YAMAHA YDRE 48 User Manual

OWNER’S / OPERATOR’S
MANUAL

YDRE

48 VOLT GOLF CAR

LI T -19626-21-07

JW2-F8199-10

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 GOLF-CAR COMPANY

YDRE OWNER’S/OPERATOR’S

MANUAL

© 2006 by Yamaha Golf-Car Company

1st Edition

All rights reserved. Any reprinting

or unauthorized use without the

written permission of

Yamaha Golf-Car Company

is expressly prohibited.

Printed in U.S.A.

LIT-19626-21-07

JW2

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IMPORTANT MANUAL

!

INFORMATION

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

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

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.

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

G Yamaha continually seeks

advancements in product design
and quality; therefore, while this
manual contains the most current
product information available at the
time of printing, there may be
minor discrepancies between your
golf car and this manual. If you
have any questions concerning this
manual, please consult your
Yamaha dealer.

G This manual should be considered

a permanent part of your golf car
and should remain with the car
when resold.

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

This message provides additional
key information.

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CONTENTS

WARRANTY

IMPORTANT LABELS 2

OPERATOR SAFETY 3

SAFETY CONSIDERATIONS 4

CONTROLS 5

PRE-OPERATION CHECKS 6

OPERATION 7

MAINTENANCE 8

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STORAGE

SPECIFICATIONS

WIRING 11

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WARRANTY

1

Yamaha Golf-Car Company hereby warrants that any
new YDRA gas or YDRE electric Yamaha golf car
purchased from an authorized Yamaha golf car dealer

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in the United States will be free from defects in material
and workmanship for THREE years from date of
purchase, subject to the stated limitations.

DURING THE PERIOD OF WARRANTY any

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

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the machine’s warranty period. All parts replaced
under warranty become property of Yamaha Golf-Car
Company.

GENERAL EXCLUSIONS from this warranty shall

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include any failures caused by:

a. Abnormal strain, neglect, or abuse, including

lack of proper maintenance, and use contrary
to the Owner’s/Operator’s Manual instructions.

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b. Accident or collision damage.
c. Installation of parts or accessories that are not

original equipment.

d. Fading, rust, or deterioration due to exposure

or ordinary wear and tear.

e. Modifications or alterations that affect 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, i.e. lightning, hail damage,

flooding, fire, etc.

SPECIFIC EXCLUSIONS: The first year of warranty
shall cover the entire car except for the specific
exclusions below. Parts excluded from the second year
of warranty include the YDRA battery, 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 and the
electrical system (except electronic speed controller,
battery charger, 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 and air filter ele­ments, tire wear, spark plugs, starter and clutch drive
belts. Any charges incurred in transporting a golf car or
charger to and from an authorized Yamaha golf car
dealer for service or in performing field service is also
excluded from this warranty.

YAMAHA LIMITED 3-YEAR

GOLF CAR WARRANTY

THE CUSTOMER’S RESPONSIBILITY under this

warranty shall be to:

1. Operate and maintain the golf car and charger as
specified in the appropriate Owner’s/Operator’s
Manual;

2. Give notice to an authorized Yamaha golf car
dealer of any and all apparent defects within ten
(10) days after discovery, and make the machine
or charger 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 GOLF-CAR COMPANY 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 GOLF-CAR COMPANY 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 Golf-Car Company,
NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 10/01/06
LIT-13710-03-06B

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WARRANTY

YAMAHA FOUR-YEAR LIMITED WARRANTY FOR TROJAN BRAND

ELECTRIC GOLF CAR AND UTILITY VEHICLE BATTERIES WHEN

CHARGED WITH A YAMAHA 48-VOLT CHARGER

Yamaha Golf-Car Company (herein referred to as “YGC”)
hereby warrants to the Original Retail Purchaser or Lessee
of a Yamaha YDRE golf car or PTV, G23E or G27E utility
vehicles purchased from an Authorized Yamaha Dealer, that
the Trojan batteries charged with a Yamaha battery charger
will be free from defects in materials and workmanship, and
will provide “36-hole performance” for a period of four-years
or “1,000 rounds” from the date of purchase, whichever event
occurs first, subject to the terms and conditions contained
herein.

