to prevent
accidents. If it is impractical to
reroute traffic, erect warning signs
to warn pedestrians of golf car traf­fic, and to warn golf car operators to
drive slowly, use caution, and watch
for pedestrians.

MAINTENANCE

6

REQUIRED FOR GOLF
CAR SAFETY

Practice the following to help ensure

7

the safety of golf car operators:

● Preventative Maintenance. Per-

8

9

form all scheduled maintenance in
accordance with manufacturer’s
recommendations to provide the
golfing patron with a safe, properly
operating golf car.

● Ventilation. Properly ventilate all

maintenance and storage areas in
accordance with applicable fire
codes and ordinances to avoid fire
hazards. Ventilation is required to
remove flammable vapors and
fumes from gasoline powered car
storage areas. Ventilation is also
required to remove hydrogen gas
from electric powered car storage
areas during the charging process.

For electric powered golf cars, the
amount of hydrogen gas emitted dur­ing charging depends on a number of
factors, such as the condition of the
batteries, the output rate of the bat­tery charger, and the amount of time
the batteries are on charge. Because
of the highly volatile nature of hydro­gen gas and its propensity to rise and
accumulate at the ceiling in pockets, a
minimum of 5 air changes per hour is
recommended. Consult applicable fire
and safety codes for the specific ven­tilation levels requirement, as well as
requirements for the use of explosion
proof electrical apparatus.

● Personnel. Allow only qualified,

10

11

trained, and authorized personnel
to inspect, adjust, and maintain golf
cars.

● Parts and Materials. Use only

replacement parts and materials
recommended by the manufacturer.

4-2

G16A/E

MAINTENANCE SAFETY PROGRAM

!

SAFETY PRECAUTIONS
DURING MAINTENANCE

When performing maintenance, fol­low all safety instructions contained
in the manufacturer’s operation and
service manuals, as well as the fol­lowing safety procedures:

● Properly immobilize golf car before

beginning any maintenance.

● Properly block chassis before

working underneath golf car.

● Before disconnecting any part of

the fuel system, drain the applica­ble part of the system to prevent
fuel leaks.

● Avoid fire hazards, and have appro-

priate fire protection equipment
available.

● Before working on an electric golf

car, disable the car’s electrical sys-
tem in accordance with the manu­facturer’s instructions.

● 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.

● Maintain in a legible condition all

nameplates, warnings, and instruc­tions provided by the manufacturer.

● If new nameplates, warnings, or

instructions are needed, contact
your Yamaha dealer.

FUEL HANDLING/
STORAGE AND
BATTERY CHARGING

Take the following precautions to
ensure maintenance worker safety:

1

2

3

4

5

6

7

8

● Use only properly insulated tools

when working on electrically pow­ered golf cars or around batteries.

● Maintain all safety devices includ-

ing brakes, steering mechanisms,
warning devices, and governors, in
a safe operating condition. Do not
modify these safety devices as
supplied by the manufacturer.

● After each maintenance or repair,

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.

G16A/E

● Supervise the storage and han-

dling of liquid fuels in accordance
with applicable fire and safety
requirements.

● Only use battery changing and

charging facilities and procedures
that are in accordance with applic­able ordinances and regulations.

● Periodically inspect fueling and

charging facilities and procedures
to be certain that applicable safety
codes, regulations, and procedures
are being followed.

4-3

9

10

11

CONTROLS

1

710

2

3

18

4

6

5

5

4

1

6

Y-506

8

9

Y-12

FEATURES

1 Steering wheel
2 Seat
3 Fuel cap (for G16A)
4 Brake pedal
5 Parking brake pedal
6 Accelerator pedal
7 Drive selector lever
8 Main switch
9 Oil warning light (for G16A)
a Choke knob (for G16A)
b Front cowl
c Front tire
d Front bumper
e Rear cowl
f Rear bumper
g Rear tire
h Battery (for G16A)
i Receptacle (for G16E)

7

2

8

9

11

14

12

17

3

10

11

5-1

15

13

Y-13

16

Y-507

G16A/E

CONTROLS

OFF

MAIN SWITCH

The main switch controls the follow­ing items:

OFF
Ignition circuit is switched off.
The key can be removed only in this
position.

ON

1

2

3

4

Y-15

5

OFF

ON
Electrical circuits are switched on.
The golf car can be driven.

6

ON

7

Y-16

OIL WARNING LIGHT

OIL

WARNING

OFF

A

ON

Y-17

(G16A)

When the engine oil level falls below
an acceptable level, this light comes
on. If the light comes on, stop the

engine, check the engine oil level,
and add oil as necessary. (See
page 6-3).

8

9

10

G16A/E

å Oil warning light

11

5-2

CONTROLS

1

2

3

Y-18

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

4

5

The back-up buzzer will beep when
the drive select lever is turned to “R.”

6

Y-19

7

ACCELERATOR PEDAL

8

A

The accelerator pedal controls the
golf car’s speed.

