Yamaha G-MAX 48V 48 VOLT ELECTRIC-G22-E User Manual

OWNER'S
MANUAL

/

OPERATOR

GOLF CAR G22E

,

S

LIT-19626-00-79

JU2-F8199-12

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

G22E

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-19626-00-79

G22E

i

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.

ii

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

G22E

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

G22E

iii

9

10

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

1-1

G22E

IMPORTANT LABELS

Y-844

WARNING

1

2

1

3

4

SAFETY AND

INSTRUCTION

1

LABELS

2

Please read the following
labels carefully before
operating your golf car, and

Y-654a

5

promptly replace any labels
which become damaged or
removed.

3

2

3

4

5

6

7

Y-500

Y-655

8

4

G22E

5

Y-656

Y-843

2-1

9

10

11

IMPORTANT LABELS

NOTE:

1

2

3

JU2

Y-102b

4

NUMBER

The golf car serial number 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.

5

6

7

8

GOLF CAR SERIAL

9

10

11

2-2

G22E

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.

1

2

3

4

5

6

7

8

9

10

G22E

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.

3-1

11

!

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

Y-10

7

8

● 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.

9

10

11

3-2

Y-69

G22E

!

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:

G22E

● 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

GOLF COURSE 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 occupants:

● 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 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

G22E

!

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.

● 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 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.

● 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.

STORAGE AND
BATTERY CHARGING

Ta ke the following precautions to
ensure maintenance worker safety:

● Only use battery changing and

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

● Periodically inspect charging facili-

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

1

2

3

4

5

6

7

8

9

10

11

G22E

4-3

CONTROLS

1

6

5

2

4

P

3

1

7

8

Y-6 59a

FEATURES

1 Steering wheel
2 Seat
3 Batteries
4 Brake pedal
5 Parking brake pedal
6 Accelerator pedal
7 Main switch
8 Drive selector switch
9 Tow switch

4

a Front cowl
b Front tire
c Front bumper

5

d Rear cowl
e Rear bumper
f Rear tire

16

3

Y-658

g Receptacle

6

7

8

2

10

11

13

9

10

11

5-1

14

12

Y-660

9

CAUTION / AVERTISSEMENT

Y-6 62a

15

Y-661

G22E

CONTROLS

REV FWD

REV FWD

MAIN SWITCH

The main switch controls the follow­ing items:

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

OFF

ON

position.

1

2

3

4

Y-663

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

OFF

ON

5

6

7

8

Y-664

G22E

9

10

11

5-2

NOTE:

CONTROLS

1

OFF

2

REV FWD

ON

3

Y-665

DRIVE SELECT SWITCH

The drive select switch is used to
shift the golf car into forward or
reverse. After coming to a complete
stop, move the switch to the desired
position.

Switch Position Car Movement

FWD FORWARD

REV REVERSE

4

5

The back-up buzzer will beep when
the drive select switch is depressed
to the “REV” position.

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

G22E

NOTE:

WARNING

NOTE:

CONTROLS

A1

F2

C

CAUTION / AVERTISSEMENT

PARKING BRAKE
PEDAL

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

ç Parking brake pedal

Y-22a

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
the “ON” position, depressing the
accelerator may suddenly cause the
golf car to move.

5

6

7

TOW SWITCH

Before operating the car, make sure

TOW

RUN

A

the tow switch is in the “RUN” posi­tion.

å Tow switch

8

9

G22E

Anytime the tow switch is moved from

Y-666a

the “RUN” position to the “TOW” posi­tion and immediately moved back to
“RUN”, there is a delay of approxi­mately 30 seconds before the car will
run.

Make sure the tow switch is in the
“TOW” position if towing this vehicle.

10

11

5-4

PRE-OPERATION CHECKS

WARNING

1

2

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.

3

● Be sure the main switch key is

removed before performing the

4

pre-operation checks to prevent
accidental starting, and apply
the parking brake to keep the car
from moving.

5

PRE-OPERATION

6

7

8

CHECKLIST

Before each use check the following:

✔ Batteries
✔ Tire condition
✔ Steering system
✔ Back-up buzzer
✔ Pedal operation
✔ Body and chassis

9

10

11

6-1

SEAT

Open the seat for checking and ser­vicing.