This limited warranty covers defects in materials and work­manship only for a period of four-years or “1,000 rounds”, as
applicable, from date of purchase, whichever event occurs
first. The terms of this four-year or “1,000 round” limited
warranty shall be as follows:

For YDRE golf car or PTV, G23E or G27E utility vehicles free
replacement within four years or 20,000 amp-hours discharged
or 500 hours elapsed time usage, whichever event occurs first,
as determined by YGC using the information recorded and
stored in the Genius controller.

This warranty only applies to Trojan battery sets charged with
a Yamaha brand battery charger supplied by YGC.

The customer must perform (or have a contracted Yamaha
Dealer perform) all periodic maintenance and discharge testing
as specified in the Yamaha Service Manual Maintenance
Schedule. No labor or transportation expenses are included
in this limited warranty.

“Thirty-six hole performance” is defined as 60-minutes
discharge time as tested and recorded using a Lester model
#17770 discharge machine at an ambient temperature of
between 60 and 100 degrees F (16 and 38 degrees C).

mbient temperatures between 60 and 80 degrees F (16 and
27 degrees C) must be corrected using the formula: Adjusted
Discharge Time = (Discharge Minutes)/(1-(((80-TEMP)/100)
x 0.64)).

The customer must notify the Dealer within 10 days that a
vehicle has failed to make 36 holes per day. Yamaha reserves
the right to test and recharge any batteries in question.

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE SHALL BE VOID
AND EXCLUDED SUBSEQUENT TO ONE YEAR FROM THE
DATE OF PURCHASE. THE REPLACEMENT OF THE
BATTERY IS THE EXCLUSIVE REMEDY UNDER THIS
WRITTEN WARRANTY OR ANY IMPLIED WARRANTY.
YAMAHA MAKES NO OTHER REPRESENTATION OR
WARRANTY OF ANY KIND, AND NO REPRESENTATIVE,
EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA
HAS THE AUTHORITY TO MAKE OR IMPLY ANY
REPRESENTATION, PROMISE OR AGREEMENT WHICH
IN ANY WAY VARIES THE TERMS OF THIS LIMITED
WARRANTY.

LIMITED WARRANTY EXCLUSIONS

Without limiting the generality of the foregoing in any way,
and as part of its limited warranty exclusion, YAMAHA does
not warrant that its battery is suitable for use in any application
other than in a golf car or utility vehicle. As in the use of any
battery, a prudent owner will read and study the charger
owner’s manual, the vehicle owner’s manual, the operator’s
instructions, and the battery warning labels; and will exercise
due care in working on or around batteries.

THE PROVISIONS OF THIS LIMITED WARRANTY SHALL
NOT APPLY TO FAILURE DUE TO:

Abuse or neglect such as improper fluid levels, loose wiring,
rusted or corroded hardware; Lack of proper maintenance as
outlined in the electric vehicle Owner’s/Operator’s Manual;
Damage caused by improper installation of the battery;
Neglect, breakage, freezing, fire, explosion, wreckage, the
addition of any chemical, or the operation of the battery in an
uncharged condition (below half-charge – 1.200 specific
gravity); and a battery charged by systems other than the
original equipment type battery charger. The golf car facility
must have ample electrical power to charge the cars, and the
chargers must be allowed to shut off automatically.

THIS BATTERY IS INTENDED TO BE USED BY PERSONS
WITH TRAINING AND EXPERIENCE WITH BATTERIES
AND ONLY IN YAMAHA ELECTRIC VEHICLES. ANY
OTHER USE RENDERS THE LIMITED WARRANTIES
EXPRESSED HEREIN AND ALL IMPLIED WARRANTIES
NULL AND VOID AND SAME ARE HEREBY EXCLUDED.

