Yamaha ULTIMA 48 VOLT ELECTRIC-G19-E User Manual

OWNER’S/
OPERATORS
MANUAL

GOLF CAR

LIT-19626-00-76

G19E

JR1-F8199-11

INTRODUCTION

Congratulations on your purchase of
a Yamaha golf car. This manual con­tains information you will need for
proper operation, maintenance, and
care of your golf car. A thorough
understanding of these simple
instructions will help you to obtain
maximum enjoyment from your new
Yamaha.

If you have any questions about the
operation or maintenance of your golf
car, please consult a Yamaha dealer.

TECHNICAL SERVICE DEPT

GOLF CAR SALES GROUP

YAMAHA MOTOR

MANUFACTURING CORP OF

AMERICA

G19E

G19E

OWNER’S/OPERATOR’S

MANUAL

© 2000 by Yamaha Motor

Manufacturing Corporation

of America

1st edition

All rights reserved. Any reprinting

or unauthorized use without the

written permission of

Yamaha Motor Manufacturing

Corporation of America
is expressly prohibited.

Printed in U.S.A.

P/N LIT-19626-00-76

i

IMPORTANT MANUAL

WARNING

CAUTION

WARNING

!

INFORMATION

Particularly important information is
distinguished in this manual by the fol­lowing notations:

The Safety Alert Symbol means
ATTENTION! BE ALERT! YOUR
SAFETY IS INVOLVED!

Failure to follow WARNING instruc­tions could result in severe injury
or death 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.

G19E

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

G19E

iii

9

10

WARRANTY

1

YAMAHA MOTOR MANUFACTURING

CORPORATION OF AMERICA

2

Yamaha Motor Manufacturing Corporation of America
hereby warrants that any new G19E Yamaha Golf Car
purchased from an authorized Yamaha dealer in the
United States, will be free from defects in material and

3

workmanship for the period of time stated herein, sub­ject to the stated limitations.

THE PERIOD OF WARRANTY for any G19E will be
three years from date of purchase.

4

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

The second year of warranty shall cover the transmis­sion, axles, electrical system, frame, suspension com-

5

ponents, electric motor, control cables, and steering
gear.

Parts excluded from the second year of warranty include
the body parts, seats, mats, bumper assembly, bag car-

6

rier, scorecard holder, and the trim.

The third year of warranty shall cover the transmission,
axles, frame, suspension components, steering gear,
and electronic speed controller.

Parts excluded from the third year of warranty include

7

the second year exclusions and the electrical system
(except electronic speed controller), electric motor, and
control cables.

DURING THE PERIOD OF WARRANTY any authorized

8

Yamaha Golf Car Dealer will, free of charge, repair or
replace, at Yamaha’s option, any part adjudged defective
by Yamaha due to faulty workmanship or material from
the factory. Parts used in warranty repairs will be war­ranted for the balance of the machine’s warranty period.

9

All parts replaced under warranty become property of
Yamaha Motor Manufacturing Corporation of America.

GENERAL EXCLUSIONS from this warranty shall
include any failures caused by:
a. Abnormal strain, neglect, or abuse, including lack of

10

11

proper maintenance, and use contrary to the

Owner’s/Operator’s Manual instructions.
b. Accident or collision damage.
c. Installation of par ts or accessories that are not origi-

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

nary wear and tear.
e. Modification or alteration that affects the car’s condi-

tion, operation, performance, or durability, or which

makes the car serve a purpose other than use as a

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

etc.)

G19E

LIMITED WARRANTY

SPECIFIC EXCLUSIONS from this warranty shall
include any parts replaced due to normal wear or routine
maintenance, such as brake shoes. Any charges
incurred in transporting a golf car to and from an autho­rized Yamaha Golf Car Dealer for service or in perform­ing field service is also excluded from this warranty.

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

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

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

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

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

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

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

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

Effective Date: 2/1/96
LIT-13710-01-96

1-1

G19E

IMPORTANT LABELS

Y-844

WARNING

1

2

1

3

2

5

4

Y-654

3

SAFETY AND
INSTRUCTION
LABELS

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

1

2

3

4

5

6

7

Y-500

Y-655

8

4

G19E

5

Y-656

Y-843

9

10

11

2-1

IMPORTANT LABELS

1

2

3

JR1

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

G19E

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

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.

