JW8-F8199-21_cover_LIT_19626_11_07 cover.

qxd 9/18/12 11:14 AM Page 1

OWNER’S / OPERATOR’S
MANUAL

READ THIS MANUAL CAREFULLY!

! It contains important safety information.

YDRA
4 STROKE GOLF CAR

Printed in U.S.A YAMAHA GOLF-CAR

2012-KCC COMPANY
1000 HWY 34 East LIT-19626-11-13 JW8-F8199-21
Newnan, GA 30265
JW8-F8199-21 770-254-4000
JW8-F8199-21_cover_LIT_19626_11_07 cover.qxd 9/18/12 11:14 AM Page 2
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 1

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

YDRA OWNER’S/OPERATOR’S
MANUAL
© 2012 by Yamaha Golf-Car Company
3rd 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-19626-11-13

JW8-F8199-21

JW8 i
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 2

IMPORTANT MANUAL
INFORMATION
Particularly important information is TIP
distinguished in this manual by the Yamaha continually seeks
following notations: advancements in product design
and quality; therefore, while this
manual contains the most current
This is the safety alert symbol. It is product information available at the
used to alert you to potential person- time of printing, there may be minor
al injury hazards. Obey all safety discrepancies between your golf car
messages that follow this symbol to and this manual. If you have any
avoid possible injury or death. questions concerning this manual,
please consult your Yamaha dealer.

A WARNING indicates a potentially

hazardous situation which, if not Read and understand this manual
avoided, could result in death or completely before operating your
serious injury. golf car. This manual should be
considered a permanent part of
your golf car and should remain
NOTICE with the car when resold.
A NOTICE indicates special pre-
cautions that must be taken to
avoid damage to the vehicle or
other property.

TIP
A TIP provides key information to
make procedures easier or clearer.

ii JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 3

CONTENTS

WARRANTY 1

IMPORTANT LABELS 2

OPERATOR SAFETY 3

SAFETY CONSIDERATIONS 4

CONTROLS 5

PRE-OPERATION CHECKS 6

OPERATION 7

MAINTENANCE 8

STORAGE 9

SPECIFICATIONS 10

WIRING 11

JW8 iii
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 4

WARRANTY
LIMITED 4-YEAR GOLF CAR LIMITED WARRANTY
1
Yamaha Golf-Car Company hereby warrants that any • Any charges incurred in transporting a golf car
new YDRA gas or YDRE electric Yamaha golf car or charger to and from an authorized Yamaha
purchased from an authorized Yamaha golf car deal- golf car dealer for service or in performing field
er in the United States will be free from defects in service are also excluded from this warranty.
2 material and workmanship for FOUR years from date • Gasoline powered golf car starting batteries on
of purchase, subject to the stated limitations. vehicles equipped with a golf course GPS
device, or any other device with a parasitic
DURING THE PERIOD OF WARRANTY any autho- current draw, unless the vehicle is equipped
rized Yamaha golf car dealer will, free of charge, from the factory with an optional deep cycle
3 repair or replace, at Yamaha’s option, any part
adjudged defective by Yamaha due to faulty work-
starting battery.

manship or material from the factory. Parts used in THE CUSTOMER’S RESPONSIBILITY under this
warranty repairs will be warranted for the balance of warranty shall be to:
the vehicle’s warranty period. All parts replaced 1. Operate and maintain the golf car and charger as
4 under warranty become property of Yamaha Golf-Car
Company.
specified in the appropriate Owner’s/Operator’s
Manual;
2. Give notice to an authorized Yamaha golf car deal-
GENERAL EXCLUSIONS from this warranty shall er of any and all apparent defects within ten (10)
include any failures caused by: days after discovery, and make the vehicle or
5 a. Abnormal strain, neglect, or abuse, including
lack of proper maintenance, and use contrary
charger available at that time for inspection and
repairs by the dealer’s authorized representative.
to the Owner’s/Operator’s Manual instructions.
b. Accident or collision damage. WARRANTY TRANSFER: Any transfer of warranty
c. Installation of parts or accessories that are not must take place within the first three years of the
original in-service date of the vehicle. The vehicle
6 original equipment.
d. Fading, rust, or deterioration due to exposure must be re-registered by an authorized Yamaha Golf-
or ordinary wear and tear. Car Dealer within 30 days of transfer. A fee may be
e. Modifications or alterations that affect the car’s charged for the transfer of the warranty.
condition, operation, performance, or durability,
or which makes the car serve a purpose other YAMAHA GOLF-CAR COMPANY MAKES NO
7 than use as a two-person, golf course vehicle. OTHER WARRANTY OF ANY KIND, EXPRESSED
f. Damage due to improper transportation. OR IMPLIED. ALL IMPLIED WARRANTIES OF
g. Acts of God, i.e. lightning, hail damage, MERCHANTABILITY AND FITNESS FOR A
flooding, fire, etc. PARTICULAR PURPOSE WHICH EXCEED THE
OBLIGATIONS AND TIME LIMITS STATED IN THIS
8 WARRANTY COVERAGE: WARRANTY ARE HEREBY DISCLAIMED BY
Year 1: The first year of warranty shall cover the entire YAMAHA GOLF-CAR COMPANY AND EXCLUDED
vehicle except for the Specific Exclusions FROM THIS WARRANTY.
below.
Year 2: The second year exclusions are the YDRA SOME STATES DO NOT ALLOW LIMITATIONS
9 battery, body parts, seats, mats, bumper ON HOW LONG IMPLIED WARRANTY LASTS,
assembly, bag carrier, scorecard holder, trim, SO THE ABOVE LIMITATION MAY NOT APPLY
and the Specific Exclusions below. TO YOU. ALSO EXCLUDED FROM THIS
Year 3: The third year exclusions include the second WARRANTY IS ANY INCIDENTAL OR
year exclusions, plus the control cables and CONSEQUENTIAL DAMAGES INCLUDING LOSS
10 electrical system (except electronic speed OF USE. SOME STATES DO NOT ALLOW THE
controller, battery charger, and electric motor), EXCLUSION OR LIMITATION OF INCIDENTAL OR
and the Specific Exclusions below. CONSEQUENTIAL DAMAGES, SO THE ABOVE
Year 4: The fourth year of the warranty covers only EXCLUSION MAY NOT APPLY TO YOU.
the electric motor, speed controller, battery
11 charger, and transaxle on the YDRE and the
engine, clutch system (except drive belt), and
THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER
transaxle on the YDRA. RIGHTS, WHICH VARY, FROM STATE TO STATE.

SPECIFIC EXCLUSIONS: Specific exclusions from

this warranty shall include the following: Yamaha Golf-Car Company,
• Electric car batteries, which are covered under NEWNAN, GEORGIA 30265-1320
a separate warranty.
• Any parts replaced due to normal wear or EFFECTIVE DATE: 6/1/11 LIT-13710-01-12
routine maintenance, including oil and air filter
elements, tire wear, spark plugs, starter and
clutch drive belts.