ALSO EXCLUDED FROM THIS LIMITED WARRANTY ARE
ANY AND ALL INCIDENTAL OR CONSEQUENTIAL
DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF
USE OR REVENUE, LOSS OF TIME, INCONVENIENCE
OR ANY OTHER ECONOMIC LOSS.

Some states do not allow limitation on the duration of an
implied warranty, exclusions or limitations of incidental or
consequential damages. Therefore, the above limitations or
exclusions may not apply to you.

WARRANTY LIMITATIONS

Yamaha Golf-Car Company and Trojan Battery Company’s
liability shall be to replace a defective battery. Replacement
shall mean furnishing a new battery or used battery with
sufficient life to complete the remainder of the warranty term,
which is identical or reasonably equivalent to the warranted
product at no cost to the purchaser during the limited
warranty period, except for labor or transportation expenses.

Damage not resulting from a defect in materials or
workmanship or which occurs due to abuse or neglect
(including failure to provide reasonable and necessary
maintenance), accident, alteration or acts of God is excluded
from this limited warranty.

This warranty gives you specific legal rights, and you may
also have other rights, which vary from state to state.

For further information or to submit a warranty claim,
contact your local Yamaha Golf-Car Dealer or contact
Yamaha Golf-Car Company toll free at [phone].

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Yamaha Golf-Car Company,
NEWNAN, GEORGIA 30265-1320
EFFECTIVE DATE: 10/01/06 LIT-13710-EL-16B

1-2

IMPORTANT LABELS

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Y-924

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.

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Y-844a

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Y-500a

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IMPORTANT LABELS

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IMPORTANT LABELS

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1

GOLF CAR SERIAL
NUMBER

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

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The first three digits of the serial

0

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0
00

-00
X

JW

4

Y-910b

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
Golf-Car Company dealer.

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OPERATOR SAFETY

Y-68

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

BEFORE OPERATING
THE GOLF CAR

G Read this Owner’s/Operator’s

manual and all safety and instruction
labels on the golf car before
operating.

G Perform the pre-operation checks

found in Section 6 of this manual.

G Only authorized people should

drive the golf car, from the driver’s
side only, and only in designated
areas.

G Do not allow more than two

occupants per seat. This golf car is
restricted to two occupants unless
equipped with a rear seat.

G 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.

G Do not operate the golf car on

public streets, roads or highways
unless allowed by law or local
regulating authority.

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Y-9 28

WHILE OPERATING THE
GOLF CAR

G Keep your entire body inside the

golf car, remain seated, and hold
on when the car is in motion.

G Do not start the golf car until all

occupants are seated.

G Keep your hands on the steering

wheel and your eyes on the path
ahead.

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!

OPERATOR SAFETY

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G Use extra care in congested areas

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

G Avoid starting or stopping abruptly.

G Vary the speed of the golf car to

match the terrain of the course.

G Avoid turning the steering wheel

too sharply at higher speeds.

G Always drive slowly straight up or

straight down slopes – never at an
angle.

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Y- 9 2 1

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G Do not run the engine indoors.

Exhaust gas is poisonous.

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Y-922

G 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- 9 2 3

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SAFETY CONSIDERATIONS

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

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

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

DRIVER
QUALIFICATIONS

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

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

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

GOLF COURSE SAFETY
SURVEY

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

GOLF COURSE HAZARD
PREVENTION

The following golf course hazards
must be made safe:

G 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:

Steep Grade, Descend Slowly
With Foot On Brake

G 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.

G Wet Areas. Wet grass may cause

a golf car to lose traction and may
affect stability. Reduce speed in
wet areas or during periods of
inclement weather.

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SAFETY CONSIDERATIONS

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G Loose Terrain. Loose terrain may

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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.

G Golf Car and Pedestrian

Interference. 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:

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G Preventative Maintenance.

Perform all scheduled
maintenance in accordance with

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manufacturer’s recommendations
to provide the golfing patron with a
safe, properly operating golf car.