9

10

11

5-3

Action Car Speed

Depress pedal Increase

Release pedal Decrease

Y-20

å Accelerator pedal

BRAKE PEDAL

Press down on the brake pedal to
stop the golf car.

å Brake pedal

A

Y-21

G16A/E

CONTROLS

PARKING BRAKE
PEDAL

A

Press down on the parking brake
pedal whenever parking the golf car.

å Parking brake pedal

Y-22

Release the parking brake by
depressing the accelerator pedal.

1

2

3

4

CHOKE KNOB (G16A)

Pull and hold out choke knob when
starting a cold engine. Release the
knob after the engine starts.

A

CHOKE

Y-23

å Choke knob

5

6

7

8

G16A/E

9

10

11

5-4

PRE-OPERATION CHECKS

WARNING

1

2

3

4

5

6

7

8

9

10

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.

● 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.

● For the G16A: During the pre-

operation checks, avoid touch­ing engine parts or the muffler
while they are still hot.

PRE-OPERATION
CHECKLIST

Before each use check the following:

✔ Fuel system (G16A)
✔ Engine oil level (G16A)
✔ Battery
✔ Tire condition
✔ Steering system
✔ Back-up buzzer
✔ Pedal operation
✔ Body and chassis

11

6-1

SEAT

Open the seat for checking and ser­vicing.

Y-512

G16A/E

PRE-OPERATION CHECKS

CAUTION

WARNING

FUEL SYSTEM (G16A)

Make sure there is sufficient fuel in
the tank, and check fuel line and con-

B

A

Y-513

nections for leakage.

å Fuel tank
∫ Fuel cap

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.

● Stop engine and allow it to cool

for several minutes before refuel­ing.

● Refuel in a well-ventilated area.

● Take care not to spill gasoline. If

gasoline spills, wipe it up imme­diately with dry rags. Always dis­pose of gasoline-soaked rags
properly.

● Tighten the filler cap securely

after refueling.

● If you swallow gasoline, inhale a

lot of gasoline vapor, or get gaso­line in your eyes, get immediate
medical attention.

● If any gasoline gets on your skin,

immediately wash with soap and
water. Change clothing if gaso­line spills on it.

1

2

3

4

5

6

7

8

9

10

Recommended fuel:

Unleaded gasoline

Fuel tank capacity:

6.3 US gal
(24.0 L, 5.3 Imp gal)

G16A/E

11

Avoid using gasoline blended with
methyl alcohol which can damage
fuel system parts.

6-2

CAUTION

PRE-OPERATION CHECKS

1

2

3

4

5

6

7

8

9

10

11

B

MIN

C

A

Recommended oil:

YAMALUBE 4-cycle oil or

SAE 10W-30

Engine oil capacity:

1.16 US qt
(1.0 L, 0.24 Imp gal)

Oil change quantity:

1.0 US qt
(0.9 L, 0.19 Imp gal)

MAX

A

Y-514

Y-28

Y-515

ENGINE OIL (G16A)

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).

å Oil level dipstick
∫ Maximum oil level
ç Safe operating range

If the oil level is below the MIN mark
on the dipstick, add oil through the oil
filler hole until the oil level is between
the MIN and MAX marks.

å Oil filler hole

● Use care not to fill past the MAX

dipstick mark, and be sure no
foreign material enters the
crankcase.

● Use care not to get oil on the

starter belt.

The distance between the dipstick
marks represents approx. 1/2 US qt
(1/2 L) of oil.

Recommended engine oil classifica­tion: API Service SE, SF, or SG.
Engine oils labeled “Energy Con­serving II” are recommended.

6-3

G16A/E

PRE-OPERATION CHECKS

Engine Cooling Inlet Duct

1

Check the engine cooling inlet duct for
debris. Remove any debris present.

A

å Engine cooling inlet duct

2

BATTERY

3

Charge G16E batteries before each
use. See charging steps in chapter 8,

Maintenance.

G16A1

Check that the battery (G16A) or bat­teries (G16E) are held securely in
place to prevent the batteries 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.

4

5

6

TIRE CONDITION

7

Tire Air Pressure

Check the tire air pressure before
operating the golf car.

8

G16A/E

Tire pressure:

9

For G16A: 16 psi

(108 kPa, 1.1 kgf/cm2)

Y-30

A

Y-31

For G16E: 20 psi

(137 kPa, 1.4 kgf/cm2)

Tire Wear Limit

Check the tire surface for damage,
cracks or embedded objects. When
tire tread wears down to 0.04 in. (1
mm), replace the tire.

å Wear limit

10

11

6-4

PRE-OPERATION CHECKS

1

2

3

4

Y-32

5

6

STEERING SYSTEM

Check the steering system for exces­sive 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 hear
rattling sounds which may indicate
loose steering components, consult a
Yamaha dealer.

BACK-UP BUZZER

Check the back up buzzer by moving
the drive select lever to “R” for
reverse. The buzzer should sound.

7

Y-33

8

PEDAL OPERATION

9

10

11

6-5

Check the following pedal controls for
proper operation. If a pedal does not
work properly, consult a Yamaha
dealer.