G19E

11

3-1

OPERATOR SAFETY

!

1

2

3

● Keep your hands on the steering

wheel and your eyes on the path
ahead.

● Use extra care in congested areas

or when backing up. Always back
up slowly, and watch carefully.

● Avoid starting or stopping abruptly.

● Vary the speed of the golf car to

match the terrain of the course.

4

● Avoid turning the steering wheel too

sharply at higher speeds.

5

● Always drive slowly straight up or

straight down slopes – never at an
angle.

6

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

G19E

MAINTENANCE SAFETY PROGRAM

!

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

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

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

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

GOLF COURSE SAFETY
SURVEY

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

GOLF COURSE HAZARD
PREVENTION

The following golf course hazards
must be made safe:

● Steep Grades. Where steep

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

Warning: Steep Grade, Descend
Slowly With Foot On Brake

1

2

3

4

5

6

7

8

DRIVER
QUALIFICATIONS

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

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

G19E

● Sharp Turns, Blind Corners,

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

● Wet Areas.Wet grass may cause a

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

4-1

9

10

11

MAINTENANCE SAFETY PROGRAM

!

● Loose Terrain. Loose terrain may

1

2

3

4

5

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

● Golf Car and Pedestrian Interfer-

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

MAINTENANCE

6

REQUIRED FOR GOLF
CAR SAFETY

Practice the following to help ensure

7

the safety of golf car operators:

● Preventative Maintenance. Per-

8

9

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

● Ventilation. Properly ventilate all

maintenance and storage areas in
accordance with applicable fire
codes and ordinances to avoid fire
hazards. Ventilation is required to
remove 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

G19E

MAINTENANCE SAFETY PROGRAM

!

SAFETY PRECAUTIONS
DURING MAINTENANCE

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

● Properly immobilize golf car before

beginning any maintenance.

● Properly block chassis before

working underneath golf car.

● Avoid fire hazards, and have appro-

priate fire protection equipment
available.

● Before working on an electric golf

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

● 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

Take 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

G19E

4-3

CONTROLS

1

FEATURES

1 Steering wheel
2 Seat

2

3 Batteries
4 Brake pedal
5 Parking brake pedal

3

16

3

Y-658

6 Accelerator pedal
7 Main switch
8 Drive selector switch

1

4

5

6

5

4

7

8

9 Tow switch
a Front cowl
b Front tire
c Front bumper
d Rear cowl
e Rear bumper
f Rear tire

Y-659

g Receptacle

6

7

8

2

10

11

13

9

10

11

5-1

14

12

Y-660

9

Y-662

15

Y-661

G19E

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

G19E

9

10

11

5-2

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

7

Y-19

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-20

Release pedal Decrease

å Accelerator pedal

BRAKE PEDAL

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

å Brake pedal

A

Y-21

G19E

CONTROLS

PARKING BRAKE
PEDAL

A

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

å Parking brake pedal

Y-22

Release the parking brake by
depressing the accelerator pedal.

1

2

3

4

TOW SWITCH

TOW

A

RUN

Before operating the car, make sure
the tow switch is in the “RUN” position.

å Tow switch

5

6

Y-666

Anytime the tow switch is moved from
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.

7

8

G19E

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

5-4

9

10

11

PRE-OPERATION CHECKS

WARNING

1

2

3

4

Pre-operation checks should be
made each time you use your golf
car. Get in the habit of performing the
following checks in the same way so
that they become second nature.

● Be sure the main switch key is

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

5

PRE-OPERATION
CHECKLIST

6

7

8

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

G19E

PRE-OPERATION CHECKS

Y-30

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

9

G19E

Tire Wear Limit

10

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

6-2

11

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.

å Brake pedal

A

Y-21

G19E

PRE-OPERATION CHECKS

WARNING

Parking Brake Pedal

A

Y-22

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

å Parking brake pedal

Release the parking brake by
depressing the accelerator pedal.

