Yamaha YTF1 Owner'S/Operator'S Manual Download Page 49

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JW6

rake Pedal Free Play

djustment

efore 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
utility vehicle.

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

1.77-1.96 in. (45-50 mm)

3. If the free play distance needs

adjusting, loosen the lock nut

and turn the adjusting nut

∫

or out until the free play
specification is met. Then tighten
the lock nut in place.

Do not over-tighten the brake
cables. Over-tightening will
increase brake wear and affect
overall performance of vehicle.
Premature brake wear can result.

Y-61c

Y-909A

Y-62b

CAUTION

8-13

INTEN

NCE

Summary of Contents for YTF1

Page 1: ...UTILITY VEHICLE YTF1 LIT 19626 61 09 JW6 F8199 00 ...

Page 2: ......

Page 3: ...help you to obtain maximum enjoyment from your new Yamaha If you have any questions about the operation or maintenance of your utility vehicle please consult a Yamaha dealer YAMAHA GOLF CAR COMPANY YTF1 OWNERXS OPERATORXS MANUAL 2009 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 p...

Page 4: ...nd understand this manual completely before operating your utility vehicle Death or serious personal injury can result from failing to comply with the warning instructions in this manual NOTE 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 co...

Page 5: ...iii JW6 WARRANTY CONTENTS IMPORTANT LABELS SAFETY CONSIDERATIONS MAINTENANCE STORAGE SPECIFICATIONS WIRING OPERATION PRE OPERATION CHECKS CONTROLS OPERATOR SAFETY 1 2 4 8 9 11 7 6 5 3 10 ...

Page 6: ...nd the engine clutch system except drive belt and transaxle on gasoline powered vehicles SPECIFIC EXCLUSIONS 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 vehicle or charger to and from an authorized Ya...

Page 7: ...RUCTION LABELS Read the following labels carefully before operating your utility vehicle and promptly replace any labels which become damaged or removed Death or serious personal injury can result from failing to read and comply with the safety instruction labels Y 500b 1 9 8 7 11 Y 1674 ...

Page 8: ...outer d essence pendant que le moteur est chaud Ne pas modifier le système d alimetation Toute révision doit être faite chez le fournissuer ou par du personnel qualifié OPERATION AT HIGHER SPEEDS OPERATION AT HIGHER SPEEDS COULD CAUSE LOSS OF CONTROL COULD CAUSE LOSS OF CONTROL THAT COULD RESULT IN SEVERE THAT COULD RESULT IN SEVERE INJURY OR DEATH INJURY OR DEATH Do not tamper with Do not tamper ...

Page 9: ...CERTIFIED TO OPERATE ON UNLEADED GASOLINE DISPLACMENT 357cc EMISSIONCONTROLSYSTEM EM EVAPORATIVECODE COYMX34A MAINTENANCESPECIFICATIONS ENGINEOIL SAE10W30 IGNITIONTIMING 27BTDC SPARKPLUGGAP 028 031 NOOTHERADJUSTMENTSNEEDED The air index of this engine is 3 0 2 4 6 8 10 Most Clean Least Clean Note The lower the Air Index the less Pollution This engine is certified to be emissions compliant for the ...

Page 10: ...Y 1672a 7 Y 1671a 8 JW6 2 4 IMPORTANT LABELS 1 2 3 4 5 6 7 8 9 10 11 Y 1670a 9 ...

Page 11: ...Y 1610 a Y 1673a b JW6 2 5 IMPORTANT LABELS 1 2 3 4 5 6 7 8 9 10 11 ...

Page 12: ...he location shown The first three digits of the serial number are for model identification the remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha dealer The engine serial number is affixed in the location shown NOTE Y 852A ç Engine Information Y 1633 JWX 000000 A B C II III II III I III II I I I I SM 03 399 JW6 2 6 IMPORTA...

Page 13: ...ore than two occupants per seat This utility vehicle is restricted to two occupants Never carry passengers in the cargo bed Do not operate the utility vehicle while under the influence of alco hol or drugs their affect on vision and judgment make operating a utility vehicle dangerous Do not operate the utility vehicle on public streets roads or high ways unless allowed by law or local regulating a...

Page 14: ...ng the steering wheel too sharply at higher speeds Always drive slowly straight up or straight down slopes never at an angle Do not brake abruptly when carry ing loads in the cargo bed or when towing a trailer Do not run the engine indoors Exhaust gas is poisonous Do not make any modification or addition which affects capacity or safe operation or make any changes not in accordance with the ownerʑ...

