Page 1
OWNER'S
MANUAL
/
OPERATOR’S
GOLF CAR G22A
LIT-19626-16-04
JU0-F8199-12
Page 2
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
Page 3
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
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
i
Page 4
IMPORTANT MANUAL
WARNING
NOTE:
NOTE:
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 to the golf car
occupants, a bystander, or a
person inspecting or repairing
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.
ii
G22A
Page 5
CONTENTS
WARRANTY
IMPORTANT LABELS 2
OPERATOR SAFETY 3
MAINTENANCE SAFETY PROGRAM 4
CONTROLS 5
PRE-OPERATION CHECKS 6
OPERATION 7
MAINTENANCE 8
1
STORAGE
SPECIFICATIONS
WIRING 11
G22A
iii
1
9
10
Page 6
WARRANTY
1
YAMAHA MOTOR MANUFACTURING
CORPORATION OF AMERICA
2
Yamaha Motor Manufacturing of America hereby warrants that any new Yamaha Golf Car (gas and electric
models) purchased from an authorized Yamaha dealer
in the United States will be free from defects in material
3
and workmanship for THREE years from date of purchase, subject to the stated limitations.
DURING THE PERIOD OF WARRANTY any authorized Yamaha Golf Car Dealer will, free of charge, repair
4
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
5
property of Yamaha Motor Manufacturing Corporation of
America.
GENERAL EXCLUSIONS from this warranty shall
include any failures caused by:
6
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 parts or accessories that are not
7
8
9
10
11
original equipment.
d. Fading, rust, or deterioration due to exposure or
ordinary wear and tear.
e. Modifications or alteration that affects the car’s
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,
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
respective manufacturers. Parts excluded from the second 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 warranty include the second year exclusions, the electrical
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.
LIMITED 3-YEAR
GOLF CAR WARRANTY
THE CUSTOMER’S RESPONSIBILITY under this war-
ranty 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
1-1
G22A
Page 7
IMPORTANT LABELS
WARNING
1
2
1
SAFETY AND
1
INSTRUCTION
4
3
LABELS
2
2
Please read the following
labels carefully before
3
operating your golf car,
and promptly replace any
Y-505
labels which become damaged or removed.
4
4
WARNING
5
AVERTISSEMENT
Ne pas toucher au
Y-500
Do not tamper
with governor
to increase
speed. Operation
at higher speeds
can cause loss
of control that
can result in
severe injury or
death.
YAMAHA
régulateur afin
d’augmenter la
vitesse. Un
fonctionnement
à des vitesses
supérieures au
réglage initial
peut causer une
perte de contrôle
qui peut mener
à une blessure
grave, voire
fatale.
JN3-K8299-10
6
7
8
3
G22A
9
10
Y-502
11
2-1
Page 8
IMPORTANT LABELS
NOTE:
1
1
GOLF CAR SERIAL
NUMBER
2
JU0
3
2
4
I
I
I
I
I
III
IIIII
I
I
I
I
I
II
Y-102a
5
6
3
SM-03-399
The golf car serial number 1 is
stamped 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.
The engine serial number 2 is
affixed in the location shown.
3 Engine Information
7
8
9
10
11
2-2
Y-852A
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
Page 9
!
OPERATOR SAFETY
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
G22A
● Do not start the golf car until all
occupants are seated.
Y-67
3-1
Page 10
!
OPERATOR SAFETY
● Keep your hands on the steering
1
wheel and your eyes on the path
ahead.
2
3
● 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
Y-10
7
● Do not run the engine indoors.
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
G22A
Page 11
!
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.
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:
G22A
● 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
Page 12
GOLF COURSE SAFETY PROGRAM
!
● Loose Terrain. Loose terrain may
1
2
3
4
5
6
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
7
Practice the following to help ensure
the safety of golf car operators:
● 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.
8
● Preventative Maintenance. Per-
form all scheduled maintenance in
accordance with manufacturer’s
9
10
recommendations to provide the
golfing patron with a safe, properly
operating golf car.
● Personnel. Allow only qualified,
trained, and authorized personnel
to inspect, adjust, and maintain golf
cars.
11
4-2
G22A
Page 13
!
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.
● 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.