Y-512

G22E

PRE-OPERATION CHECKS

BATTERY

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

Maintenance.

Check that the batteries 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.

TIRE CONDITION

Tire Air Pressure

Check the tire air pressure before
operating the golf car.

Tire pressure:

20 psi
(137 kPa, 1.4 kgf/cm2)

1

2

3

4

5

6

7

8

G22E

Y-30

9

Tire Wear Limit

A

Y-31

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

6-2

PRE-OPERATION CHECKS

1

2

3

4

Y-667

5

6

REV FWD

OFF

ON

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 switch to “REV” for
reverse. The buzzer should sound.

7

8

Y-668

PEDAL OPERATION

9

10

11

6-3

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

G22E

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.

1

2

3

4

Accelerator Pedal

5

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

Make sure the accelerator pedal

A

operates smoothly.

å Accelerator pedal

6

7

8

G22E

Y-20A

BODY AND CHASSIS

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

6-4

9

10

11

OPERATION

NOTE:

WARNING

CAUTION

1

OFF

2

REV FWD

ON

3

Y-665

STARTING

1. With the parking brake applied,
turn the drive select switch to
“FWD” for forward, or “REV” for
reverse.

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

4

2. Turn the main switch to “ON.”

5

OFF

REV FWD

ON

6

7

8

Y-664

A

9

Do not depress the accelerator
pedal when turning on the main
switch or the golf car may sudden­ly start moving.

3. 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.

10

11

7-1

å Accelerator pedal

Y-20A

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

G22E

OPERATION

CAUTION

STOPPING

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

∫ Brake pedal

When the car has come to a stop,

C

apply the parking brake pedal and
turn the main switch to “OFF.”

ç Parking brake pedal

1

2

3

4

B

Y-65a

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

5

6

7

8

G22E

9

10

11

7-2

MAINTENANCE

1

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

2

3

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.

PERIODIC MAINTENANCE CHARTS

4

5

6

7

8

9

10

11

8-1

G22E

MAINTENANCE

FOR G22E

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

PRE-OP

EVERY
MONTH

EVERY 6
MONTHS

EVERY
YEAR

EVERY 4
YEARS

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 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

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.

Pre-

20 rounds 125 rounds 250 rounds 500 rounds 1000 rounds

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

600 mls

1000 kms

(Every 6
months)

125 hrs

S

S

CA

C

CA

C

C

C

C

C

C

C

250 hrs

1200 mls

2000 kms

(Every

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

8-5

8-3/

6-2

8-9/
8-10

6-3

6-2

6-4

*

6-3

8-3/8-4

*

—

*

*

*

—

*

*

8-9/

8-8

*

*

8-8

1

2

3

4

5

6

7

8

9

*

10

11

G22E

8-2

MAINTENANCE

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, cigarettes, etc.,
away.

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

KEEP OUT OF REACH OF CHIL­DREN.

Six 8-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.

8-3

Do not allow cleaning solution to
enter battery cells.

2. Check the fluid level before and

after charging.

G22E

MAINTENANCE

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 helps prevent boil over.

D

A

C

B

Y-829

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

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

1

2

3

4

5

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

G22E

8-4

MAINTENANCE

CAUTION

WARNING

WARNING

REV FWD

OFF

ON

Y-663

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

8-5

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.

Y-669

Use only battery chargers that are
rated for use with 48 volt Yamaha
Golf Cars. Thoroughly read and
understand the user manual
supplied with your 48 volt charger.

G22E

MAINTENANCE

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.

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

4. 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

1

2

3

4

5

6

C

B

G22E

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.

å Forward
∫ Battery
ç Battery fitting plate

7

8

9

10

11

Y-7 51a

8-6

MAINTENANCE

CAUTION

WARNING

CAUTION

WARNING

B

A

-

+

-

+

-

+

-

+

-

+

-

+

D

C C

FORWARD

Y-653

B

A

1

2. Connect the wire leads as shown.

å Forward
∫ To receptacle

2

ç To motor control unit
∂ Between batteries

To relay

3

4

5

6

7

When installing batteries:

● Carefully place battery cables

and holddowns making sure that
cables do not lay across vent
caps.