Brake Pedal

Make sure the brake pedal feels firm
when pressed and returns to its orig­inal position when released.

å Brake pedal

A

Y-21

G16A/E

PRE-OPERATION CHECKS

WARNING

Parking Brake Pedal

A

Y-22

Make sure the parking brake pedal
locks in place with a positive click,
and releases when the accelerator
pedal is pressed.

å Parking brake pedal

Release the parking brake by
depressing the accelerator pedal.

1

2

3

4

Accelerator Pedal

5

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

Make sure the accelerator pedal

A

operates smoothly.

å Accelerator pedal

6

7

8

G16A/E

Y-20

BODY AND CHASSIS

Before each use, visually inspect the
golf car body and chassis for damage
and/or missing parts.

6-6

9

10

11

OPERATION

WARNING

CAUTION

1

STARTING

1. With the parking brake applied,
turn the drive select lever to “F”
for forward, or “R” for reverse.

2

3

Y-18

4

OFF

5

ON

Do not shift from “F” forward to
“R” reverse while the golf car is
moving.

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.

6

Y-16

3. Pull the choke knob out and hold

7

8

A

9

KE

O

H

C

Y-23

it while starting (G16A). Release
the choke knob after the engine
starts.

å Choke knob

The choke is not required when the
engine is warm.

10

11

7-1

4. Check that your path is clear in

A

Y-20

the direction you plan to go, and
slowly depress the accelerator
pedal. The golf car will start to
move.

å Accelerator pedal

The parking brake automatically
releases when the accelerator pedal
is depressed.

G16A/E

OPERATION

CAUTION

B

A

Y-65

TROUBLESHOOTING
G16A

If G16A’s gas engine won’t start, use
the following chart:

Cause Remedy

Fuel System
No fuel in tank Fill fuel tank
Clogged fuel Clean fuel

line line – Consult

Yamaha dealer

Foreign matter Clean fuel
in fuel filter fiter – Consult

Yamaha dealer

Clogged Clean carburetor
carburetor – Consult

Yamaha dealer

Electrical System

Spark plug dirty Clean carbon
with carbon, or or wipe spark
wet plug dry

Faulty ignition Consult
system Yamaha

dealer

STOPPING

To stop the golf car, gradually press
down on the brake pedal.

å Brake pedal

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

∫ Parking brake pedal

Do not hold the golf car on an
incline with the accelerator – use
the brake.

1

2

3

4

5

6

7

8

9

10

11

G16A/E

7-2

MAINTENANCE

1

PERIODIC MAINTENANCE CHARTS

Regular maintenance is required for the best performance and safe operation of your golf car.

WARNING

Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless

2

otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a
Yamaha dealer or other qualified mechanic.

FOR G16A

3

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

20 Rounds 125 rds 250 rds 500 rds 1000 rds

Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mls

4

PRE- Check engine oil C C C 6-3

OPER- Check air cooling duct CC C C C C*

5

ATION Check fuel lines for leakage C C C C C C 6-2

CHECKS Check fuel level C C C C C C 6-2

Check for looseness

6

7

8

9

EVERY Check fuel filter for clogging CCCCC*

MONTH

10

EVERY 6 Wash pre-filter, check air
MONTHS

11

and corrosion of battery C C C C C C 6-4
terminals and hold downs

Check brake pedal freeplay
and adjust if necessary

Check steering operation C C C C C 6-5

Check tire pressure, tread
depth, tire surface for damage

Check body and chassis for
damage

Check tightness of all bolts,
nuts, and screws

Check reverse buzzer
operation

Check wear of drive belt C C C C C 8-9

Check operation of
Forward / Reverse shifting

Clean / Lube pedal control area CL —

cleaner element

Check spark plug and plug cap
condition** / Check compression

Check shock absorbers for oil
leaks and damaged springs

Pre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs

tion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms

(Every (Every 6 (Every (Every (Every

month) months) year) 2 years) 4 years) Page

C CA CA CA CA CA 8-18

C CA CA CA CA CA 6-4

CC C C C C

CC C C C C*

C C C C C C 6-5

CCCCC—

S S S S 8-7

C C C C 8-5/*

CCC *

6-6

* Items with out a page number reference should be serviced by a Yamaha dealer or other qualified

mechanic. This manual does not contain these procedures. They are contained in the Service Manual.

**Related to emission control system.

8-1

G16A/E

MAINTENANCE

FOR G16A (continued)

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

20 Rounds 125 rds 250 rds 500 rds 1000 rds

Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mls

EVERY Replace engine oil R R R 8-6

YEAR Adjust throttle cables,**

EVERY Check brushes for wear and
2 YEARS commutator for dir t

EVERY Replace fuel filter and
4 YEARS fuel hoses

choke cable, check carburetor CA CA CA *
throttle shaft for wear**

Check starter V-belt for
damage and tension

Check drive belt for slippage,
wear or scratches

Check sliding sheave and
ramp shoes; Grease secondary
sheave bearing.