1-1 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 5

WARRANTY
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS 1
The California Air Resources Board and Yamaha Free from defects in materials and workmanship that
Golf-Car Company are pleased to explain the emis- cause the failure of a warranted part to be identical in
sions control system warranty on your 2010 or later all material respects to that part as described in
small off-road engine (SORE) vehicle. In California, Yamaha Golf-Car Company’s application for certifica- 2
new SORE vehicles must be designed, built and tion.
equipped to meet the State’s stringent anti-smog
standards. Yamaha Golf-Car Company must warrant The warranty period begins on the date the SORE
the EECS on your SORE vehicle for the period of vehicle is delivered to an ultimate purchaser or first
time listed below provided there has been no abuse, placed into service. The warranty period is two years. 3
neglect or improper maintenance of your SORE
vehicle. Subject to certain conditions and exclusions as stated
below, the warranty on emission-related parts is as fol-
Your EECS may include parts such as the carburetor, lows:
fuel-injection system, the ignition system, catalytic 4
converter, fuel tanks, fuel lines, fuel caps, valves, 1. Any warranted part that is not scheduled for
canisters, filters, vapor hoses, clamps, connectors, replacement as required maintenance in the writ-
and other associated emission-related components. ten instructions supplied, is warranted for the war-

Where a warrantable condition exists, Yamaha Golf-

ranty period stated above. If the part fails during
the period of warranty coverage, the part will be
5
Car Company will repair your SORE vehicle at no repaired or replaced by Yamaha Golf-Car
cost to you including diagnosis, parts and labor. Company according to subsection (4) below. Any
such part repaired or replaced under warranty will
MANUFACTURER’S WARRANTY COVERAGE:
This emissions control system is warranted for two 2.
be warranted for the remainder of the period.
Any warranted part that is scheduled only for regu-
6
years. If any emission-related part on your equip- lar inspection in the written instructions supplied is
ment is defective, the part will be repaired or warranted for the warranty period stated above.
replaced by Yamaha Golf-Car Company. Any such part repaired or replaced under warranty

OWNER’S WARRANTY RESPONSIBILITIES:

will be warranted for the remaining warranty
period.
7
As the SORE vehicle owner, you are responsible for 3. Any warranted part that is scheduled for replace-
performance of the required maintenance listed in your ment as required maintenance in the written
owner’s manual. Yamaha Golf-Car Company recom- instructions supplied is warranted for the period of
mends that you retain all receipts covering mainte-
nance on your SORE vehicle, but Yamaha Golf-Car
time before the first scheduled replacement date 8
for that part. If the part fails before the first sched-
Company cannot deny warranty solely for the lack of uled replacement, the part will be repaired or
receipts. replaced by Yamaha Golf-Car Company according
to subsection (4) below. Any such part repaired or
As the SORE vehicle owner, you should however be replaced under warranty will be warranted for the 9
aware that Yamaha Golf-Car Company may deny you remainder of the period prior to the first scheduled
warranty coverage if your SORE vehicle or a part has replacement point for the part.
failed due to abuse, neglect, or improper maintenance 4. Repair or replacement of any warranted part under
or unapproved modifications. the warranty provisions herein must be performed
at a warranty station at no charge to the owner. 10
You are responsible for presenting your SORE vehicle 5. Notwithstanding the provisions herein, warranty
to Yamaha Golf-Car Company’s distribution center or services or repairs will be provided at all of our dis-
service center as soon as the problem exists. The war- tribution centers that are franchised to service the
ranty repairs should be completed in a reasonable subject engines or equipment.
amount of time, not to exceed 30 days. If you have a 6. The SORE vehicle owner will not be charged for 11
question regarding your warranty coverage, you should diagnostic labor that is directly associated with
contact YGC Service at 1-866-747-4027. diagnosis of a defective, emission-related warrant-
ed part, provided that such diagnostic work is per-
GENERAL EMISSIONS WARRANTY COVERAGE: formed at a warranty station.
Yamaha Golf-Car Company warrants to the ultimate 7. Yamaha Golf-Car Company is liable for damages
purchaser and each subsequent purchaser that the to other engine or equipment components proxi-
SORE vehicle is: mately caused by a failure under warranty of any
warranted part.
Designed, built and equipped so as to conform with all
applicable regulations; and

JW8 1-2
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 6

WARRANTY

1
8. Throughout the SORE vehicle warranty period
stated above, Yamaha Golf-Car Company will
maintain a supply of warranted parts sufficient to
2 meet the expected demand for such parts.
9. Any replacement part may be used in the perfor-
mance of any warranty maintenance or repairs and
must be provided without charge to the owner.
Such use will not reduce the warranty obligations
3 of Yamaha Golf-Car Company.
10. Add-on or modified parts that are not exempted by
the Air Resources Board may not be used. The
use of any non-exempted add-on or modified parts
by the ultimate purchaser will be grounds for disal-
4 lowing a warranty claims. Yamaha Golf-Car
Company will not be liable to warrant failures of
warranted parts caused by the use of a non-
exempted add-on or modified part.
5 WARRANTED PARTS:
The repair or replacement of any warranted part other-
wise eligible for warranty coverage may be excluded
from such warranty coverage if Yamaha Golf-Car
6 Company demonstrates that the SORE vehicle has
been abused, neglected, or improperly maintained, and
that such abuse, neglect, or improper maintenance was
the direct cause of the need for repair or replacement
of the part. That notwithstanding, any adjustment of a
7 component that has a factory installed, and properly
operating, adjustment limiting device is still eligible for
warranty coverage. The following emission warranty
parts are covered:

8 1.
2.
Fuel Tank
Fuel Cap
3. Fuel Line
4. Fuel Line Fittings
5. Clamps
9 6. Control Valves
7. Control Solenoids
8. Electronic Controls
9. Control Cables
10. Control Linkages
10 11. Vapor Hoses
12. Carbon Cannister
13. Cannister Mounting Brackets

11

1-3 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 7

IMPORTANT LABELS
SAFETY AND INSTRUCTION LABELS 1

Read the following labels carefully before operating your golf car, and
promptly replace any labels which become damaged or removed. Death or 2
serious personal injury can result from failing to read and comply with
the safety labels in this manual.
3

4
6
1
5
3 5
4
2 6
7

Y-924d 8

9
1
10

11

JW8 Y-500a 2-1

 9
8
7
6
5
4
3
2
1

11
10
2

2-2
3
IMPORTANT LABELS
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 8

Y-1606

GASOLINE IS HIGHLY FLAMMABLE AND OPERATION AT HIGHER SPEEDS L’ESSENCE EST HAUTEMENT INFLAMMABLE ET EXPLOSIVE. L’UTILISATION A DES VITESSES
EXPLOSIVE. A fire or explosion could COULD CAUSE LOSS OF CONTROL Un incendie ou une explosion peuvent provoquer de SUPÉRIEURES PEUT ENTRAINER UNE PERTE
cause SEVERE INJURY or DEATH
DEATH. THAT COULD RESULT IN SEVERE GRAVES BLESSURES ou la MORT.
MORT DE CONTROLE QUI PEUT PROVOQUER DE
INJURY OR DEATH. GRAVES BLESSURES OU LA MORT.
Keep heat, sparks, and open flame Eloigner toute source de chaleur, d’étincelles et de
away from fuel tank and fuel lines. Do not tamper with flammes nues du réservoir et des conduites de
Do not add duel while engine is governor to increase carburant. Ne pas altérer le régulateur pour
running or hot. speed. Ne pas ajouter de carburant pendant que le moteur augmenter la vitesse.
Do not modify fuel system. tourne ou qu’il est chaud.
Services should be performed be Ne pas modifier le circuit d’alimentation.
dealer or qualified personnel. Les révisions doivent être effectuées par le
concessionnaire ou par du personnel qualifié. JW1-K8297-01