G Parts and Materials. Use only

replacement parts and materials
recommended by the manufacturer.

G 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.

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.

G Personnel. Allow only qualified,

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trained, and authorized personnel
to inspect, adjust, and maintain
golf cars.

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!

SAFETY CONSIDERATIONS

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:

G Properly immobilize golf car before

beginning any maintenance.

G Properly block chassis before

working underneath golf car.

G Avoid fire hazards, and have

appropriate fire protection
equipment available.

G Before working on an electric golf

car, disable the car’s electrical
system in accordance with the
manufacturer’s instructions.

G Use only properly insulated tools

when working on electrically
powered golf cars or around
batteries.

G Maintain all safety devices including

brakes, steering mechanisms,
warning devices, and governors, in
a safe operating condition. Do not
modify these safety devices as
supplied by the manufacturer.

G 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.

maintenance. Periodically inspect
maintenance log to ensure
accurate and complete entries.

G Provide operator comment cards

to assist in identifying non-periodic
maintenance needs for specific
golf cars.

G Maintain in a legible condition all

nameplates, warnings, and
instructions provided by the
manufacturer.

G If new nameplates, warnings, or

instructions are needed, contact
your Yamaha Golf-Car Company
dealer.

STORAGE AND
BATTERY CHARGING

Take the following precautions to
ensure maintenance worker safety:

G Only use battery charging facilities

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

G Periodically inspect charging

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

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G Record all maintenance performed

in a maintenance record log by
date, name of person performing
maintenance, and type of

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CONTROLS

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FEATURES

1 Brake pedal
2 Parking brake pedal
3 Accelerator pedal
4 Steering wheel
5 Main switch
6 Receptacle

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1

Y-916a

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7 Batteries
8 Seat
9 Front cowl
a Front tire
b Front bumper
c Rear cowl

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d Rear tire
e Rear bumper
f Tow switch
g FWD/REV switch

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Y-9 35

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10

Y-918a

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Y-930a

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Y-919a

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CONTROLS

REV

REV

FWD

FWD

OFF

OFF

ON

ON

Y- 9 1 2

Y- 9 1 3

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.

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CONTROLS

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REV

FWD

OFF

ON

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3

Y- 9 0 4

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 lever to the desired
position.

Switch Position Car Movement

FWD FORWARD

REV REVERSE

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BEEP

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

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Y- 9 2 0

ACCELERATOR PEDAL

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A

The accelerator pedal controls the
golf car’s speed.

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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

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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.

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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.

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CONTROLS

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CAUTION / AVERTISSEMENT

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O

W

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R

U

N

A

TOW SWITCH

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

å Tow switch

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Y-666a

4

5

Ensure that the “Drive Select
Switch” is in the “FWD” position
and then move the “TOW Switch”
to “TOW” before towing.

Failure to do so may lead to drive
system damage.

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PRE-OPERATION CHECKS

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.

G 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:

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

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Y-905

SEAT

Open the seat for checking and
servicing.

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PRE-OPERATION CHECKS

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BATTERIES

Check that the batteries are held
securely in place to prevent them
from being damaged from vibration
or jarring. Also check that no battery
caps are missing to prevent battery
acid from spilling from the batteries.
Check the battery terminals for
corrosion.

TIRE CONDITION
Tire Air Pressure

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Check the tire air pressure before
operating the golf car.

Tire pressure:

For JW2: 20 psi

(138 kPa, 1.4 kgf/cm2)

Y-30

Tire Wear Limit

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A

9

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

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Y-31

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PRE-OPERATION CHECKS

REV

FWD

OFF

Y- 9 3 2

ON

Y-9 11b

STEERING SYSTEM

Check the steering system for
excessive free play by:

G moving the steering wheel up and

down, and back and forth.

G turning the steering wheel slightly

to the right and left.

If you feel excessive free play, 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.

PEDAL OPERATION

Check the following pedal controls
for proper operation. If a pedal does
not work properly, consult a Yamaha
dealer.