1

2

3

4

Accelerator Pedal

5

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

Make sure the accelerator pedal

A

operates smoothly.

å Accelerator pedal

6

7

8

G19E

Y-20

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

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-20

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

G19E

OPERATION

CAUTION

STOPPING

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

å Brake pedal

When the car has come to a stop,

B

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

∫ Parking brake pedal

1

2

3

4

A

Y-65

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

5

6

7

8

G19E

9

10

11

7-2

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.

PERIODIC MAINTENANCE CHARTS

3

4

5

6

7

8

9

10

11

8-1

G19E

MAINTENANCE

FOR 19E

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 kingpin play, seal, and
cap / Adjust wheel alignment

Check wheel nut tightness, front
wheel bearing play

Check gear box oil level and
leakage

Check operation and adjust pedal
stop if necessary

Replace gear box oil

Check for grease leakage; adjust
gear box if necassry

Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does

*

not contain these procedures. They are contained in the Service Manual.

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

125 hrs

600 mls

1000 kms

(Every 6
months)

CA

CA

250 hrs

1200 mls

2000 kms

(Every

Year)

S

S

S

S

CA

C

C

CA

C

C

C

C

C

C

C

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

G19E

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, ciga-rettes, etc.,
away.

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

KEEP OUT OF REACH OF CHIL­DREN.

Six 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.

G19E

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 prevents boil over.

D

A

C

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

1

2

3

4

5

B

Y-829

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

6

7

3. Using a hydrometer, check the

specific gravity of the battery fluid

Y-47

in each cell against the readings
on the chart below. Consult a
Yamaha dealer if any low readings
are found, or if readings vary more
than one point between cells.

Temperature

˚F ˚C

120 48.9 1.244

110 43.3 1.248

100 37.8 1.252

90 32.2 1.256

80 26.7 1.260

70 21.1 1.264

60 15.6 1.268

50 10.0 1.272

40 4.4 1.276

30 -1.1 1.280

Satisfactory Uncorrected

Hydrometer Reading

8

9

10

11

G19E

8-4

MAINTENANCE

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

G19E

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.

1

2

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

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

B

C

1. Install the battery holddown
plates as shown.

å Forward
∫ Battery
ç Battery fitting plate

3

4

5

6

7

8

9

10

G19E

Y-751

11

8-6

MAINTENANCE

CAUTION

WARNING

CAUTION

WARNING

Y-672

A

C

B

D

D

Y-653

B

A

1

2. Connect the wire leads as shown.

å Forward
∫ To relay

2

ç To controller and receptacle
∂ Between batteries

3

4

5

When installing batteries:

● Carefully place battery cables

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

● Always remove the negative (–)

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

6

7

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

8

Fuse Replacement

9

10

11

Fuse Type:

8-7

3 Amp, Blade Style

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

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

å Fuse case
∫ Fuse

G19E

MAINTENANCE

CAUTION

Y-48

Y-520

A

B

Gear Box Oil

To check gear box oil level:

1. Place the golf car on a level sur-

face.

2. Remove the access panel by

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

3. Remove the oil level plug (A).

4. Add gear oil little by little until oil

flows from the level plug hole (B).

Recommended oil:

SAE 90 gear oil

Gearcase capacity:

0.32 US qt
(0.3 L, 0.06 Imp gal)

5. Allow excess gear oil to flow out

until it stops.

1

2

3

4

5

6

7

8

G19E

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

1

2

3

4

Y-57

Wheel Replacement

To remove and install a wheel on
your golf car:

1. With the wheels blocked to pre-

vent the golf car from moving,
loosen the wheel nuts.

2. Elevate the golf car with a jack

and remove the wheel nuts and
the wheel.

3. Reverse the removal steps when

installing the wheel.

5

Wheel nut tightening torque:

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

6

Brake Adjustment

7

8

The brakes on your golf car are self­adjusting.

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

9

10

11

8-9

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

G19E

MAINTENANCE

WARNING

CAUTION

25-30 mm

Brake Pedal Free Play

1

Adjustment

2

Before adjusting brake pedal free
play, pump the brake pedal several
times to self-adjust the brakes.