JW8
Y-1669a
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 9

IMPORTANT LABELS

5 1
YEAR OF CONSTRUCTION: 20XX MODEL: YDRAX
YAMAHA MOTOR POWERED PRODUCTS CO., LTD. MAX. POWER: X.X KW
200-1 SAKAGAWA, KAKEGAWA, JAPAN DRY WEIGHT: XXX kg 2
MAX. BATTERY WEIGHT: XX kg JXX-F4236-XX
Y-1607c
3
6
4

Y-1599c
7

7 8

10

11

Y-1610

JW8 2-3
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 10

IMPORTANT LABELS
1 GOLF CAR SERIAL
1
NUMBER
The golf car serial number 1 is
identified in the location shown.
2
TIP
The first three digits of the serial
3 number are for model identification;
JWX-000000

the remaining digits are the unit

production number. Keep a record
of these numbers for reference
4 when ordering parts from a Yamaha
Y-1539
Golf-Car Company dealer.

5 2 The engine serial number 2 is

I
affixed in the location shown.
II
III
I III
III
II
III
II

3 Engine Information
7
SM-03-399

8 3

9 THIS ENGINE MEETS **** - **** CALIFORNIA EMISSION REGULATIONS FOR OFF-ROAD ENGINES.
THIS ENGINE CONFORMS TO **(*****.******) U.S. EPA REGULATIONS FOR SMALL NONROAD ENGINES.

Y-851a

10
Y-852A

11

2-4 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 11

! OPERATOR SAFETY
Yamaha golf cars are designed to be
simple to operate. However, be sure 1
to observe the following to reduce
the risk of serious injury or death due
to loss of control and other hazards:
2
BEFORE OPERATING
THE GOLF CAR 3
l Read this Owner’s/Operator’s
manual and all safety and instruction
labels on the golf car before
operating. 4
l Perform the pre-operation checks
found in Section 6 of this manual.
l Only authorized people should 5
drive the golf car, from the driver’s
side only, and only in designated
areas. 6
l Do not allow more than two
occupants per seat. This golf car is
restricted to two occupants unless
equipped with a rear seat. 7
l Do not operate the golf car while
under the influence of alcohol or
drugs; their effect on vision and 8
judgment make operating a golf
car dangerous.
l Do not operate the golf car on
public streets, roads or highways 9
unless allowed by law or the local
regulating authority.
Y-68
10
WHILE OPERATING THE
GOLF CAR
11
l Keep your entire body inside the
golf car, remain seated and hold
on when the car is in motion.
l Do not start the golf car until all
occupants are seated.
Y-928 l Keep your hands on the steering
wheel and your eyes on the path
ahead.
JW8 3-1
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 12

! OPERATOR SAFETY
l Use extra care in congested areas
1 or when backing up. Always back
up slowly, and watch carefully.

l Avoid starting or stopping abruptly.

2
l Vary the speed of the golf car to
match the terrain of the course.
3 l Avoid turning the steering wheel
too sharply at higher speeds to
avoid tipping or rolling the golf car.
4
l Always drive slowly straight up or
straight down slopes – never at an
angle to avoid tipping or rolling the
5 golf car.
Y-921

6
l Do not run the engine indoors.
7 Exhaust gas is poisonous and
could result in carbon monoxide
poisoning.

9
Y-922

10 l Do not make any modification or

addition which affects capacity or
safe operation, or make any
changes not in accordance with
11 the owner’s/operator’s manual.

Y-923

3-2 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 13

! SAFETY CONSIDERATIONS
Like all machines, golf cars can
cause injury if improperly used or 1
maintained. This section contains Do not operate golf cars or
broad safety practices required for utility vehicles when under the
safe golf car operation. Before golf influence of alcohol or drugs.
cars are operated, golf course Death or serious personal injury 2
personnel should establish any can result from failing to comply
additional safety practices that may with the safety and warning
be required for safe operation. instructions affixed to the golf car
or utility vehicle. 3
Experience has shown that golf
cars are safe when operated in GOLF COURSE SAFETY
accordance with the safety warnings
SURVEY 4
affixed to every golf car. This safe
operation is enhanced when golf Perform safety surveys regularly to
cars are used according to the safety identify hazardous areas where golf
rules and practices established to cars should not be operated. 5
meet the terrain and conditions of
the course they are used on. GOLF COURSE HAZARD
The information contained here is PREVENTION 6
intended for golf course personnel The following golf course hazards
responsible for golf car safety. If you must be made safe:
are responsible for the operation l Steep Grades. Where steep 7
and maintenance of this golf car, we grades exist, restrict golf cars to
encourage you to implement this designated golf car pathways
golf car safety program. where possible. In addition,
identify steep grades with a 8
DRIVER suitable warning like:
QUALIFICATIONS 9
Allow only authorized people to Descend steep grades slowly with
operate golf cars. It is recommended foot on brake. Death or serious per-
that only people who possess a sonal injury can result from failing
valid motor vehicle driver’s license to comply with the safety and warn- 10
be allowed to operate golf cars. ing instructions affixed to the golf
car or utility vehicle.
Place operation and safety 11
instructions recommended by the l Sharp Turns, Blind Corners,
golf car manufacturer, along with Bridge Approaches. Chain or
the golf course safety rules, in a rope off these potentially
conspicuous place near the golf car hazardous areas or identify them
rental area or golf car pick-up area. with a suitable warning describing
It is also recommended that the the nature of the hazard and the
following warning be posted in a proper precautions to be taken to
conspicuous location: avoid the hazard.

JW8 4-1
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 14

! SAFETY CONSIDERATIONS
l Wet Areas. Wet grass may cause l Personnel. Allow only qualified,
1 a golf car to lose traction and may trained, and authorized personnel
affect stability. Golf car operators to inspect, adjust and maintain golf
should reduce speed in wet areas cars.
or during periods of inclement
2 weather. l Parts and Materials. Use only
replacement parts and materials
l Loose Terrain. Loose terrain may recommended by the manufacturer.
3 cause a golf car to lose traction
and may affect stability. Repair l Ventilation. Properly ventilate all
loose terrain, chain or rope off maintenance and storage areas in
these areas, or identify loose accordance with applicable fire
4 terrain with a suitable warning. codes and ordinances to avoid fire
hazards. Ventilation is required to
l Golf Car and Pedestrian remove flammable vapors and
Interference. Reroute golf car fumes from gasoline powered car
5 traffic or pedestrian traffic in storage areas. Ventilation is also
congested areas wherever possible required to remove hydrogen gas
to prevent accidents. If it is from the car storage areas during
impractical to reroute traffic, erect the battery charging process.
6 warning signs to warn pedestrians
of golf car traffic, and to warn golf
car operators to drive slowly, use
7 caution and watch for pedestrians.

8 MAINTENANCE
REQUIRED FOR GOLF
CAR SAFETY
9 Practice the following to help ensure
the safety of golf car operators:

10 l Preventative Maintenance.
Perform all scheduled
maintenance in accordance with
manufacturer’s recommendations
11 to provide the golfing patron with a
safe, properly operating golf car.