G22A
● 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
Page 14
CONTROLS
1
6
5
2
4
P
3
1
8
9
Y-1 2a
FEATURES
1 Steering wheel
2 Seat
3 Fuel cap
4 Brake pedal
5 Parking brake pedal
6 Accelerator pedal
7 Drive selector lever
8 Main switch
9 Oil warning light
4
710
a Choke knob
b Front cowl
c Front tire
5
d Front bumper
e Rear cowl
f Rear bumper
g Rear tire
6
Y-506
h Battery
7
2
8
9
11
12
17
14
3
10
11
5-1
13
Y-13
15
16
Y-507
G22A
Page 15
CONTROLS
OFF
OFF
ON
ON
Y-15
Y-16
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.
1
2
3
4
5
6
7
G22A
OIL WARNING LIGHT
OIL
WARNING
OFF
A
ON
Y-17
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
8
9
10
11
5-2
Page 16
NOTE:
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
The back-up buzzer will beep when
5
the drive select lever is turned to “R.”
6
Y-19
7
ACCELERATOR PEDAL
A
8
The accelerator pedal controls the
golf car’s speed.
9
10
11
5-3
Action Car Speed
Depress pedal Increase
Y-20A
Release pedal Decrease
å Accelerator pedal
BRAKE PEDAL
Press down on the brake pedal to
stop the golf car.
∫ Brake pedal
B
Y-21a
G22A
Page 17
WARNING
NOTE:
CONTROLS
PARKING BRAKE
PEDAL
Press down on the parking brake
pedal whenever parking the golf car.
C
Y-22a
ç Parking brake pedal
Release the parking brake by
depressing the accelerator pedal.
1
2
3
4
The parking brake will automatically
release when the accelerator pedal
is depressed. If the main switch is in
A
Y-23
the “ON” position, depressing the
accelerator may suddenly cause the
golf car to move.
CHOKE KNOB
Pull and hold out choke knob when
starting a cold engine. Release the
knob after the engine starts.
5
6
7
8
G22A
å Choke knob
9
10
11
5-4
Page 18
PRE-OPERATION CHECKS
WARNING
Pre-operation checks should be
1
2
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.
3
4
5
6
7
8
9
10
● 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.
PRE-OPERATION
CHECKLIST
Before each use check the following:
✔ Fuel system
✔ Engine oil level
✔ Battery
✔ Tire condition
✔ Steering system
✔ Back-up buzzer
✔ Pedal operation
✔ Body and chassis
SEAT
Open the seat for checking and servicing.
11
6-1
Y-512
G22A
Page 19
PRE-OPERATION CHECKS
CAUTION
WARNING
FUEL SYSTEM
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:
6.1 US gal
(23.0 L)
G22A
11
Avoid using gasoline blended with
methyl alcohol which can damage
fuel system parts.
6-2
Page 20
NOTE:
NOTE:
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
(1.1 L, 1100 cc)
Oil change quantity:
1.0 US qt
(0.9 L, 900 cc)
MAX
A
Y-514
Y-28
Y-515
ENGINE OIL
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
G22A
Page 21
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
Check that the battery is held securely in place to prevent the battery from
being damaged from vibration or jar-
G22A1
ring. Also check that no battery caps
are missing to prevent battery acid
from spilling from the battery. Check
the battery terminals for corrosion.
TIRE CONDITION
4
5
6
Tire Air Pressure
Check the tire air pressure before
operating the golf car.
7
G22A
Y-30
Tire pressure:
For G22A: 16 psi
(110 kPa, 1.1 kgf/cm2)
8
9
A
Y-31
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
6-4
10
11
Page 22
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
9
10
11
6-5
PEDAL OPERATION
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.
∫ Brake pedal
B
Y-21a
G22A
Page 23
PRE-OPERATION CHECKS
WARNING
NOTE:
Parking Brake Pedal
Make sure the parking brake pedal
locks in place with a positive click,
and releases when the accelerator
pedal is pressed.
C
Y-22a
ç Parking brake pedal
Release the parking brake by
depressing the accelerator pedal.
Accelerator Pedal
Before checking operation of the
accelerator pedal, be sure the
main switch is in the “OFF” position.
1
2
3
4
5
6
7
A
Make sure the accelerator pedal
operates smoothly.