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Accelerator Pedal

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A

Y-20A

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

Make sure the accelerator pedal
operates smoothly.

å Accelerator pedal

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PRE-OPERATION CHECKS

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B

3

Y-21a

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C

Y-22a

Brake Pedal

Make sure the brake pedal feels firm
when pressed and returns to its
original position when released.

∫ Brake pedal

Parking Brake Pedal

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

ç Parking brake pedal

Release the parking brake by
depressing the accelerator pedal.

7

BODY AND CHASSIS

8

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

9

10

11

6-4

JW2

OPERATION

REV

REV

FWD

FWD

OFF

OFF

A

ON

Y- 9 3 3

ON

Y-9 11b

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.

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. 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

1

2

3

4

5

6

7

8

JW2

Y-20A

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

7-1

9

10

11

OPERATION

1

2

3

B

STOPPING

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

å Brake pedal

When the car has come to a stop,
apply the parking brake pedal and
turn the main switch to “OFF.”

∫ Parking brake pedal

4

A

5

Y-6 5b

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

6

7

8

9

10

11

7-2

JW2

MAINTENANCE

PERIODIC MAINTENANCE CHARTS

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

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.

1

2

3

4

5

6

7

8

JW2

9

10

11

8-1

1

2

3

4

5

6

7

8

9

10

11

MAINTENANCE

FOR JW2

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,
screws and rivets

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 rear axle bearing play
for roughness or freeplay

Check steering knuckle
bushing freeplay / Adjust
wheel alignment

Check wheel nut tightness, front
wheel bearing play

Check transaxle oil level and
inspect for leakage

Check pedal stop operation and
adjust if necessary

Replace transaxle oil

Inspect internal wet brake and
replace pads if necessary

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.

40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds

Daily

Pre-

Opera-

tion

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

*

*

*

*

8-2

JW2

MAINTENANCE

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.

Four 12-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.

1

2

3

4

5

6

7

8

9

10

11

JW2

Do not allow cleaning solution to
enter battery cells.

2. Check the fluid level before and

after charging.

8-3

MAINTENANCE

1

2

3

4

5

6

7

8

9

10

11

Electrolyte 1/8” Below
Bottom of Fill Well

Max. Level ­charged battery

Max. Level ­discharged battery

N

E

G

1/8”

Fill Well

P

O

S

Electrolyte

Y-9 37

G Before charging: only add distilled

water if fluid is below the top of the
plates, and then add just enough to
cover plates.

G After charging: open the vent caps

and look inside the fill wells. Add
distilled water until the electrolyte
level is 1/8" below the bottom of the
fill well. A piece of rubber can be
used safely as a dipstick to help
determine this level. Clean, replace
and tighten all vent caps.

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

3. Using a hydrometer, check the
specific gravity of the battery fluid
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

8-4

Y-936

JW2

MAINTENANCE

CAUTION

REV

FWD

OFF

ON

Y-912

Battery Charging

Read and understand the owner’s
manual provided with your golf
car’s battery charger before
charging batteries.

Explosive hydrogen gas is
produced while batteries are
being charged. Only charge
batteries in well ventilated areas
(a minimum of five 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.

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.

1

2

3

4

5

6

7

8

9

10

11

JW2

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.

8-5

MAINTENANCE

1

Do not disconnect the DC output
cord from the battery receptacle

2

when the charger is on or an arc
could occur that may cause an
explosion.

3

4

5

6

7

8

9

10

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

A

C

B

POS

NEG

POSNEG

POS

NEG

POSNEG

Y-751B

objects across the battery
terminals. An arc can occur
causing explosion of the battery.

1. Install the battery holddown
plates and torque to 7-9 Nm
(0.7-0.9 m•kg, 62-80 in•lb) as
shown.

å Forward
∫ Battery
ç Battery holddown plate

11

8-6

2. Connect the wire leads and
torque to 9-10 Nm (0.9-1.0 m•kg,
80-89 in•lb) as shown.

Y-672b

JW2

MAINTENANCE

When installing batteries:

G Carefully place battery cables

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

G 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.