4-2 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 15

! SAFETY CONSIDERATIONS
SAFETY PRECAUTIONS l Record all maintenance performed
in a maintenance record log by 1
DURING MAINTENANCE date, name of person performing
When performing maintenance, follow maintenance and type of
all safety instructions contained in the maintenance. Periodically inspect
maintenance log to ensure 2
manufacturer’s operation and service
manuals, as well as the following accurate and complete entries.
safety procedures: l Provide operator comment cards
l Properly immobilize golf car before to assist in identifying non-periodic 3
beginning any maintenance to avoid maintenance needs for specific
any unexpected vehicle movement. golf cars.

l Properly block chassis before

l Maintain in a legible condition all 4
working underneath golf car to avoid nameplates, warnings, and
any unexpected vehicle movement. instructions provided by the
manufacturer.
l Before disconnecting any part of the
l If new nameplates, warnings or
5
fuel system, drain the applicable part
of the system to prevent fuel leaks. instructions are needed, contact
your Yamaha Golf-Car Company
l When working on the fuel system or dealer. 6
the battery, do not smoke, or allow
any sparks or open flames near
the vehicle, to avoid any fires or FUEL HANDLING/
explosions.
STORAGE AND 7
Before performing any maintenance,
l
disable the car’s electrical system in
BATTERY CHARGING
accordance with the manufacturer’s Take the following precautions to 8
instructions. ensure maintenance worker safety:
l Use only properly insulated tools l Supervise the storage and
when working around batteries to handling of liquid fuels in
avoid electrical shock or damage to accordance with applicable fire
9
the electrical system. and safety requirements to avoid
l Maintain all safety devices, includ- any fires or explosions.
ing brakes, steering mechanisms, l Only use battery charging facilities 10
warning devices and governors, in a and procedures that are in
safe operating condition. Do not accordance with applicable
modify these safety devices as ordinances and regulations to
supplied by the manufacturer. avoid explosions, electrical shock
11
l After each maintenance or repair, or damage to the electrical system.
the car must be driven by a l Periodically inspect fueling to be
qualified, trained and authorized certain that applicable safety
person – in an area free of codes, regulations and
pedestrian traffic – to ensure proper procedures are being followed to
operation and adjustment. avoid any fires or explosions.

JW8 4-3
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 16

CONTROLS
FEATURES a Front body
4
1 b Front tire
1 Brake pedal c Front bumper
6 2 Parking brake d Battery
2 pedal e Rear body
3 5 3 Accelerator f Rear tire
pedal g Rear bumper
4 Steering wheel h Fuel tank
3 5 Oil warning i Fuel cap
light j Fuel shutoff
2 1
Y-916g
6 Main switch valve
4 7 Drive select k Fuel tank vent
lever (California
8 8 Choke knob models only)
9 Seat
5
7

6
Y-903aa 14
7 13

9
8
10 16 15
Y-919f

9
8
7
10 11
12 Y-918e 18

11 19 20

17
Y-1990d

5-1 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 17

CONTROLS
MAIN SWITCH
1
The main switch controls the
following items:

OFF “OFF” 2
ON All electrical circuits are switched off.
The key can be removed only in this
position. 3

4
Y-912bb

OFF “ON” 5
ON Electrical circuits are switched on.
The golf car can be driven.
6

7
Y-911aa

OFF OIL WARNING LIGHT 8

ON
When the engine oil level falls below
an acceptable level, this light comes
on. 9

Y-914c
NOTICE 10
If the light comes on, stop the
engine, check the engine oil level
and add oil as necessary. Engine 11
damage can result from low
engine oil levels. (See page 6-3).

å Oil warning light

JW8 5-2
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 18

CONTROLS
DRIVE SELECT LEVER
1
The drive select lever is used to shift
the golf car into forward or reverse.
After coming to a complete stop,
2 move the lever to the desired
position.

3 Y-18
Lever Position Car Movement
F FORWARD
R REVERSE
4
TIP
The reverse alarm will sound when
5 BEEP the drive select lever is turned to “R.”

6
Y-920

7
A
ACCELERATOR PEDAL
8
The accelerator pedal controls the
golf car’s speed.
9 Action Car Speed
Y-20A Depress pedal Increase
Release pedal Decrease
10
å Accelerator pedal

11 BRAKE PEDAL
Press down on the brake pedal to
stop the golf car.

B ∫ Brake pedal
Y-21a

5-3 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 19

CONTROLS
PARKING BRAKE
PEDAL 1
Press down on the parking brake
pedal whenever parking the golf car. 2
C ç Parking brake pedal
Y-22a
TIP 3
Release the parking brake by
depressing the accelerator pedal.
4

The parking brake will automatically 5

release when the accelerator pedal
is depressed. If the main switch is
in the “ON” position, depressing
the accelerator may suddenly 6
cause the golf car to move. Death
or serious personal injury can
result from failing to comply with
the safety instructions in this 7
A manual.

8
CHOKE KNOB
Pull and hold out choke knob when
starting a cold engine. Release the 9
knob after the engine starts.
Y-903
å Choke knob
Clockwise/closed
10
FUEL SHUTOFF VALVE
A
Ensure the fuel shutoff valve is in
the “OPEN” position for normal 11
operation.

å Fuel shutoff valve

Counterclockwise/open
Y-1572

JW8 5-4
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 20

PRE-OPERATION CHECKS
Pre-operation checks should be
1 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
2 nature.

3
To keep car from moving while
performing pre-operation checks:
l Remove main switch key.
4 l Apply parking brake.
Death or serious personal injury
can result from failing to comply
5 with the safety instructions in this
manual.

6 PRE-OPERATION
CHECKLIST
Before each use check the following:
7
4 Fuel system
4 Engine oil level
8 4 Battery
4 Tire condition
4 Steering system
9 4 Reverse alarm
4 Pedal operation
4 Body and chassis
10
SEAT
Open the seat for checking and
11 servicing.

Y-905

6-1 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 21

PRE-OPERATION CHECKS
FUEL SYSTEM
Make sure there is sufficient fuel in
1
the tank and that the fuel shutoff
B valve is open. Also check fuel line
and connections for leakage. 2
å Fuel tank
C D ∫ Fuel cap
ç Fuel shutoff valve
A ∂ Fuel tank vent 3
Y-1990b

Gasoline and its vapors are highly 4

flammable and explosive. To avoid
fires and explosions and to reduce
the risk of injury when refueling,
follow these instructions. 5
1. Stop engine and allow it to
cool for several minutes
before refueling. 6
Do not smoke when refueling
and keep away from sparks,
flames or other sources of 7
ignition.
Refuel in a well-ventilated area.
2. Take care not to spill gasoline.
If gasoline spills, wipe it up 8
immediately with dry rags.
Always dispose of gasoline-
soaked rags properly.
3. Tighten the filler cap securely
9
after refueling.

Recommended fuel:
10
Unleaded gasoline Gasoline is poisonous and can
cause injury or death. If you
swallow gasoline, inhale a lot of
Fuel tank capacity:
gasoline vapor or get gasoline in 11
22.0 L (5.8 US gal) your eyes, get immediate medical
attention.
Gasoline-based fuels containing
more than 10% ethanol are not If any gasoline gets on your skin,
recommended and may void the immediately wash with soap and
warranty. water. Change clothing if gasoline
spills on it.