G22A
Y-20A
å Accelerator pedal
BODY AND CHASSIS
Before each use, visually inspect the
golf car body and chassis for damage
and/or missing parts.
6-6
8
9
10
11
Page 24
OPERATION
NOTE:
NOTE:
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
6
ON
Y-16
7
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.
3. Pull the choke knob out and hold
it while starting. Release the
choke knob after the engine
starts.
8
9
10
11
7-1
å Choke knob
A
Y-23
A
Y-20A
The choke is not required when the
engine is warm.
4. Check that your path is clear in
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.
G22A
Page 25
OPERATION
CAUTION
C
B
Y-65a
TROUBLESHOOTING
If the vehicle’s 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.
∫ Brake pedal
When the car has come to a stop,
apply the parking brake pedal and
turn the main switch to “OFF.”
ç 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
G22A
7-2
Page 26
MAINTENANCE
1
Regular maintenance is required for the best performance and safe operation of your
golf car.
2
WARNING
Be sure to turn off the main switch and apply the parking brake when you perform
maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic.
3
FOR G22A
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
PERIODIC MAINTENANCE CHARTS
4
PRE- Check engine oil CC C 6-3
5
OPER- Check air cooling duct CC C C C C
ATION Check fuel lines for leakage CC C C C C
CHECKS Check fuel level CC C C C C6-2
6
7
8
9
EVERY Check fuel filter for clogging CCCCC
MONTH
10
11
EVERY 6 Wash pre-filter, check air
MONTHS
Check for looseness
and corrosion of battery CC C C C C
terminals and hold downs
Check brake pedal freeplay
and adjust if necessar
Check steering operation CC 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
oper
Check wear of drive belt CCCCC8-8
Check operation of
Forward / Reverse
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
Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mls
y
ation
shifting
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 (Ever
month) months) year) 2 years) 4 years) Pa
CCA CA CACACA
CCA CA CACACA
CC C C C C
CC C C C C
CC C C C C
CCCCC
SSSS
CCCC
CCC *
y
ge
*
6-2
6-4
8-12
6-4
6-6
*
6-5
*
6-5
8-7
8-4
* 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
8-1
system.
G22A
Page 27
MAINTENANCE
FOR G22A
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 RR R8-5
YEAR Adjust throttle cables,**
EVERY
2 YEARS
EVERY
4 YEARS
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 steering knuckle
bushing freeplay / 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 brushes for wear and
commutator for dirt
Replace fuel filter and
fuel hoses
Check tightness of cylinder
head / Adjust valv
Replace gear box oil R
Check for grease leakage;
adjust gearbox if necessary
es
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 (Ever
month) months) year) 2 years) 4 years) Pa
CC C
CC C
CL CL CL
CC C
CC C
CA CA CA
CC C
CC C
CA CA CA
CS
y
R
CA
CA *
8-8
–
*
*
*
8-10
*
*
*
*
1
2
ge
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
G22A
system.
8-2
Page 28
MAINTENANCE
EXHAUST EMISSION CONTROL SYSTEM
1
AND COMPONENTS
Item Acronym
2
3
4
5
6
7
• 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.
8
9
10
11
8-3
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.
G22A
Page 29
MAINTENANCE
WARNING
Spark Plug Inspection
You should periodically remove and
inspect the spark plug. Dirty or worn
B
A
A
Y-516
Y-37
spark plugs can cause poor performance.
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:
1
2
3
4
5
6
7
8
9
Spark plug torque:
14.5 ft.lb
(20 Nm, 2.0 m.kg)
10
G22A
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.
8-4
11
Page 30
MAINTENANCE
NOTE:
NOTE:
WARNING
1
2
Engine Oil Replacement
1. Warm up the engine for several
minutes, place the golf car on a
level surface, then stop the
engine.
3
Use caution not to touch hot
engine oil or hot engine parts, dur-
4
ing the following procedure.
2. Place an oil pan under the engine
drain plug.
5
3. Remove the oil drain plug and let
the oil drain completely.
6
Dispose of used oil in an environmentally safe way, such as taking oil to an
7
Y-624
8
oil collection station.