Grease primary sheave LL L*

Check operation of speed limiter CC C*

Apply battery terminal protectant SS S—

Check wiring connections
and insulation

Check shoe lining thickness
and rear axle bearing play

Check kingpin play, seal, and
cap / Adjust wheel alignment

Check wheel nut tightness,
front wheel bearing play

Check gear box oil level
and leakage

Check operation and adjust
pedal stop if necessary

Check tightness of cylinder
head / Adjust valves

Replace gear box oil R

Check for grease leakage;
adjust gearbo

x if necessary

Pre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs

tion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms

(Every (Every 6 (Every (Every (Every

month) months) year) 2 years) 4 years) Page

CC C*

C C C 8-8

CL CL CL *

CC C—

CC C*

CA CA CA *

CC C*

C C C 8-16

CA CA CA *

CS*

R*

CA *

CA *

1

2

3

4

5

6

7

8

9

10

*

11

* Items with out a page number reference should be serviced by a Yamaha dealer or other qualified

mechanic. This manual does not contain these procedures. They are contained in the Service Manual.

**Related to emission control system.

G16A/E

8-2

MAINTENANCE

FOR 16E

1

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

2

Charge

Clean battery tops, check for
tightness of hold-down screws and
terminals

Check brake pedal freeplay and
adjust 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 reverse buzzer operation

Check electrolyte level

Check for loose or broken
connections

Clean/Lube pedal control area

Check all wire insulation for cracks
and/or worn spots

Check shock absorbers for oil leaks
and damaged springs

Perform a discharge test

Apply Terminal protectant

Check shoe lining thickness and
rear axle bearing play

Check kingpin play, seal, and
cap / Adjust wheel alignment

Check wheel nut tightness, front
wheel bearing play

Check gear box oil level and
leakage

Check operation and adjust pedal
stop if necessary

Replace gear box oil

Check for grease leakage; adjust
gear box if necassry

Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual
does not contain these procedures. They are contained in the Service Manual.

3

4

5

6

7

8

9

10

11

PRE-OP

EVERY
MONTH

EVERY 6
MONTHS

EVERY
YEAR

EVERY 4
YEARS

*

Pre-

20 rounds 125 rds 250 rds 500 rds 1000 rds

Opera­tion

S

S

C

C

C

C

C

C

20 hours

100 miles

160 kms

(Every

Month)

S

S

CA

C

CA

C

C

C

C

C

CL

125 hrs
600 mls

1000 kms

(Every 6

months)

CA

CA

250 hrs

1200 mls

2000 kms

(Every

S

S

C

C

C

C

C

C

C

C

Year)

S

S

CA

C

CA

C

C

C

C

C

C

C

S

S

C

CA

C

C

CA

500 hrs

2500 mls

4000 kms

(Every 2

years)

S

S

CA

C

CA

C

C

C

C

C

C

C

S

S

C

CA

C

C

CA

1000 hrs
5000 mls

8000 kms

(Every 4

years)

S

S

CA

C

CA

C

C

C

C

C

C

C

S

S

C

CA

C

C

CA

R

CA

PageRemarks

8-13

8-11

8-18

6-5

6-4

6-6

*

6-5

8-12

*

*

*

*

*

*

*

8-16

*

*

*

8-3

G16A/E

MAINTENANCE

EXHAUST EMISSION CONTROL SYSTEM
AND COMPONENTS

Item Acronym

• CARB. ASSY., LH., JT., CARB (Carburetor)
CARBURETOR 2 & JT.,
CARBURETOR 1

• T.C.I. MAGNETO ASSY. & El (Electronic Ignition)
PLUG, SPARK

• CRANKCASE 1 & HEAD, PCV (Positive Crankcase
CYLINDER 1 Ventilation)

• AIR FILTER ASSY. ACL (Air Cleaner)

• MUFF., 2

The above items and the correspond­ing acronyms are provided in accor­dance with U.S. EPA REGULATIONS
FOR SMALL NONROAD ENGINES
and the CALIFORNIA REGULA­TIONS FOR NEW 1995 AND LATER
OFF-HIGHWAY RECREATIONAL
VEHICLES AND ENGINES.

The acronyms conform to the latest
version of the SAE’s recommended
practice document J1930, “Diagnostic
Acronyms, Terms, and Definitions For
Electrical/Electronic System”.

It is recommended that these items
be serviced by a Yamaha dealer or
other qualified mechanic.

1

2

3

4

5

6

7

8

9

10

G16A/E

11

8-4

MAINTENANCE - G16A

WARNING

1

2

3

4

5

6

7

8

9

10

Spark Plug Inspection

You should periodically remove and
inspect the spark plug. Dirty or worn
spark plugs can cause poor perfor-

B

A

A

Y-516

Y-37

mance.

å Spark plug
∫ Spark plug cap

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.