3

To adjust the brake pedal free play:

1. Remove the service lid from the
floor of the golf car.

4

5

Y-61

6

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

18

17

16

15

14

13

12

11

10

9

8

7

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

7

8

Y-62

Brake pedal free play:

25-30 mm (0.98-1.18 in.)

9

G19E

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

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. Increase the tire pressure to 20

5

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

G19E

SPECIFICATIONS

GENERAL SPECIFICATIONS

Items G19E

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 64.1 in. (1629 mm)
Tread:
Front 34.3 in. (870 mm)
Rear 38.6 in. (980 mm)

Min. ground clearance 3.8 in. (97 mm)

Weight:

Dry weight (without battery) 560 lb (254 kg)

Performance:

Maximum speed 12-15 mph

(19-24 km/h)

Minimum turning radius 113.0 in. (2.8 m)

Seating capacity 2 persons

Hill climbing ability 24˚ (44% grade)

on pavement

1

2

3

4

5

6

7

8

TRANSMISSION

Items G19E

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

0.32 US qt (0.3 L,

0.26 Imp qt)

BATTERIES

Items G19E

Battery: BCI group GC-2H

RC: minimum 105 min

G19E

9

10

11

10-1

SPECIFICATIONS

CHASSIS

1

Items G19E

Steering system:

2

3

4

5

6

7

8

9

Type Worm and pin
Steering angle (L.H.) 1.5 turn
Steering angle (R.H.) 1.5 turn

Lubricant/capacity Grease/3.0 US oz (0.09 L, 3.17 Imp oz)

Brakes:

Brake system Mechanical drum brake on each rear wheel

Type of brake Dual internal expanding shoe.

Brake pedal freeplay linkage
adjustment 25-30 mm

(Brake cable end play) 0.004-0.02 in. (0.1-0.5 mm)

Parking brake:

Type Foot type; parking brake with automatic

Release timing

(Bolt heads round parallel to arm) 0.04 in. (1 mm)

Wheel:

Tire size:
Front 18 x 8.50–8.00/4 PR
Rear 18 x 8.50–8.00/4 PR
Rim size: 7.00–I–8.00
Tire pressure: 20 psi (137 kPa, 1.4 kgf/cm2)

with self-adjusters.

Leading/trailing shoes (self-adjusting)

release.

10

11

10-2

G19E

G19E WIRING DIAGRAM

WIRING

Main switch

Tow/storage switch

Accelerator stop switch

123456789

5

REV FWD

321

W R/Y Y

Y

W

R/Y

4

BPB

P

Br

OFF ON

Br

R/W

R/W

3

2

OFF ON

R/Y R

R

R/Y

Buzzer

Directional switch

DC motor

Controller

Y

Y

R/Y

W R/Y

W

W R/Y Y

B

P

Br

Br

R/W

R/W

RY

RW

R/W

R/W

Throttle sensor

Relay

Receptacle

Fuse (3A)

Batteries (6 x 8V)

101112

R/W

R/Y

R/Y

R/Y

R/Y

R

COLOR CODE

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

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

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

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

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

F2

A2

A1

F1

T

A

C

H

B

G

R

151416

10

236 4 5
1

1

987

11

R/B

R/Y

R/B

R/B

Y

R/W

+

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

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

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

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

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

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

(F2)

(F1)

3/4 REC

6

(P) (A1) (A2)

23

–

+

ASSY

BOARD

MOSFET

BOARD

CONTROL

L

B

O

BB

OO

LL

L

B

O

8

5K

+

–

–

+

–

+

Y-671

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

7

(N)

ASSY

B

9

RR

12

–

–

+

1

2

3

4

5

6

7

8

9

10

11

G19E

1

OFF ON

R

R/W

R

R

11

10

11-1

Yamaha Motor Corp., USA

Cypress, California

made in

12/01/00

LIT196260076

USA

*LIT196260076*

1PC - G19E O/M

MANUFACTURING CORP.

YAMAHA MOTOR

OF AMERICA

Printed in U.S.A.

KCC