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

Manufacturing Corporation

of America

1st edition

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

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.

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

STORAGE

SPECIFICATIONS

WIRING 11

G16A/E

iii

WARRANTY

YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA

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

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-

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

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

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

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.

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

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

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.

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

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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 (770) 254-4164.

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

G16A/E

1-2

WARRANTY

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

G16E

G16A

G16E

G16A

SAFETY AND INSTRUCTION LABELS

Y-505

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

Y-500

G16A/E

Y-502

2-1

IMPORTANT LABELS

GOLF CAR SERIAL NUMBER

The golf car serial number is stamped

Y-102a

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.

ç Engine Information

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

Y-852A

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

JR3-2179R-04

Y-851

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.

● Do not start the golf car until all

occupants are seated.

G16A/E

3-1

OPERATOR SAFETY

● 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.

● Avoid turning the steering wheel too

sharply at higher speeds.

● Always drive slowly straight up or

straight down slopes – never at an angle.

Y-10

● Do not run the engine indoors

(G16A). Exhaust gas is poisonous.

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

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

MAINTENANCE SAFETY PROGRAM

● 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 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

REQUIRED FOR GOLF CAR SAFETY

Practice the following to help ensure

the safety of golf car operators:

● Preventative Maintenance. Per-

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,

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:

● 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

CONTROLS

710

Y-506

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)

5-1

Y-13

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.

Y-15

OFF

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

Y-16

OIL WARNING LIGHT

OIL

WARNING

OFF

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).

G16A/E

å Oil warning light

5-2

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