4. Install the drain plug, along with a
new drain plug gasket, finger tight
before tightening to the following
torque:
9
10
11
Recommended oil:
YAMALUBE 4-cycle oil or
SAE 10W-30
Engine oil capacity:
1.16 US qt
(1.1 L, 1100 cc)
Oil change quantity:
1.0 US qt
(0.9 L, 900 cc)
8-5
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.
G22A
Page 31
MAINTENANCE
CAUTION
CAUTION
A
Y-515
A
B
A
A
Y-518
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
1
2
3
4
5
6
7
8
A
B
G22A
Y-519
Be careful not to drop anything
into the air inlet.
8-6
9
10
11
Page 32
MAINTENANCE
CAUTION
CAUTION
Inspection and cleaning:
1
A
B
3. Wash the foam pre-filter in soap
and water. Allow it to dry.
2
3
Y-508
å Soap and water
∫ Foam element
4. Check the filter element. If dam-
aged or dirty, replace it.
4
Do not wring out the foam pre-filter, this could cause it to tear.
5
5. To replace the elements, reverse
the above steps.
6
The pre-filter has a notch on one
7
8
9
side. It will only fit in the case one
way.
Drive Belt
To remove the drive belt:
1. Set the drive select lever halfway
between forward and reverse.
10
11
8-7
Y-60
2. Pull up on the drive belt and push
it outward over the edge of the
secondary sheave.
3. Turn the secondary sheave clockwise and the drive belt will roll off
the sheave.
4. Remove the drive belt from the
primary sheave.
G22A
Page 33
MAINTENANCE
WARNING
Inspection:
1
A
B
Y-44
To inspect the drive belt, check for
frayed edges or tears, and measure
drive belt against the following specification. If the belt shows excessive
wear or damage, replace the belt with
a new one.
å New: 1.22 in. (31.0 mm)
∫ Replace when belt reaches:
1.06 in. (27 mm)
2
3
4
5. To install the drive belt, reverse
the above steps, rolling the belt
back over the secondary sheave.
5
Battery
6
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.
7
8
9
10
11
G22A
8-8
Page 34
MAINTENANCE
NOTE:
CAUTION
WARNING
1
–
–
+
+
2
The 12-volt battery that provides starting 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.
3
Fuse Replacement
4
5
Y-45
Be sure to use the specified fuse.
Using a wrong fuse can cause electrical system damage and create a
fire hazard.
6
When replacing a fuse be sure the
7
A
8
B
main switch is turned off to prevent
accidental short circuiting.
1. Remove cap screw on cover. Pull
fuse case cover forward.
9
10
11
8-9
å Cap screw
∫ Fuse case cover
Y-522
D
C
Y-523
You do not have to remove the cover.
2. Pull cap off fuse. Pull fuse out and
replace if necessary.
ç Fuse cap
∂ Fuse
Replacement Fuse:
10 Amp, Blade Style
G22A
Page 35
MAINTENANCE
NOTE:
CAUTION
B
Recommended oil:
SAE 90 gear oil
Gearcase capacity:
G22A: 0.44 US qt
(415 mL, 415 cc)
A
Y-520
Y-48
Gear Box Oil
To check gear box oil level:
1. Place the golf car on a level surface.
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. Remove the oil level plug å.
4. Add gear oil little by little until oil
flows from the level plug hole ∫.
5. Allow excess gear oil to flow out
until it stops.
Do not allow foreign material to
enter the gear box.
6. 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
G22A
11
8-10
Page 36
MAINTENANCE
WARNING
CAUTION
1
Before performing wheel or brake
maintenance, verify that the main
2
3
switch is in the “OFF” position.
Wheel Replacement
To remove and install a wheel on
your golf car:
4
5
6
7
8
9
10
Y-57
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.
Wheel nut tightening torque:
58 ft.lb (80 Nm, 8.0 m.kg)
Brake Adjustment
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.
11
8-11
Consult your Yamaha dealer
before using your golf car if you
suspect brake problems. Brake
failure could result in a serious
accident.
G22A
Page 37
MAINTENANCE
WARNING
CAUTION
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-61a
6
2. Check the brake pedal free play
by pressing against the pedal
with two fingers (using light force)
a
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
G22A
Y-63
Y-62b
Brake pedal free play Å:
20-25 mm (0.79-0.98 in.)