JW8 6-2
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 22

PRE-OPERATION CHECKS

1 NOTICE
Avoid using gasoline blended with
methyl alcohol which can damage
fuel system parts.
2
ENGINE OIL
3 With the golf car parked on level
ground, remove the dipstick and
make sure the engine oil is between
the MIN and MAX marks (the
4 crosshatched area on the end of the
Y-514 dipstick).
å Oil level dipstick
5 B ∫ Maximum oil level
ç Safe operating range
MIN MAX If the oil level is below the MIN mark
6 on the dipstick, add oil through the
C oil filler hole until the oil level is
A between the MIN and MAX marks.
7 Y-28
å Oil filler hole

A NOTICE
8 Engine damage can result.
l Use care not to fill past the MAX
dipstick mark, and be sure no
foreign material enters the
9 crankcase.
l Use care not to get oil on the
starter belt.
Y-515
10
TIP
Recommended oil:
YAMALUBE 4-cycle oil or 10W30 The distance between the dipstick
marks represents approx. 1/2 L
11 (1/2 US qt) of oil.
Engine oil capacity:
1.0 L, 1000 cc
(1.0 US qt) TIP
Recommended engine oil
Oil change quantity: classification: API Service SE, SF, or
1.0 L, 1000 cc SG. Engine oils labeled “Energy
(1.0 US qt) Conserving II” are recommended.

6-3 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 23

PRE-OPERATION CHECKS
Engine Cooling Inlet Duct
1
Check the engine cooling inlet duct
for debris. Remove any debris
present.
2
å Engine cooling inlet duct

BATTERY
A
Check that the battery is held securely
3
Y-1347
in place to prevent the battery from
being damaged from vibration or
jarring. Also check that no battery caps 4
are missing to prevent battery acid
from spilling from the battery. Check
the battery terminals for corrosion.
5
Battery electrolyte is poisonous
and dangerous, causing severe 6
burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes
or clothing. Ventilate when charg-
ing or using in enclosed space. 7
Always shield eyes when working
near batteries. KEEP OUT OF
REACH OF CHILDREN.
8
TIRE CONDITION
Tire Air Pressure 9
Check the tire air pressure before
operating the golf car.

Tire pressure: 10
110 kPa, 1.1 kgf/cm2 (16 psi)
Y-30

Tire Wear Limit 11

A Check the tire surface for damage,
cracks or embedded objects. When
tire tread wears down to 1 mm
(0.04 in.), replace the tire.
å Wear limit

Y-31

JW8 6-4
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 24

PRE-OPERATION CHECKS
STEERING SYSTEM
1
Check the steering system for exces-
sive free play by:
2 l moving the steering wheel up and
down, and back and forth.
l turning the steering wheel slightly
3 to the right and left.
If you feel excessive free play, or
Y-932 hear rattling sounds which may
4 indicate loose steering components,
consult a Yamaha dealer.

5 REVERSE ALARM
Check the reverse alarm by moving
the drive select lever to “R” for
6 reverse. The alarm should sound.

PEDAL OPERATION
7 Y-33
Check the following pedal controls
for proper operation. If a pedal does
not work properly, consult a Yamaha
8 dealer.

Accelerator Pedal
9
A

Make sure the main switch is in

10 the “OFF” position.

Make sure the accelerator pedal

11 operates smoothly.
Y-20A

å Accelerator pedal

6-5 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 25

PRE-OPERATION CHECKS
Brake Pedal
1
Make sure the brake pedal feels firm
when pressed and returns to its
original position when released.
2
∫ Brake pedal
B
Y-21a Parking Brake Pedal 3
Make sure the parking brake pedal
locks in place with a positive click,
and releases when the accelerator 4
pedal is pressed.

ç Parking brake pedal

5
TIP
Release the parking brake by
C depressing the accelerator pedal. 6
Y-22a

7
BODY AND CHASSIS
Before each use, visually inspect
the golf car body and chassis for 8
damage and/or missing parts.

10

11

JW8 6-6
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 26

OPERATION
STARTING
1
1. With the parking brake applied,
turn the drive select lever to “F” for
forward, or “R” for reverse.
2
NOTICE
Do not shift from “F” forward to
3 Y-18 “R” reverse while the golf car is
moving. Transmission damage
can result.
OFF
4 ON
2. Turn the main switch to “ON.”

5 Do not depress the accelerator

pedal when turning on the main
switch or the golf car may start
6 Y-911aa moving unexpectedly. Death or
serious personal injury can result
from failing to comply with the
safety instructions in this manual.
7 A
3. Pull the choke knob out and hold it
while starting. Release the choke
knob after the engine starts.
8
å Choke knob

9 Y-903
TIP
The choke is not required when the
engine is warm.
10 B 4. Check that your path is clear in the
direction you plan to go, and slow-
ly depress the accelerator pedal.
11 The golf car will start to move.

∫ Accelerator pedal

Y-20B TIP
The parking brake automatically
releases when the accelerator pedal
is depressed.

7-1 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 27

OPERATION
STOPPING
1
To stop the golf car, gradually press
down on the brake pedal.

å Brake pedal 2
When the car has come to a stop,
B apply the parking brake pedal and 3
turn the main switch to “OFF.”

∫ Parking brake pedal

4
NOTICE
A
Y-65c
Do not hold the golf car on an
incline with the accelerator – use 5
the brake. Transmission damage
can result.
6

10

11

JW8 7-2
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 28

MAINTENANCE
PERIODIC MAINTENANCE CHARTS
1
Regular maintenance is required for the best performance and safe operation of
your golf car.

2
Be sure to turn off the main switch and apply the parking brake when you per-
form maintenance, unless otherwise specified. If the owner is not familiar with
servicing the machine, death or serious personal injury can result. When in
3 doubt the work should be done by a Yamaha dealer or other qualified mechanic.

CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
40 Rounds 250 rds 500 rds 1000 rds 2000 rds
4 Remarks
Daily
Pre-
20 hours
100 miles
125 hrs
600 mls
250 hrs
1200 mls
500 hrs
2500 mls
1000 hrs
5000mls
Opera- 160 kms 1000 kms 2000 kms 4000 kms 8000 kms
tion (Every (Every 6 (Every (Every (Every
month) months) year) 2 years) 4 years) Page

5 PRE-OP Check engine oil CS CS CS 6-3

Check air cooling duct CS CS CS CS CS CS *
Check fuel lines for leakage CS CS CS CS CS CS 6-2
Check fuel level CS CS CS CS CS CS 6-2
6 Check for looseness
and corrosion of battery CS CS CS CS CS CS 6-4
terminals and hold downs
Check brake pedal free play
7 and adjust if necessary CS CA CA CA CA CA 8-13
Check steering operation CS CS CS CS CS 6-5
Check tire pressure, tread
depth, tire surface for damage CS CA CA CA CA CA 6-4
8 Check body and chassis for
damage CS CS CS CS CS CS 6-6
Check tightness of all bolts,
CS CS CS CS CS CS *
nuts, screws and rivets
9 Check reverse alarm
operation CS CS CS CS CS CS 6-5
EVERY Check fuel filter for clogging CS CS CS CS CS *
10 MONTH
Check wear of drive belt CS CS CS CS CS
8-7/
8-8
Check operation of
Forward / Reverse shifting CS CS CS CS CS 7-1