● Always remove the negative (–)

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

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

8

9

10

11

Fuse Type:

8-7

3 Amp, Blade Style

Fuse Replacement

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

G22E

MAINTENANCE

NOTE:

CAUTION

Y-48

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

3. Remove the oil level plug å.

1

2

3

4

4. Add gear oil little by little until oil

flows from the level plug hole ∫.

5

Recommended oil:

SAE 90 gear oil

A

B

Y-520A

Gearcase capacity:

0.32 US qt
(300 mL, 300 cc)

6

7

5. Allow excess gear oil to flow out

until it stops.

8

G22E

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.

8-8

9

10

11

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

11

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.

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

8-9

G22E

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

Brake pedal free play Å:

20-25 mm (0.79-0.98 in.)

Y-62b

9

G22E

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.

8-10

10

11

STORAGE

NOTE:

CAUTION

Perform the following preparations

1

when storing your golf car for extend­ed periods of time:

2

Turn main switch key to “OFF” posi­tion, remove key, and store key in a
safe place. Move the tow switch into
the “TOW” position.

3

CHASSIS

4

PREPARATION

1. Verify the tire pressure is set to

5

20 psi (137 kPa, 1.4 kgf/cm2).

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

6

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

7

8

BATTERY
PREPARATION

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

Do not allow cleaning solution to
enter battery cells.

2. Clean the tops of the batteries

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

9

10

11

9-1

G22E

SPECIFICATIONS

GENERAL SPECIFICATIONS

Items G22E

Dimensions:

Overall length 93.9 in. (2385 mm)
Overall width 47.2 in. (1200 mm)
Overall height (steering height) 46.9 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) 549 lb (249 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 20°

on pavement

1

2

3

4

5

6

7

8

TRANSMISSION

Items G22E

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

0.32 US qt (300 mL,
300 cc)

BATTERIES

Items G22E

Battery: BCI group GC-2H

RC: minimum 105 min

G22E

9

10

11

10-1

SPECIFICATIONS

CHASSIS

1

Items G22E

Steering system:

2

3

4

5

6

7

8

9

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

Type of brake Dual internal expanding shoe.

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 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: 20 psi (137 kPa, 1.4 kgf/cm2)

with self-adjusters.

Leading/trailing shoes (self-adjusting)

release.

10

11

10-2

G22E

G22E WIRING DIAGRAM

Main switch

Tow/storage switch

Accelerator stop switch

Buzzer

Directional switch

DC motor

Controller

Throttle sensor

Relay

Receptacle

Fuse (3A)

123456789

R

R

B/

W

B

W

W

TRANSCEIVER

Y

1

REV FWD

R/Y

32

W R/Y

W R/Y Y

Y

W

5

B

B

P

Br

R/W

P

Br

R/W

BUZZER

OFF ON

Br

R/W

4

3

2

OFF ON

R

R/Y R

R/Y

B/W

B

Y

R/Y

W

B

P

Br

R/W

WR/Y Y

RW

R/W

R/W

RY

101112

B/W

B

R/Y

R/Y

R

R

W

R/Y

W

B

R/Y

Batteries (6 x 8V)

R/W

COLOR CODE

B.....................Black

L.......................Blue

G...................Green

F2

F1

T

A

C

H

B

R

G

GRR

G

BB

B

R

G

19

18

10

236 45

1

1

987

11

R/B

R/Y

R

11

Y...................Yellow

R.......................Red

P.......................Pink

Br...................Brown

W....................White

A2

A1

6

21

20

15

23

14

16

R/B

R/B

Y

R/W

R

3/4 REC

(P) (A1) (A2)

L

BLL

B

L

5KΩ

WIRING

B/R..........Black/Red

Y/B......Yellow/Black

R/Y........Red/Yellow

R/W........Red/White

B/W......Black/White

(F2)

(F1)

ASSY

BOARD

MOSFET

(N)

ASSY

BOARD

CONTROL

B

O

OO

B

O

8

R

R

B

9

12

Y-671

7

1

2

3

4

5

6

7

8

9

10

11

G22E

1

OFF ON

R/W

R

10

11-1

NOTES

G22E

Printed in U.S.A

2004-KCC

YAMAHA MOTOR

MANUFACTURING CORP.

OF AMERICA
1000 HWY 34 East
Newnan, GA 30265

770-254-4000