1

2

3

4

5

B

A

Fuse Type:

3 Amp, Blade Style

Y-523a

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 short­circuiting.

1. Locate the in-line fuse holder on
the main wire harness adjacent
to the tow switch.

2. Pull fuse holder cover off.

3. Pull fuse out, inspect and replace
if necessary.

å Fuse holder
∫ Fuse

6

7

8

9

10

11

JW2

8-7

MAINTENANCE

4

Y-1214

1

2

1

3

2

4

5

Y-1215

6

7

8

9

Transaxle Oil

To check transaxle oil level:

1. Place the golf car on a flat, level
surface.

2. Remove seven plastic rivets 1

3

and two bolts 2, and remove the
bag holder insert 3.

3. Place an oil pan under the
transaxle case.

4. Clean area around servicing plug 4.

5. Using an 8 mm hex wrench,
remove transaxle oil servicing
plug located on the rear of the
transaxle case.

6. Transaxle oil should be at the top
of the oil servicing hole or just
beginning to run out of hole.

Do not allow foreign material to
enter transaxle.

7. If needed, add SAE80 W90 API

GL-5 limited slip high perfor­mance gear oil until it is at the
top of the plug hole or just begin­ning to run out of servicing hole.

10

11

8-8

The YDRE Golf Car is equipped with
an internal wet brake. Use of oil other
than SAE80 W90 API GL-5 limited
slip high performance gear oil will
cause brake noise.

8. Install the transaxle servicing

plug and tighten to 14-19 Nm
(1.4-1.9 m•kg, 120-168 in•lb).

9. Install the bag holder insert 3

and secure with two bolts 2 and
seven plastic rivets 1.

JW2

MAINTENANCE

For transaxle oil replacement, con­sult a Yamaha dealer or other quali­fied mechanic.

1

2

Y-57

Before performing wheel or brake
maintenance, verify that the main
switch is in the “OFF” position.

Wheel Replacement

To remove and install a wheel on
your golf car:

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
self-adjusting.

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

3

4

5

6

7

8

9

10

11

JW2

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

8-9

MAINTENANCE

1

2

3

4

5

6

7

8

9

10

11

Brake Pedal Free Play
Adjustment

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

To adjust the brake pedal free play:

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

Y- 61 c

a

8
1

17

16

15

14

13

12

1

1

10

9

8

7

Y-62b

A

B

2. Check the brake pedal free play
by pressing against the pedal
with two fingers (using light
force) and measuring the
distance the pedal travels before
resistance is felt.

Brake pedal free play Å:

45-50 mm (1.77-1.96 in.)

3. If the free play distance needs
adjusting, loosen the lock nut å
and turn the adjusting nut ∫ in
or out until the free play
specification is met. Then tighten
the lock nut in place.

8-10

Y-909A

Do not over-tighten the brake
cables. Over-tightening will
increase brake wear and affect
overall performance of car.

JW2

STORAGE

Perform the following preparations
when storing your golf car for
extended periods of time:

Turn main switch key to “OFF”
position, remove key, and store key
in a safe place.

CHASSIS
PREPARATION

1. Verify the tire pressure is set to
20 psi (138 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 batteries from the
golf car and store them in a cool,
dry place that stays between
32˚F (0˚C) and 90˚F (30˚C).

2. Have the batteries recharged
every 60-90 days to keep them
fully charged. The batteries must
be kept fully charged to avoid
damage.

Do not allow cleaning solution to
enter battery cells.