11 Clean / Lube pedal control area CL *

EVERY 6 Wash pre-filter, check air 8-6/
MONTHS cleaner element S S S S
8-7
Check spark plug and plug cap
condition** / Check compression CS CS CS CS 8-4

Check shock absorbers for oil

CS CS CS *
leaks and damaged springs
* 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.
**Related to emission control system.
8-1 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 29

MAINTENANCE

1
CS - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE
40 Rounds 250 rds 500 rds 1000 rds 2000 rds
Daily 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs
Remarks Pre-
Opera-
100 miles
160 kms
600 mls
1000 kms
1200 mls
2000 kms
2500 mls
4000 kms
5000mls
8000 kms
2
tion (Every (Every 6 (Every (Every (Every
month) months) year) 2 years) 4 years) Page

EVERY Replace engine oil R R R 8-5

YEAR Adjust throttle cables,** 3
choke cable, check carburetor CA CA CA *
throttle shaft for wear**
Check starter V-belt for
CS CS CS *
damage and tension 4
Check drive belt for slippage,
wear or scratches CS CS CS 8-7

Check operation of speed limiter CS CS CS *

Apply battery terminal protectant S S S * 5
Check wiring connections
and insulation CS CS CS *
Check rear axle bearing play
for roughness or freeplay
CS CS CS * 6
Check steering knuckle
bushing free play / Adjust CA CA CA *
wheel alignment
Check wheel nut tightness, 7
front wheel bearing play CS CS CS *

Check transaxle oil level and

CS CS CS 8-10
inspect for leakage
Check operation and adjust 8
pedal stop if necessary CA CA CA *

EVERY Check brushes for wear and

CS S *
2 YEARS commutator for dirt
Replace transaxle oil R *
9
EVERY Replace fuel filter and
R *
4 YEARS fuel hoses
Check tightness of cylinder
head / Adjust valves CA * 10
Inspect internal wet brake and
CS R *
replace pads if necessary

* Items without a page number reference should be serviced by a Yamaha dealer or other qualified
11
mechanic. This manual does not contain these procedures. They are contained in the Service Manual.
**Related to emission control system.

JW8 8-2
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 30

MAINTENANCE
EXHAUST EMISSION CONTROL SYSTEM
1 AND COMPONENTS
Item Abbreviation
2 • CARB. ASSY., LH., JT., CARB (Carburetor)
CARBURETOR 2 & JT.,
CARBURETOR 1
3 • T.C.I. MAGNETO ASSY. & El (Electronic Ignition)
PLUG, SPARK
• CRANKCASE 1 & HEAD, PCV (Positive Crankcase
CYLINDER 1 Ventilation)
4
• AIR FILTER ASSY. ACL (Air Cleaner)
• MUFF. ASSY., 1 MUFF., 2
5 • CARBON CANISTER CC
• INVERSION VALVE IV

6
The above items and the TROUBLESHOOTING
corresponding abbreviations are
7 provided in accordance with U.S. If the vehicle’s engine won’t start,
EPA REGULATIONS FOR SMALL use the following chart:
NONROAD ENGINES and the
CALIFORNIA REGULATIONS FOR Cause Remedy
8 NEW 1995 AND LATER OFF- Fuel System
HIGHWAY RECREATIONAL No fuel in tank Fill fuel tank
VEHICLES AND ENGINES. Fuel shutoff valve Open fuel shutoff
9 closed valve
The abbreviations conform to the
Clogged fuel Clean fuel line –
latest version of the SAE’s recom- line Consult Yamaha
mended practice document J1930, dealer
10 “Diagnostic Acronyms, Terms, and
Foreign matter Clean fuel filter –
Definitions For Electrical/Electronic in fuel filter Consult Yamaha
System”. dealer
Clogged Clean carburetor –
11 It is recommended that these items carburetor Consult Yamaha
be serviced by a Yamaha dealer or dealer
other qualified mechanic.
Electrical System
Spark plug dirty Clean carbon or
with carbon, or wipe spark plug
wet dry
Faulty ignition Consult Yamaha
system dealer

8-3 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 31

MAINTENANCE
Spark Plug Inspection 1
You should periodically remove and
inspect the spark plug. Dirty or
worn spark plugs can cause poor
performance. 2

When removing or installing the 3

spark plug, be careful not to
damage the insulator. A damaged
insulator could allow external 4
sparks, which could lead to
explosion or fire. Death or serious
personal injury can result from
failing to comply with the safety 5
instructions in this manual.

å Spark plug 6
∫ Spark plug cap
1. Check for discoloration and
remove carbon deposits with a 7
spark plug cleaner or wire
B
brush. The normal electrode
color will be tan.
2. Check the spark plug type, and 8
A
Y-516 check the spark plug gap with a
feeler gauge.

Standard spark plug:

9
BPR2ES
Spark plug gap:
0.7 ˜ 0.8 mm (0.028 ˜ 0.031 in.) 10
å Gap
3. Clean the gasket and plug 11
surfaces and install the spark
A plug finger-tight before tightening
to the following torque:

Spark plug torque:

20 Nm, 2.0 m.kg
Y-37
(14.5 ft.lb)

JW8 8-4
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 32

MAINTENANCE
Engine Oil Replacement
1
1. Warm up the engine for several
minutes, place the golf car on a
level surface, then stop the engine.
2

3 Use caution not to touch hot

engine oil or hot engine parts,
during the following procedure.
Death or serious personal injury
4 can result from failing to comply
with the safety instructions in this
manual.
5 2. Place an oil pan under the
engine drain plug.

3. Remove the oil drain plug and let

6 the oil drain completely.

TIP
7 Dispose of used oil in an
environmentally safe way, such as
Y-624
taking oil to an oil collection station.
8 4. Install the drain plug, along with
a new drain plug gasket, finger-
tight before tightening to the
9 following torque:
Recommended oil:
YAMALUBE 4-cycle oil or 10W30 Drain plug torque:
31 Nm, 3.1 m.kg
10 Engine oil capacity: (23 ft.lb)
1.0 L, 1000 cc
(1.0 US qt) 5. Add the correct quantity of oil
through the oil filler hole.
11 Oil change quantity:
1.0 L, 1000 cc TIP
(1.0 US qt) Recommended engine oil
classification: API Service SE, SF, or
SG. Engine oils labeled “Energy
Conserving II” are recommended.

8-5 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 33

MAINTENANCE
å Oil filler hole
A 1
NOTICE
Use care not to fill past the MAX
dipstick mark, and be sure no 2
foreign material enters the
crankcase. Serious engine
damage can result. 3
Y-515
After replacing engine oil, check for
oil leaks around the drain plug. If oil
leaks are found, consult a Yamaha 4
dealer.

A
Air Filter 5
B To remove the air filter elements:
A
1. Unlatch the air filter cover clips 6
and remove cover.
A
å Air filter cover clips
∫ Air filter cover 7
Y-518

2. Lift the air filter and pre-filter out

of the air filter case. 8
ç Air filter
∂ Pre-filter
9
C
NOTICE
Be careful not to drop anything 10
D into the air inlet. Serious engine
Y-519a damage can result.