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.
8-12
9
10
11
Page 38
STORAGE
WARNING
NOTE:
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
Gasoline and its vapors are highly
flammable and explosive.
● Do not smoke when draining fuel
and keep away from sparks,
flames, or other sources of ignition.
● Stop engine and allow it to cool
for several minutes before draining fuel.
● Drain fuel 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 checking fuel level.
● If you 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.
9-1
A
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.
G22A
Page 39
STORAGE
CAUTION
NOTE:
ENGINE PREPARATION
With the key removed and the spark
plug lead disconnected, turn the
clutch by hand until compression is
felt. This puts the valves in the closed
position.
CHASSIS
PREPARATION
1. 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
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.
3. Clean the top of the battery with
a solution of baking soda and
water, as necessary, to remove
corrosion.
Do not allow cleaning solution to
enter battery cells.
1
2
3
4
5
6
7
8
G22A
9
10
11
9-2
Page 40
SPECIFICATIONS
GENERAL SPECIFICATIONS
1
Items G22A
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 64.3 in. (1632 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) 670 lb (304 kg)
Performance:
Factory speed setting 12 mph (19 km/h)
Maximum speed 15 mph (24 km/h)
Minimum turning radius 114.2 in. (2.9 m)
Seating capacity 2 persons
Hill climbing ability 27˚ (50% grade)
on pavement
8
9
10
11
10-1
G22A
Page 41
SPECIFICATIONS
ENGINE
Items G22A
Description:
Engine type 4-stroke, Gasoline, OHV
Number of cylinders Single
Displacement 357 cm
Bore x stroke 3.30 x 2.48 in. (85 x 63 mm)
Compression ratio 8.1:1
Rated output 11.4 hp (8.5 kw)/3500 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 (1.1 L, 1100 cc)
Oil change quantity 1.0 US qt (0.9 L, 900 cc)
3
TRANSMISSION
Items G22A
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: G22A
Differential type Bevel gear
Lubricant/capacity SAE 90 gear oil/
0.44 US qt (415 mL,
415 cc)
1
2
3
4
5
6
7
8
9
10
11
BATTERIES
G22A
Items G22A
Battery: BCI group 24,
RC: minimum 75 min
CCA: minimum 400A
10-2
Page 42
CHASSIS
1
2
3
4
5
6
7
8
9
SPECIFICATIONS
Items G22A
Steering system:
Type Rack and Pinion
Steering angle (L.H.) 1.55 turn
Steering angle (R.H.) 1.55 turn
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 20-25 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
(With pedal segment in second
notch)
(Bolt heads round parallel to arm) 0.000 ~ 0.001 in. (0.0 ~ 0.3 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 (110 kPa, 1.1 kgf/cm2)
10
11
10-3
G22A
Page 43
G22A 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
Br
Br
B
RW
R
Br
R
RY
Br
Br
16
1
2
3
4
5
6
7
8
9
10
14
15
13
12
11
19
10211312413514615716
8
Engine stop relay
Engine ground
Pickup
Rotor
Oil Level gauge
Blade Fuse (10A)
Voltage Regulator
Starter generator
Relay
Battery
Pilot lamp (12V, 3.4W)
Main switch
Accelerator stop switch
Back switch
Buzzer
Body ground
B..............................Black
L................................Blue
G ............................Green
COLOR CODE
Y ............................Yellow
WIRING
1
2
R................................Red
P ...............................Pink
Br ...........................Brown
W ............................White
B/R...................Black/Red
Y/B ...............Yellow/Black
R/Y .................Red/Yellow
R/W .................Red/White
3
4
5
6
7
8
9
G22A
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 Vo l ta ge regulator f Buzzer
8 Starter generator g Body ground
10
11
11-1
Page 44
NOTES
1
2
3
4
5
6
7
8
9
10
11
G22A
Page 45
NOTES
1
2
3
4
5
6
7
G22A
8
9
10
11
Page 46
NOTES
1
2
3
4
5
6
7
8
9
10
11
G22A
Page 47
Printed in U.S.A
2004-KCC
YAMAHA MOTOR
MANUFACTURING CORP.
OF AMERICA
1000 HWY 34 East
Newnan, GA 30265
770-254-4000
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