Yamaha G22A Manual

OWNER'S / OPERATOR’S MANUAL

GOLF CAR G22A

LIT-19626-16-04

2

JU0-F8199-1

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

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.

YAMAHA MOTOR MANUFACTURING

CORP OF AMERICA

G22A

OWNER’S/OPERATOR’S

MANUAL

© 2004 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-19626-16-04

G22A

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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!

WARNING

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.

NOTE:

●Yamaha continually seeks advancements 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.

CAUTION

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

NOTE:

This message provides additional key information.

WARNING

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

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G22A

CONTENTS

WARRANTY	1
IMPORTANT LABELS	2
OPERATOR SAFETY	3
MAINTENANCE SAFETY PROGRAM	4
CONTROLS	5
PRE-OPERATION CHECKS	6
OPERATION	7
MAINTENANCE	8
	1
STORAGE	9
SPECIFICATIONS	10
WIRING	11

G22A

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		WARRANTY
	1	YAMAHA MOTOR MANUFACTURING
		CORPORATION OF AMERICA
		LIMITED 3-YEAR
	2	GOLF CAR WARRANTY

		Yamaha Motor Manufacturing of America hereby war-
		rants that any new Yamaha Golf Car (gas and electric
	3	models) purchased from an authorized Yamaha dealer
		in the United States will be free from defects in material
		and workmanship for THREE years from date of pur-
		chase, subject to the stated limitations.
		DURING THE PERIOD OF WARRANTY any autho-
	4
		rized 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
	5	will be warranted for the balance of the machine’s war-
		ranty period. All parts replaced under warranty become
		property of Yamaha Motor Manufacturing Corporation of
		America.
		GENERAL EXCLUSIONS from this warranty shall
	6
		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.
	7
		c. Installation of parts or accessories that are not
		original equipment.
		d. Fading, rust, or deterioration due to exposure or
		ordinary wear and tear.
		e. Modifications or alteration that affects the car’s
	8	condition, 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, ie: lightning, hail damage, flooding, fire,
	9	etc.
		SPECIFIC EXCLUSIONS: The first year of warranty
		shall cover the entire car except for batteries, battery
		chargers, tires and rims, which are warranted by their
	10	respective manufacturers. Parts excluded from the sec-
		ond year of warranty include the body parts, seats,
		mats, bumper assembly, bag carrier, scorecard holder,
		and the trim. Parts excluded from the third year of war-
		ranty include the second year exclusions, the electrical
	11	system (except electronic speed controller and electric
		motor) and control cables. Other 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 are 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 will 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 PARTICULIAR 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 CORP., NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 06/01/02

LIT-13710-03-02

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G22A

IMPORTANT LABELS

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2

1

Y-500

2

		SAFETY AND
		INSTRUCTION
3		LABELS
		WARNING
		Please	read the	following
		labels	carefully	before
		operating your		golf	car,
		and promptly replace			any
	Y-505	labels which become dam-
		aged or removed.
4
		WARNING
		AVERTISSEMENT
			Ne pas toucher au
		Do not tamper	régulateur afin
			d’augmenter la
		with governor
			vitesse. Un
		to increase
			fonctionnement
		speed. Operation
			à des vitesses
		at higher speeds
			supérieures au
		can cause loss
			réglage initial
		of control that
			peut causer une
		can result in
			perte de contrôle
		severe injury or
			qui peut mener
		death.
			à une blessure
			grave, voire
	YAMAHA		fatale.
			JN3-K8299-10

Y-502

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G22A

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IMPORTANT LABELS

1	1
2	JU0
3				Y-102a
4	2
				II
			III	IIII
		I IIII
	II	IIII
5
6				SM-03-399
7	3
8
9				852A
10
11
	2-2

GOLF CAR SERIAL NUMBER

The golf car serial number 1 is stamped in the location shown.

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 dealer.

The engine serial number 2 is affixed in the location shown.

3 Engine Information

THIS ENGINE MEETS **** - **** CALIFORNIA EMISSION REGULATIONS FOR OFF-ROAD ENGINES.

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

Y-851

G22A

! OPERATOR SAFETY

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

BEFORE OPERATING

THE GOLF CAR

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2

Y-8

Y-68

Y-67

●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.

●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 public 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.

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G22A

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! OPERATOR SAFETY

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● 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. Exhaust gas is poisonous.

-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
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! GOLF COURSE 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.

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:

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

●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.

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! GOLF COURSE SAFETY PROGRAM

●Loose Terrain. Loose terrain may

1cause a golf car to lose traction and may affect stability. Repair loose terrain, chain or rope off these areas, or identify loose terrain with

2a suitable warning.

●Golf Car and Pedestrian Interfer-

3ence. Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent

		accidents. If it is impractical to
	4
		reroute traffic, erect warning signs
		to warn pedestrians of golf car traf-
		fic, and to warn golf car operators to
	5	drive slowly, use caution, and watch
		for pedestrians.

6MAINTENANCE REQUIRED FOR GOLF

CAR SAFETY

7

Practice the following to help ensure the safety of golf car operators:

8 ● Preventative Maintenance. Perform all scheduled maintenance in accordance with manufacturer’s recommendations to provide the 9 golfing patron with a safe, properly

operating golf car.

10	● Personnel.	Allow only	qualified,
	trained, and	authorized	personnel

to inspect, adjust, and maintain golf

cars.

11

●Parts and Materials. Use only replacement parts and materials recommended by the manufacturer.

●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 the car storage areas during the battery charging process.

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G22A

! GOLF COURSE 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 appropriate fire protection equipment available.

●Before working on an electric golf car, disable the car’s electrical system in accordance with the manufacturer’s instructions.

●Use only properly insulated tools when working on electrically powered golf cars or around batteries.

●Maintain all safety devices including 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.

●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:

●Supervise the storage and handling 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.

G22A

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CONTROLS

	1	FEATURES
	9	8
6		1 Steering wheel
5		2 Seat
		3 Fuel cap
4
		4 Brake pedal
	P	5 Parking brake pedal
		6 Accelerator pedal
		Y-12a
		7 Drive selector lever
		8 Main switch
		9 Oil warning light
10	7	a Choke knob

b Front cowl c Front tire

d Front bumper e Rear cowl

f Rear bumper g Rear tire

h Battery

Y-506

2

11

14	3

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12

15 16

13

Y-507

Y-13

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G22A

OFF

ON

Y-15

OFF

ON

Y-16

	OIL	OFF
	WARNING
A		ON

Y-17

CONTROLS

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

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

OIL WARNING LIGHT

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).

å Oil warning light

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