11

JW8 8-6
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 34

MAINTENANCE
Inspection and cleaning:
1
3. Wash the foam pre-filter in soap
B and water. Allow it to dry.
A
2 å Soap and water
∫ Foam element

3 4. Check the filter element. If

damaged or dirty, replace it.

Y-508
4 NOTICE
Do not wring out the foam
pre-filter, this could cause it to
tear.
5
5. To replace the elements,
reverse the above steps.
6
NOTICE
The pre-filter has a notch on one
7 side. It will only fit in the case one
way. Serious engine damage can
result from an improperly posi-
8 tioned filter.

9 Drive Belt
To remove the drive belt:

10 1. Set the drive select lever halfway

between forward and reverse.

2. Pull up on the drive belt and

11 push it outward over the edge of
the secondary sheave.

3. Turn the secondary sheave

clockwise and the drive belt will
Y-60 roll off the sheave.

4. Remove the drive belt from the

primary sheave.
8-7 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 35

MAINTENANCE
Inspection:
To inspect the drive belt, check for 1
frayed edges or tears, and measure
A drive belt against the following
specification. If the belt shows 2
B excessive wear or damage, replace
the belt with a new one.
å New: 31.0 mm (1.20 in.)
∫ Replace when belt reaches: 3
27.0 mm (1.06 in.)
Y-44
5. To install the drive belt, reverse
the above steps, rolling the belt 4
back over the secondary sheave.

Battery 5
The 12-volt battery that provides
starting power to your gas car
normally does not require the
++ addition of water. If the battery loses 6
its charge, have an experienced
mechanic charge it.
– –

7
Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid 8
contact with skin, eyes, or clothing.
Antidote:
EXTERNAL: Flush with water.
Y-45
INTERNAL: Drink large quantities of 9
water or milk. Follow with milk of
magnesia, beaten egg, or
vegetable oil. Call physician imme-
diately. 10
EYES: Flush with water for 15
minutes and get prompt medical
attention. 11
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.
JW8 8-8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 36

MAINTENANCE

1 Fuse Replacement

Be sure to use the specified fuse.

2 Using a wrong fuse can cause
electrical system damage and
create a fire hazard. Death or
serious personal injury can result
3 from failing to comply with the
safety instructions in this
manual.
4
NOTICE
When replacing a fuse, be sure
5 the main switch is turned off to
prevent accidental short-circuiting
and electrical system damage.
6
1. Locate the in-line fuse holder on
the main wire harness adjacent to
the battery.
7
2. Pull fuse holder cover off.

3. Pull fuse out, inspect and replace

8 if necessary.

B A å Fuse holder
Y-523a
9 ∫ Fuse

Fuse Type:
10 10 Amp, Blade Style

11

8-9 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 37

MAINTENANCE
Transaxle Oil 1
To check transaxle oil level:
1. Place the golf car on a flat, level
surface.
2
2. Remove seven plastic rivets 1
and two bolts 2, and remove the
1 3 bag holder insert.
3
3. Place an oil pan under the
2
transaxle case.
4. Clean area around servicing plug 4. 4
5. Using an 8 mm hex wrench,
remove transaxle oil servicing
Y-1994
plug located on the rear of the 5
transaxle case.
6. Transaxle oil should be at the top
4
of the oil servicing hole or just 6
beginning to run out of hole.
NOTICE
Do not allow foreign material to 7
enter transaxle. Serious transaxle
damage can result.
Y-1213 8
7. If needed, add Yamalube Friction
Modified Shaft Drive Gear Oil until
it is at the top of the plug hole or
just beginning to run out of servic- 9
ing hole.
TIP
The YDRA Golf Car is equipped with 10
an internal wet brake. Use of oil other
than Yamalube Friction Modified Shaft
Drive Gear Oil will cause brake noise.
11
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.

JW8 8-10
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 38

MAINTENANCE
TIP
1 For transaxle oil replacement, con-
sult a Yamaha dealer or other quali-
fied mechanic.
2 NOTICE
Before performing wheel or brake
maintenance, verify that the main
3 switch is in the “OFF” position.
Serious transaxle damage can result.

4 Wheel Replacement
Y-57
To remove and install a wheel on
your golf car:
5 1. With the wheels blocked to
prevent the golf car from moving,
loosen the wheel nuts.
6 2. Elevate the golf car with a jack
and remove the wheel nuts and
the wheel.
7 3. Reverse the removal steps when
installing the wheel.
Wheel nut tightening torque:
8 88 Nm, 8.8 m.kg (65 ft.lb)

Brake Adjustment
9 The brakes on your golf car are
self-adjusting.

Before you operate the car, press

10 down on the brake pedal several
times to make sure the brakes are
functioning properly.

11
Consult your Yamaha dealer before
using your golf car if you suspect
brake problems. Death or serious
personal injury can result from fail-
ing to comply with the safety
instructions in this manual.

8-11 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 39

MAINTENANCE
Brake Pedal Free Play
Adjustment 1
NOTICE
Before adjusting brake pedal free 2
play, pump the brake pedal several
times to self-adjust the brakes.

To adjust the brake pedal free play:

3

1. Remove the floor mat and

service lid from the floor of the 4
golf car.

Y-61c
2. Check the brake pedal free play 6
by pressing against the pedal
with two fingers (using light
force) and measuring the 7
distance the pedal travels before
a 17
18
resistance is felt.
16
15
14
13
12
11

7
8
9
10

8
Brake pedal free play Å:
45-50 mm (1.77-1.96 in.)
9
Y-62b 3. If the free play distance needs
adjusting, loosen the lock nut å
(under rubber boot) and turn the 10
A B
adjusting nut ∫ in or out until the
free play specification is met.
Then tighten the lock nut in place.
11
NOTICE
Do not over-tighten the brake
cables. Over-tightening will
Y-909D increase brake wear and affect
overall performance of car.
Premature brake wear can result.

JW8 8-12
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 40

STORAGE
Perform the following preparations 1. Fill the fuel tank with fresh fuel
1 when storing your golf car for and add the specified amount of
extended periods of time: Yamaha Fuel Stabilizer and
Conditioner or equivalent
TIP product. Operate the vehicle for
2 Turn main switch key to “OFF” at least five minutes to distribute
position, remove key, and store key treated fuel through the fuel
in a safe place. system.
3 å Float bowl drain screw
DRAINING FUEL
2. Turn the fuel shutoff valve to the
“CLOSED” position.
4
Gasoline and its vapors are highly 3. Drain the carburetor float
flammable and explosive. Death chamber into a clean container by
or serious personal injury can loosening the drain bolt; this will
5 result from failing to comply with help prevent fuel deposits from
the safety instructions in this building up. Pour the drained fuel
manual. into the fuel tank.
6 l Do not smoke when draining
fuel and keep away from sparks,
flames, or other sources of
ignition.
7 l Stop engine and allow it to cool A
for several minutes before
draining fuel.
l Drain fuel in a well-ventilated
8 area.
l Take care not to spill gasoline. Y-521
If gasoline spills, wipe it up
9 immediately with dry rags. Specified amount:
Always dispose of gasoline-
soaked rags properly. 7.5 cc of stabilizer for each liter of
l Tighten the filler cap securely fuel (1 oz. of stabilizer for each
10 after checking fuel level to gallon of fuel)
avoid leaking.
l If you inhale a lot of gasoline
vapor, or get gasoline in your TIP
11 eyes, get immediate medical Use of fuel stabilizer and conditioner
attention. eliminates the need to drain the fuel
l If any gasoline gets on your system. Consult a Yamaha dealer if
skin, immediately wash with the fuel system needs to be drained
soap and water. Change instead.
clothing if gasoline spills on it
to avoid potential fire hazard.