Standard spark plug:

BPR2ES

Spark plug gap:

0.028 ˜0.031 in (0.7 ˜ 0.8 mm)

å Gap

3. Clean the gasket and plug sur-

faces and install the spark plug
finger tight before tightening to
the following torque:

Spark plug torque:

14.5 ft.lb
(20 Nm, 2.0 m.kg)

11

8-5

When removing or installing the
spark plug, be careful not to dam­age the insulator. A damaged insu­lator could allow external sparks,
which could lead to explosion or
fire.

G16A/E

MAINTENANCE - G16A

WARNING

Y-624

Engine Oil Replacement

1. Warm up the engine for several
minutes, place the golf car on a
level surface, then stop the
engine.

Use caution not to touch hot
engine oil or hot engine parts, dur­ing the following procedure.

2. Place an oil pan under the engine
drain plug.

3. Remove the oil drain plug and let
the oil drain completely.

Dispose of used oil in an environmen­tally safe way, such as taking oil to an
oil collection station.

4. Install the drain plug, along with a
new drain plug gasket, finger tight
before tightening to the following
torque:

1

2

3

4

5

6

7

8

Recommended oil:

YAMALUBE 4-cycle oil or

SAE 10W-30

Engine oil capacity:

1.16 US qt
(1.0 L, 0.24 Imp gal)

Oil change quantity:

1.0 US qt
(0.9 L, 0.19 Imp gal)

G16A/E

Drain plug torque:

23 ft.lb
(31 Nm, 3.1 m.kg)

5. Add the correct quantity of oil
through the oil filler hole.

Recommended engine oil classifica­tion: API Service SE, SF, or SG.
Engine oils labeled “Energy Con­serving II” are recommended.

8-6

9

10

11

MAINTENANCE - G16A

CAUTION

CAUTION

1

A

2

3

Y-515

4

A

5

6

7

B

A

A

Y-518

8

å Oil filler hole

Use care not to fill past the MAX
dipstick mark, and be sure no for­eign material enters the crank­case. After replacing engine oil,
check for oil leaks around the
drain plug. If oil leaks are found,
consult a Yamaha dealer.

Air Filter

To remove the air filter elements:

1. Unlatch the air filter cover clips
and remove cover.

å Air filter cover clips
∫ Air filter cover

2. Lift the air filter and pre-filter out
of the air filter case.

å Air filter
∫ Pre-filter

9

A

10

11

8-7

Be careful not to drop anything
into the air inlet.

B

Y-519

G16A/E

MAINTENANCE - G16A

CAUTION

CAUTION

Inspection and cleaning:

1

A

B

Y-508

3. Wash the foam pre-filter in soap
and water. Allow it to dry.

å Soap and water
∫ Foam element

4. Check the filter element. If dam­aged or dirty, replace it.

2

3

4

Do not wring out the foam pre-fil­ter, this could cause it to tear.

5. To replace the elements, reverse
the above steps.

5

6

The pre-filter has a notch on one
side. It will only fit in the case one
way.

Drive Belt

7

8

G16A/E

Y-60

To remove the drive belt:

1. Set the drive select lever halfway

between forward and reverse.

2. Pull up on the drive belt and push

it outward over the edge of the
secondary sheave.

3. Turn the secondary sheave clock-

wise and the drive belt will roll off
the sheave.

4. Remove the drive belt from the

primary sheave.

8-8

9

10

11

MAINTENANCE - G16A

WARNING

1

2

3

4

5

6

7

8

9

10

11

Inspection:

To inspect the drive belt, check for

A

B

Y-44

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.

å New: 1.22 in. (31.0 mm)
∫ Replace when belt reaches:

1.06 in. (27 mm)

5. To install the drive belt, reverse
the above steps, rolling the belt
back over the secondary sheave.

Battery

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. Keep sparks, flame, ciga­rettes, etc., away.

Ventilate when charging or using
in enclosed space. Always shield
eyes when working near batteries.
KEEP OUT OF REACH OF CHIL­DREN.

8-9

G16A/E

MAINTENANCE - G16A

CAUTION

WARNING

The 12-volt battery that provides start-

+

+

–

–

ing power to your gas car normally
doesn’t require the addition of water
during the one year period provided by
the battery manufacturer. If the bat­tery loses its charge, have an experi­enced mechanic charge it.

1

2

3

Fuse Replacement

Y-45

Be sure to use the specified fuse.
Using a wrong fuse can cause elec­trical system damage and create a
fire hazard.

4

5

6

When replacing a fuse be sure the
main switch is turned off to prevent
accidental short circuiting.

A

B

1. Remove cap screw on cover. Pull
fuse case cover forward.

å Cap screw
∫ Fuse case cover

7

8

9

D

G16A/E

You do not have to remove the cover.

Y-522

2. Pull cap off fuse. Pull fuse out and
replace if necessary.

ç Fuse cap
∂ Fuse

Replacement Fuse:

C

Y-523

10 Amp, Blade Style

10

11

8-10

MAINTENANCE - G16E

CAUTION

WARNING

1

2

3

4

5

6

7

8

9

10

11

Battery Care

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.
Keep sparks, flame, ciga-rettes,
etc., away.