Page 15: ...r along with the safety rules in a conspicu ous place near the utility vehicle stor age area It is also recommended that the following warning sign be posted in a conspicuous location Do not operate utility vehicles when under the influence of alco hol or drugs Death or serious personal injury can result from failing to comply with the warn ing instructions in this manual SAFETY SURVEY Perform saf...

Page 16: ...uality Accessories should be rigidly and securely mounted An accessory which can shift position or come off while you are operating could affect your ability to control the util ity vehicle Do not mount an accessory where it could interfere with your ability to control the utility vehicle Examples include but are not limited to an object that limits your ability to turn the steering wheel or one t...

Page 17: ...ch could lead to an accident Never exceed the stated load capacity for this utility vehicle Cargo should be properly distrib uted and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater distance for braking MAINTENANCE REQUIRED FOR UTILITY VEHICLE SAFETY Practice the following to help ensure the safety of utility vehicle operators Preventative Maintenance Perform ...

Page 18: ... operating condition Do not modify these safety devices as supplied by the manufacturer After each maintenance or repair the vehicle must be driven by a qualified trained and authorized person in an area free of pedestrian traffic to ensure proper operation and adjustment Record all maintenance performed in a maintenance record log by date name of person performing maintenance and type of maintena...

Page 19: ...brake pedal 3 Horn switch 4 Accelerator pedal 5 Steering wheel 6 Oil warning light 7 Main headlight switch 8 Drive selector switch 9 Choke knob a Seat b Front cowl c Front tire d Front bumper e Battery f Rear cowl g Fuel shutoff valve h Fuel cap i Rear tire j Headlights k Taillights l Cargo box m Tailgate n Trailer hitch o Cargo bed release lever Y 1716 16 17 ...

Page 20: ... level surface This vehicle is recommended only for operators 16 or older with a valid motor vehicle license Adults must supervise use by minors Check state laws for minimum age restrictions LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Improper use can result in SEVERE INJURY or DEATH Vehicle capacity 1 operator and 1 passenger Remain seated and hold on while in motion Keep ...

Page 21: ...red position Lever Position Car Movement F FORWARD R REVERSE The back up buzzer will beep when the drive select lever is turned to R ACCELERATOR PEDAL The accelerator pedal controls the vehicleʑs speed Action Car Speed Depress pedal Increase Release pedal Decrease å Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the utility vehicle Brake pedal NOTE BEEP Y 1613 Y 20A A Y 18 Y 2...

Page 22: ...switch is in the ON position depressing the accelerator may suddenly cause the utility vehicle to move Death or serious personal injury can result from failing to comply with warning instructions in this manual CHOKE KNOB Pull and hold out choke knob when starting a cold engine Release the knob after the engine starts å Choke knob FUEL SHUTOFF VALVE Ensure the fuel shutoff valve is in the OPEN pos...

Page 23: ...down hills driving across the side of hill increases the risk of overturn Vehicle rated capacity driver passenger cargo trailer and load 750lb 340kg on level surface This vehicle is recommended only for operators 16 or older with a valid motor vehicle license Adults must supervise use by minors Check state laws for minimum age restrictions LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND...

Page 24: ...GO BED To raise pull the cargo bed release lever toward the rear to unlatch the latches The gas spring assists in raising and holding the cargo bed open The gas spring will only open hold the cargo bed when it is empty To lower push down on the box to lower it in the original position Make sure the latches for the cargo bed are securely latched å Cargo bed release lever Gas spring NOTE B A B Y 164...

Page 25: ... cargo bed Never tow cargo that is not secured Reduce speed and allow greater distances for braking Death or serious personal injury can result from failing to comply with warning instructions in this manual Fall and Thrown Object Hazard Do not carry passengers in the cargo bed Death or serious personal injury can result from failing to comply with warning instructions in this manual Crush Hazard ...

Page 26: ...11 5 8 JW6 CONTROLS TRAILER HITCH BRACKET This vehicle is equipped with a 2 in 5 cm receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at a Yamaha dealer å Trailer hitch bracket A Y 1647 ...

Page 27: ... from moving while performing pre operation checks Remove main switch key Apply parking brake Death or serious personal injury can result from failing to comply with warning instructions in this manual PRE OPERATION CHECKLIST Before each use check the following Fuel system Engine oil level Battery Tire condition Steering system Back up buzzer Pedal operation Body and chassis Headlights Taillights ...