9-1 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 41

STORAGE
ENGINE PREPARATION 2. Have the battery recharged
every 60-90 days to keep it fully 1
With the key removed and the spark charged. The battery must be
plug lead disconnected, turn the kept fully charged to avoid
clutch by hand until compression is damage.
felt. This puts the valves in the 2
closed position. 3. Batteries like the one supplied
with your car normally do not
CHASSIS require you to check the water 3
PREPARATION level inside the battery for the
one-year warranty period provid-
1. Verify the tire pressure is set to ed by the manufacturer.
110 kPa, 1.1 kgf/cm2 (16 psi). 4
2. Clean exterior of the golf car and
apply a rust inhibitor. NOTICE
Do not allow cleaning solution to 5
3. Cover the golf car with a enter battery cells. Serious bat-
breathable cover and store it in a tery damage can result.
dry, well-ventilated area.
6
4. Clean the top of the battery with
BATTERY a solution of baking soda and
PREPARATION water, as necessary, to remove
corrosion. 7
1. Remove the battery from the golf
car and store it in a cool, dry
place that stays between 0°C
(32°F) and 30°C (90°F).
8

10

11

JW8 9-2
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 42

SPECIFICATIONS
GENERAL SPECIFICATIONS
1
Items YDRA
Dimensions:
2 Overall length 2395 mm (94.3 in.)
Overall width 1200 mm (47.2 in.)
Overall height (steering height) 1190 mm (46.9 in.)
Height of floor 310 mm (12.2 in.)
3 Wheelbase 1640 mm (64.6 in.)
Tread:
Front 870 mm (34.3 in.)
4 Rear 980 mm (38.6 in.)
Minimum ground clearance 110 mm (4.3 in.)
Weight:
5 Dry weight (with suntop,
without battery) 276 kg (609 lb)
Performance:
6 Factory speed setting 19 km/h (12 mph)
Maximum speed 24 km/h (15 mph)
Minimum turning radius 2.8 m (9.2 ft)
7 Seating capacity Two occupants per seat,
four occupants maximum

Fuel Tank Capacity 22.0 L (5.8 U.S. Gallons)

8
PAINT CODES
9 Name Ditzler Number
Glacier 918519
Emerald 48748
10 Garnet 701739
Tanzanite 917834
Onyx Metallic 918520
Anthracite Metallic 918522
11 Sandstone Metallic 918523

10-1 JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 43

SPECIFICATIONS
ENGINE 1
Items YDRA
Description:
Engine type 4-stroke, Gasoline, 60i incline OHV 2
Number of cylinders Single
Displacement 357 cm3
Bore x stroke 85 x 63 mm (3.30 x 2.48 in.)
Compression ratio 8.1:1
3
Rated output 8.5 kw (11.4 hp)/3500 rpm
Cooling system Forced air-cooled
Starting system Starter 4
Ignition system TCI Magneto
Spark plug type BPR2ES
Spark plug gap 0.7-0.8 mm (0.028-0.031 in.) 5
Lubrication system Splash-style positive oil lubrication
Engine oil type YAMALUBE 4-cycle oil or 10W30
Engine oil capacity 1.0 L, 1000 cc (1.0 US qt)
Oil change quantity 1.0 L, 1000 cc (1.0 US qt) 6

TRANSMISSION 7
Items YDRA
Transmission: 8
Type V-belt automatic centrifugal engagement
V-belt width and outer line length 31.0 x 1010 mm (1.20 x 39.76 in.)
V-belt wear limit 27.0 mm (1.06 in.)
9
Governor:
Type Oil bath flyweight
Factory speed setting 19 km/h (12 mph)
10
Differential/reduction gear:
Differential type Bevel gear
Lubricant/capacity Yamalube Friction Modified Shaft Drive
Gear Oil / 1750 mL (1.85 quarts total). 11
Alternative lubricant is mixture of
1660 mL (1.75 quarts) 80W90 Gear Oil
and 90 mL (0.10 quarts) API G15
Limited Slip Additive.

JW8 10-2
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 44

SPECIFICATIONS

1 BATTERIES
Items YDRA
Battery: BCI group 24,
2 RC: minimum 75 min
CCA: minimum 400A

3
CHASSIS
Items YDRA
4 Steering system:
Type Rack and Pinion
Steering angle (L.H.) 1.85 turn
5 Steering angle (R.H.) 1.85 turn
Brakes:
Brake system Mechanical
Type of brake Maintenance-Free internal transaxle disc brake
6
Brake pedal free play linkage
adjustment 45-50 mm
(1.77-1.96 in.)
7 (Brake cable end play) 0.1-0.5 mm (0.004-0.02 in.)
Parking brake:
Type Foot type; parking brake with automatic
8 release.
Release timing
(With pedal segment in second
9 notch)
(Bolt heads round parallel to arm) 0.0 ~ 0.3 mm (0.000 ~ 0.001 in.)
Wheel:
10 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
11 Tire pressure: 110 kPa, 1.1 kgf/cm2 (16 psi)

10-3 JW8
JW8
BODY EARTH B
ENG. STOP
RELAY
B B B ENG. EARTH
BUZZER
P RL RL

BACK REV R R R R
SWITCH B P RW L
FWD B P
B B

METER PIN-OUT COLOR

1 BATTERY+ R
B RW L B 2 BATTERY- B
B L 3 ENABLED RW
4 NOT USED
B B TCI
L L

RW RW RW RW R B RW
ACCEL SW.
Br Br Br Br

JW1-H2386-10
RY RW
OFF OPTIONAL
ON HOUR METER
YDRA WIRING DIAGRAM

MAIN SW.
R Br Br R
R
Br
B RW
PILOT LAMP G G G
BR JW8-H2590-10
(12V3.4W) Y BR
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 45

DETAIL A

R
DETAIL A BR ENG. EARTH
G RW B
RW G
RW G
RW B RW G OIL LEVEL GAUGE
B
R G

R R G
BLADE FUSE (10A)-ATC

B
VOLTAGE
REGULATOR

B
BATTERY
RELAY STARTER GENERATOR Y-940i
WIRING

11-1
9
8
7
6
5
4
3
2
1

11
10
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 46

NOTES

10

11

JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 47

NOTES

10

11

JW8
JW8-F8199-21_LIT_19626_16_05.qxd 9/18/12 11:12 AM Page 48

NOTES

10

11

JW8
JW8-F8199-21_cover_LIT_19626_11_07 cover.qxd 9/18/12 11:14 AM Page 1

OWNER’S / OPERATOR’S
MANUAL

READ THIS MANUAL CAREFULLY!

! It contains important safety information.

YDRA
4 STROKE GOLF CAR

Printed in U.S.A YAMAHA GOLF-CAR

2012-KCC COMPANY
1000 HWY 34 East LIT-19626-11-13 JW8-F8199-21
Newnan, GA 30265
JW8-F8199-21 770-254-4000