Ventilate when charging or using in
enclosed space. Always shield eyes
when working near batteries.

KEEP OUT OF REACH OF CHIL­DREN.

Six 6-volt deep cycle batteries pro­vide power for your electric golf car
and must be properly maintained and
recharged for maximum performance
and service life.

To maintain your batteries:

1. Clean the tops of the batteries
with a solution of baking soda
and water, as necessary, to
remove corrosion.

8-11

Do not allow cleaning solution to
enter battery cells.

2. Check the fluid level before and

after charging.

G16A/E

MAINTENANCE - G16E

CAUTION

● Before charging: only add distilled

water if fluid is below the top of the
plates, and then add just enough to
cover plates.

● After charging: check that the fluid

level is approximately 1/4 to 1/2
inch above the plates and 1/4 to 3/8
inch below the level indicator. If the
fluid level is low, carefully add dis­tilled water. Adding distilled water

after charging prevents boil over.

D

A

C

å Battery cap
∫ Plates
ç Maximum fluid level
∂ Minimum fluid level

1

2

3

4

5

B

Y-829

Normal tap water contains miner­als which are harmful to a battery;
therefore, refill only with distilled
water.

6

7

3. Using a hydrometer, check the
specific gravity of the battery fluid

Y-47

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
than one point between cells.

Temperature

˚F ˚C

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

Satisfactory Uncorrected

Hydrometer Reading

8

9

10

11

G16A/E

8-12

MAINTENANCE - G16E

WARNING

WARNING

Y-15

OFF

ON

1

2

Battery Charging

Read and understand the owner’s
manual provided with your golf
car’s battery charger before charg­ing batteries.

3

4

5

6

7

8

Explosive hydrogen gas is pro­duced while batteries are being
charged. Only charge batteries in
well ventilated areas (a minimum
of 5 air changes per hour is rec­ommended).

To charge the batteries in your golf
car, follow the instructions contained
in your battery charger’s owner’s
manual.

The following is a summary of the
charging steps. Do not attempt to

recharge your golf car’s batteries
without thoroughly reading and
understanding the owner’s manual
provided with your charger.

9

10

11

8-13

Y-49

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

2. With the charger properly con­nected and grounded (see charg­er’s owner’s manual), insert the
DC output plug into the golf car
receptacle.

3. Monitor the ammeter on the
charger according to instructions
found in the charger’s owner’s
manual.

G16A/E

MAINTENANCE - G16E

WARNING

WARNING

Do not disconnect the DC output
cord from the battery receptacle
when the charger is on or an arc
could occur that may cause an
explosion.

4. The charger will turn off automat­ically when the batteries reach
full charge.

5. After the charger has turned off,
disconnect the DC output plug
from the golf car receptacle by
grasping the plug body and
pulling the plug straight out of the
receptacle.

Battery Installation

When working with batteries, do
not put wrenches or other metal
objects across the battery termi­nals. An arc can occur causing
explosion of the battery.

A

1. Install the battery holddown
plates as shown.

1

2

3

4

5

6

7

8

9

å Forward

B

∫ Battery
ç Battery fitting plate

10

C

G16A/E

Y-50

11

8-14

MAINTENANCE - G16E

Y-51

C

A

B

D

D

D

Y-52

Y-653

B

A

CAUTION

WARNING

CAUTION

WARNING

1

2. Connect the wire leads as shown.

å Forward
∫ To relay

2

ç To controller
∂ Between batteries

3

4

5

When installing batteries:

● Carefully place battery cables

and holddowns making sure that
cables don’t lie across vent caps.

● Always remove the negative (–)

cable to the motor controller first,
and install it last.

6

7

Do not overtighten the battery
holddown nuts. Excessive force
will damage the battery casing.

8

Fuse Replacement

9

10

11

Fuse Type:

8-15

10 Amp, Blade Style

Be sure to use the specified fuse.
Using a wrong fuse can cause
electrical system damage and cre­ate a fire hazard.

When replacing a fuse be sure the
main switch is turned off to pre­vent accidental short-circuiting.

å Fuse case
∫ Fuse

G16A/E

MAINTENANCE - G16A & G16E

CAUTION

Y-48

Y-520

A

B

Recommended oil:

SAE 90 gear oil

Gearcase capacity:

G16A: 0.44 US qt
(0.42 L, 0.09 Imp gal)

G16E: 0.32 US qt
(0.3 L, 0.06 Imp gal)

Gear Box Oil

To check gear box oil level:

1. Place the golf car on a level sur-

face.

2. Remove the access panel by

removing the screws in the two
lower corners of the panel and
pulling the panel from the car.

3. For G16A and G16E

● Remove the oil level plug (A).

● Add gear oil little by little until oil

flows from the level plug hole (B).

4. Allow excess gear oil to flow out

until it stops.

Do not allow foreign material to
enter the gear box.