3. Clean the top of the batteries

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

1

2

3

4

5

6

7

8

9

JW2

10

11

9-1

SPECIFICATIONS

GENERAL SPECIFICATIONS

1

Items YDRE

Dimensions:

2

3

4

5

6

7

8

9

Overall length 93.4 in. (2395 mm)
Overall width 47.2 in. (1200 mm)
Overall height (steering height) 46.9 in. (1190 mm)
Height of floor 12.2 in. (310 mm)
Wheelbase 64.6 in. (1640 mm)
Tread:
Front 34.3 in. (870 mm)
Rear 38.6 in. (980 mm)

Min. ground clearance 4.3 in. (110 mm)

Weight:

Dry weight (without battery) 535 lb (243 kg)

Vibration Level:

Vibration on seat (EN1032,
ISO5008) (for Europe Will not exceed 0.5 m/s
Vibration on steering wheel
(EN1032, ISO5008) (for Europe) Will not exceed 2.5 m/s

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 per seat

2

2

TRANSMISSION

10

Differential/reduction gear:

11

Differential type Bevel gear
Lubricant/capacity SAE80 W90 API GL-5 limited slip

10-1

Items YDRE

high performance gear oil/

1.43 US quarts

(1350 mL, 1350 cc)

JW2

SPECIFICATIONS

BATTERIES

Items YDRE

Battery: Trojan - Golf Car Type T-1275 (4x12-volt)

RC: minimum 102 min

CHASSIS

Items YDRE

Steering system:

Type Rack and Pinion
Steering angle (L.H.) 1.85 turn
Steering angle (R.H.) 1.85 turn

Brakes:

Brake system Mechanical
Type of brake Internal wet
Brake pedal freeplay linkage
adjustment 45-50 mm

(1.77-1.96 in.)

(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: 20 psi (138 kPa, 1.4 kgf/cm

1

2

3

4

5

6

7

8

9

10

2

)

JW2

11

10-2

WIRING

YDRE WIRING DIAGRAM

1

Y-940

2

3

4

5

6

7

8

9

10

OPTIONAL

(NOTE 1)

DIRECTIONAL SW.

I.R.

TRANSCEIVER

FWD

REV

RY

(NOTE 1)

ACCEL. SW.

TOW/STORAGE SW,

Y

W

BUZZER

OFF ON

OFF ON

R

A2

F2

F1

D.C. MOTOR

R

BW

Y

RW

RY

A1

TACH

B

G

R

B

G

R

R

G

B

B

R

G

(NOTE 2)

RB

FUSE (3 AMP)

(A1)

(P)

20

19

22

21

26 25

10 9
4

24

8

11

2

12

13

5

6

7

3

O
B
L

RY RB

RW RB

RY

W

Y

PB

RW Br

BW

B

RW Br

RW

BW

PB

Br

RW

RW

RY

RW

RY

RY

RW

W

RY

RY

RY

R

W

RW

RY

WR

RY

W

Y

RY R

RW

RY

OFF

MAIN SW. (NOTE 1)

BW

B

PB

ON

B
BW

Br

(F1)

(F2)

ASSY.

MOSFET BOARD

PWM OUTPUT

GATE DRIVER CIRCUIT

(A2)

(N)

CONTROLLER

CONTROL BOARD

ASSY

O

O

O

B

B

B

L

L

L

B

THROTTLE

SENSOR

POSITION

YR

BATTERY

(4x12v)

RELAY

RR

G

ATARECEIVE14

CHARGER D

11

COLOR CODE

11-1

...................Yellow

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

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

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

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

Y

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

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

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

Y/B .....Yellow/Black

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

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

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

ARE REQUIRED. TYPICAL

1. PRECIOUS METAL CONTACTS

IS JAE MX23A26SF1. UNUSED

CIRCUIT CAVITIES REQUIRE DUMMY

SIGNAL IS 10mA.

PLUGS P/N M120-55780.

2. THE 26 POSITION WIRE HARNESS

CONNECTOR PLUG PART NUMBER

RECEPTACLE

JW2

NOTES

1

2

3

4

5

6

7

JW2

8

9

10

11

NOTES

1

2

3

4

5

6

7

8

9

10

11

JW2

Printed in U .S. A

2006-KCC

YAMAHA GOLF-CAR

COMPANY

1000 HWY 34 East

Newnan, GA 30265

770-254-4000