Page 28: ...ources of ignition Stop engine and allow it to cool for several minutes before refueling Refuel in a well ventilated area Take care not to spill gasoline If gasoline spills wipe it up immediately with dry rags Always dispose of gasoline soaked rags properly Tighten the filler cap securely after refueling If you swallow gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get immedi...

Page 29: ...il level is between the MIN and MAX marks å Oil filler hole Engine damage can result Use care not to fill past the MAX dipstick mark and be sure no foreign material enters the crankcase Use care not to get oil on the starter belt The distance between the dipstick marks represents approx 1 2 US qt 1 2 L of oil Recommended engine oil classification API Service SE SF or SG Engine oils labeled Energy ...

Page 30: ...d from vibration or jarring Also check that no battery caps are missing to prevent battery acid from spilling from the battery Check the battery terminals for corrosion TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the utility vehicle Tire pressure 20 psi 138 kPa 1 4 kgf cm2 Tire Wear Limit Check the tire surface for damage cracks or embedded objects When tire tread...

Page 31: ...onsult a Yamaha dealer BACK UP BUZZER Check the back up buzzer by moving the drive select lever to R for reverse The buzzer should sound PEDAL OPERATION Check the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha dealer Accelerator Pedal Before checking operation of the accelerator pedal be sure the main switch is in the OFF position Death or serious ...

Page 32: ... 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 BODY AND CHASSIS Before each use visually inspect the utility vehicle body and chassis for damage and or missing parts CARGO BED Make sure cargo bed is lowered completely and is latched in the down position Make sure both tailgate latch...

Page 33: ...901A A Headlights Taillights Ensure the headlights and taillights are operational Never operate the utility vehicle at night or during inclement weather without properly working headlights taillights Horn Switch Make sure the horn operates correctly å Horn switch ...

Page 34: ...hicle handling Drive slowly in turns YAMAHA JW6 K7768 00 Y 1640 Y 18 Y 903 A Y 20B B STARTING 1 With the parking brake applied turn the drive select lever to FWD for forward or REV for reverse Do not shift from FWD forward to REV reverse while the utility vehicle is moving Transmission damage can result 2 Turn the main switch to ON Do not depress the accelerator pedal when turning on the main swit...

Page 35: ...ine with the accelerator use the brake Transmission dam age can result LOADING Cargo or a trailer can change the stability and handling of a vehicle You must use common sense and good judgment when carrying cargo or towing a trailer Keep the following points in mind Never exceed the weight limits shown An overloaded vehicle can be unstable NOTE CAUTION Y 65c A B MAXIMUM LOADING LIMIT Maximum cargo...

Page 36: ...y to reduce the weight on hitch If you are carrying cargo and towing a trailer include the tongue weight in the maximum vehicle load limit Load cargo in the cargo bed as close to the center of the vehicle as possible Tie down cargo securely in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with controls or y...

Page 37: ...C C C 6 2 Check fuel level C C C C C C 6 2 Check for looseness and corrosion of battery C C C C C C 6 4 terminals and hold downs Check brake pedal free play C CA CA CA CA CA 8 13 and adjust if necessary Check steering operation C C C C C 6 5 Check tire pressure tread C CA CA CA CA CA 6 4 depth tire surface for damage Check body and chassis for C C C C C C 6 6 damage Check tightness of all bolts C ...

Page 38: ...l bearing play Check transaxle oil level and inspect for leakage C C C 8 11 Check operation and adjust CA CA CA pedal stop if necessary EVERY 2 YEARS Check brushes for wear and C S commutator for dirt EVERY 4 YEARS Replace fuel filter and R fuel hoses Check tightness of cylinder CA head Adjust valves C R Inspect internal wet brake and replace pads if necessary Items without a page number reference...

Page 39: ...m to the latest version of the SAEʑs recommended practice document J1930 Diagnostic Acronyms Terms and Definitions For Electrical Electronic System It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic TROUBLESHOOTING If the vehicleʑs engine wonʑt start use the following chart Cause Remedy Fuel System No fuel in tank Fill fuel tank Fuel shutoff valve Open fu...

Page 40: ...lug gap with a feeler gauge Standard spark plug BPR2ES BPR4ES Spark plug gap 0 028 0 031 in 0 7 0 8 mm å Gap 3 Clean the gasket and plug surfaces and install the spark plug finger tight before tightening to the following torque Spark plug torque 14 5 ft lb 20 Nm 2 0 m kg When removing or installing the spark plug be careful not to damage the insulator A damaged insulator could allow external spark...