5. Reinstall the oil level plug.

For gear oil replacement, consult a
Yamaha dealer or other qualified
mechanic.

1

2

3

4

5

6

7

8

9

10

11

G16A/E

8-16

MAINTENANCE - G16A & G16E

WARNING

1

2

3

4

Y-57

Wheel Replacement

To remove and install a wheel on your
golf car:

1. With the wheels blocked to pre­vent the golf car from moving,
loosen the wheel nuts.

2. Elevate the golf car with a jack
and remove the wheel nuts and
the wheel.

3. Reverse the removal steps when
installing the wheel.

5

Wheel nut tightening torque:

58 ft.lb (80 Nm, 8.0 m.kg)

6

Brake Adjustment

7

8

The brakes on your golf car are self­adjusting.

Before you operate the car, press
down on the brake pedal several
times to make sure the brakes are
functioning properly.

9

10

11

8-17

Consult your Yamaha dealer before
using your golf car if you suspect
brake problems. Brake failure
could result in a serious accident.

G16A/E

MAINTENANCE - G16A & G16E

WARNING

CAUTION

25-30 mm

Brake Pedal Free Play

1

Adjustment

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 service lid from the
floor of the golf car.

4

5

Y-61

6

2. Check the brake pedal free play
by pressing against the pedal
with two fingers (using light force)

18

17

16

15

14

13

12

11

10

9

8

7

and measuring the distance the
pedal travels before resistance is
felt.

7

8

Y-62

Brake pedal free play:

25-30 mm (0.98-1.18 in.)

9

G16A/E

Y-63

3. If the free play distance needs
adjusting, loosen the lock nut and
turn the adjusting nut in or out
until the free play specification is
met. Then tighten the lock nut in
place.

Do not overtighten the brake
cables. The self adjusters may not
operate properly, reducing braking
performance.

8-18

10

11

STORAGE

WARNING

Perform the following preparations

1

when storing your golf car for extend­ed periods of time:

2

3

4

5

6

7

8

9

10

11

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

DRAINING FUEL

(G16A GAS CAR)

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.

● Stop engine and allow it to cool

for several minutes before refu­eling.

● Refuel in a well-ventilated area.

● Take care not to spill gasoline. If

gasoline spills, wipe it up imme­diately with dry rags. Always dis­pose of gasoline-soaked rags
properly.

● Tighten the filler cap securely

after refueling.

● If you swallow gasoline, inhale a

lot of gasoline vapor, or get
gasoline in your eyes, get imme­diate medical attention.

● If any gasoline gets on your skin,

immediately wash with soap and
water. Change clothing if gaso­line spills on it.

A

9-1

Y-521

1. Fill the fuel tank.

å Float bowl drain screw

2. Drain the carburetor float bowl into
a suitable container by turning the
screw located on the bottom of the
carburetor.

G16A/E

STORAGE

CAUTION

ENGINE PREPARATION

(G16A GAS CAR)

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. Increase the tire pressure to 20
psi (137 kPa, 1.4 kgf/cm2).

2. Clean exterior of the golf car and
apply a rust inhibitor.

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

BATTERY
PREPARATION

For G16A:

1. Remove the battery from the golf
car and store it in a cool, dry
place that stays between 32˚F
(0˚C) and 90˚F (30˚C).

2. Have the battery recharged every
60-90 days to keep it fully
charged. The battery must be
kept fully charged to avoid dam­age.

Batteries like the one supplied with
your car normally do not require you
to check the water level inside the
battery for the one year warranty
period provided by the manufacturer.

For G16E:

1. Clean the tops of the batteries

with a solution of baking soda
and water, as necessary, to
remove corrosion.

Do not allow cleaning solution to
enter battery cells.

2. Recharge the batteries and check
the fluid levels at least once a
month.

1

2

3

4

5

6

7

8

9

G16A/E

10

11

9-2

SPECIFICATIONS

GENERAL SPECIFICATIONS

1

Items G16A G16E

Dimensions:

2

3

4

5

6

7

Overall length 93.9 in. (2385 mm)
Overall width 47.2 in. (1200 mm)
Overall height (steering height) 46.8 in. (1190 mm)
Height of floor 11.8 in. (300 mm)
Wheelbase 64.0 in. (1629 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) 653 lb (296 kg) 560 lb (254 kg)

Performance:

Maximum speed 12 mph 12-15 mph

Minimum turning radius 113.0 in. (2.8 m) 113.0 in. (2.8 m)

Seating capacity 2 persons 2 persons

Hill climbing ability 27˚ (50% grade) 20˚ (38% grade)

(19 km/h) (19-24 km/h)

on pavement on pavement

8

9

10

11

10-1

G16A/E

SPECIFICATIONS

ENGINE

Items G16A

Description:

Engine type 4-stroke, Gasoline, OHV
Number of cylinders Single
Displacement 301 cm
Bore x stroke 3.07 x 2.48 in. (78 x 63 mm)
Compression ratio 8.1:1
Rated output 9.5 hp (7.1 kw)/4000 rpm
Cooling system Forced air cooled
Starting system Starter
Ignition system TCI Magneto
Spark plug type BPR2ES
Spark plug gap 0.028-0.031 in. (0.7-0.8 mm)
Lubrication system Splash
Engine oil type YAMALUBE 4 cycle oil or SAE 10W30
Engine oil capacity 1.16 US qt (1.0 L, 0.24 Imp gal)
Oil change quantity 1.0 US qt (0.9 L, 0.19 Imp gal)

3

TRANSMISSION

Items G16A

Transmission:

Type V-belt automatic centrifugal engagement
V-belt width and outer line length 1.22 x 39.76 in. (31 x 1010 mm)
V-belt wear limit 1.06 in. (27 mm)

Governor:

Type Oil bath flyweight
Factory speed setting 12 mph (19 km/h)

Differential/reduction gear: G16A G16E

Differential type Bevel gear Bevel gear
Lubricant/capacity SAE 90 gear oil/ SAE 90 gear oil/

0.44 US qt (0.42 L, 0.32 US qt (0.3 L,

0.09 Imp qt) 0.26 Imp qt)

1

2

3

4

5

6

7

8

9

10

11

BATTERIES

Items G16A G16E

Battery: BCI group 24, BCI group GC-2

G16A/E

RC: minimum 75 min RC: minimum 105 min
CCA: minimum 400A

10-2

1

2

3

4

5

6

7

8

9

10

SPECIFICATIONS

CHASSIS

Items G16A and G16E

Steering system:

Type Worm and pin
Steering angle (L.H.) 1.5 turn
Steering angle (R.H.) 1.5 turn
Lubricant/capacity Grease/3.0 US oz (0.09 L, 3.17 Imp oz)

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 linkage
adjustment 25-30 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
(Bolt heads round parallel to arm) 0.04 in. (1 mm)

Wheel:

Tire size:
Front 18 x 8.50–8.00/4 PR
Rear 18 x 8.50–8.00/4 PR
Rim size: 7.00–I–8.00
Tire pressure: For G16A:

16 psi (108 kPa, 1.1 kgf/cm2)

For G16E:

20 psi (137 kPa, 1.4 kgf/cm2)

11

10-3

G16A/E

G16A WIRING DIAGRAM

R

B

R

B

P

B

R

REV

FWD

R

P

BBP

P

B

P

Br

R/W

Br

R/W

Br

A1

F2

B

B

RW

RW

R

R

R

R

R/W

R/W

G

B

RW

G

G

G

G

G

B

Br

B

B

R/W

Br

R/W

OFF ON

Br

R/Y

L

BB

L

G

Br

B

R/W

R/W

L

L

L

BB

B

B

B

–

+

Y-509

GG

BrBr

B

RW

R

Br

R

RY

BrBr

16

1

2

3

4

5

6

7

8

9

10

14

15

13

12

11

WIRING

1

COLOR CODE

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

2

3

4

5

6

7

8

9

10

G16A/E

1 Engine stop relay 9 Relay

2 Engine ground a Battery

3 Pickup b Pilot lamp (12V, 3.4W)

4 Rotor c Main switch

5 Oil level gauge d Accelerator stop switch

6 Blade fuse (10A) e Back switch

7 Voltage regulator f Buzzer

11

8 Starter generator g Body ground

11-1

WIRING

G16E WIRING DIAGRAM

1

2

3

4

5

6

7

8

9

10

3 2 1 14

Y-59

1 Back switch

2 Buzzer

3 Accelerator stop switch

4 Diode (B)

5 Diode (A)

6 Main switch

7 Fuse (10A)

8 Battery

9 Receptacle

a Throttle sensor

b Controller

c Motor

d Shift switch

e Limit switch

COLOR CODE

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

S

F2

R

Y/B

Y

OFF ON

Y

Y/B

OFF ON

P

R

OFF ON

Br

R/W

B

4

R/W

R

5

R/Y

R

R/W

Br

BP

R/W

Br

B

R

R

Y

R/W

R/Y

PPP

Y/B

P

B

Br R/W

B

R/W

R

R/Y

Y/B

Br R/W

Y

P

YR

R

P

B

Br

Y/B

R/Y

SF2F1R

13

FORWARD

BACKWARD

Y

Y

Y

Y/B Br

Br

Br

Y/B

Y/B

F1

12

S1

S2

A2

A1

FD

+

P

+

–

Br

Y

Y/B

L

G

W

L

G

W

W

L

G

L

G

W

10

11

11

11-2

R/Y

BrBrR

R/W

R/W

B

–

–

6

OFF STARTCHECK

B/R

B

R

Br

R

7

++

RR

+

8

–

–

–

+

–

+

+

R

B

9

G16A/E

Yamaha Motor Corp., USA
Cypress, California

made in

07/12/01

LIT196261600

USA

*LIT196261600*

1PC - G16A/E O/M

MANUFACTURING CORP.

YAMAHA MOTOR

OF AMERICA

Printed in U.S.A.

KCC