Page 41: ... plug and let the oil drain completely Dispose of used oil in an environmentally safe way such as taking oil to an oil collection station 4 Install the drain plug along with a new drain plug gasket finger tight before tightening to the following torque Drain plug torque 23 ft lb 31 Nm 3 1 m kg 5 Add the correct quantity of oil through the oil filler hole Recommended engine oil classification API S...

Page 42: ...ine oil check for oil leaks around the drain plug If oil leaks are found consult a Yamaha dealer Air Filter To remove the air filter elements 1 Unlatch the air filter cover clips and remove cover å Air filter cover clips Air filter cover 2 Lift the air filter and pre filter out of the air filter case ç Air filter Pre filter Be careful not to drop anything into the air inlet Serious engine damage c...

Page 43: ...everse the above steps The pre filter has a notch on one side It will only fit in the case one way Serious engine damage can result from an improperly posi tioned filter Drive Belt To remove the drive belt 1 Set the drive select lever halfway between forward and reverse 2 Pull up on the drive belt and push it outward over the edge of the secondary sheave 3 Turn the secondary sheave clockwise and t...

Page 44: ...r damage replace the belt with a new one å New 1 09 in 27 6 mm Replace when belt reaches 0 95 in 24 mm 5 To install the drive belt reverse the above steps rolling the belt back over the secondary sheave Battery The 12 volt battery that provides starting power to your gas vehicle normally does not require the addition of water If the battery loses its charge have an experienced mechanic charge it M...

Page 45: ...RNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician imme diately 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 ...

Page 46: ...mply with warn ing instructions in this manual When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting which could cause electrical system damage 1 Locate the in line fuse holder on the main wire harness adjacent to the battery 2 Pull fuse holder cover off 3 Pull fuse out inspect and replace if necessary å Fuse holder Fuse Fuse Type 10 Amp Blade Style CAU...

Page 47: ... out of hole Do not allow foreign material to enter transaxle Serious transaxle damage can result 7 If needed add SAE80 W90 API GL 5 limited slip high perfor mance gear oil until it is at the top of the plug hole or just begin ning to run out of servicing hole The YTF1 utility vehicle is equipped with an internal wet brake Use of oil other than SAE80 W90 API GL 5 limited slip high performance gear...

Page 48: ...ility vehicle from moving loosen the wheel nuts 2 Elevate the utility vehicle with a jack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Brake Adjustment The brakes on your utility vehicle are self adjusting Before you operate the vehicle press down on the brake pedal several times to make sure the brakes are functioning properly Consult your Yamaha d...

Page 49: ...using light force and measuring the distance the pedal travels before resistance is felt Brake pedal free play Å 1 77 1 96 in 45 50 mm 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 Do not over tighten the brake cables Over tightening will increase brake wear and affe...

Page 50: ...A NOTE Perform the following preparations when storing your utility vehicle for extended periods of time Turn main switch key to OFF position remove key and store key in a safe place DRAINING FUEL Gasoline and its vapors are highly flammable and explosive Death or serious personal injury can result from failing to comply with warning instructions in this manu al Do not smoke when draining fuel and...

Page 51: ... PREPARATION 1 Remove the battery from the util ity vehicle and store it in a cool dry place that stays between 32 F 0 C and 90 F 30 C 2 Have the battery recharged every 60 90 days to keep it fully charged The battery must be kept fully charged to avoid damage Batteries like the one supplied with your vehicle normally do not require you to check the water level inside the battery for the one year ...

Page 52: ...l width 48 9 in 1243 mm Overall height 14 1 in 357 mm Minimum ground clearance 4 8 in 123 mm Weight Dry weight without battery 757 lb 343 kg Vibration Level Vibration on seat EN 1032 ISO5008 for Europe Will not exceed 0 5 m s2 Vibration on steering wheel EN1032 ISO5008 for Europe Will not exceed 2 5 m s2 Performance Factory speed setting 12 mph 19 km h Maximum speed 15 mph 24 km h Minimum turning ...

Page 53: ...0 8 mm Lubrication system Splash style positive oil lubrication Engine oil type YAMALUBE ACC Shaft LU 00 Engine oil capacity 1 0 US qt 1 0 L 1000 cc Oil change quantity 1 0 US qt 1 0 L 1000 cc TRANSMISSION Items YTF1 Transmission Type V belt automatic centrifugal engagement V belt width and outer line length 1 22 x 39 76 in 31 x 1010 mm V belt wear limit 0 95 in 24 mm Governor Type Oil bath flywei...

Page 54: ... Free internal transaxle disc brake Brake pedal free play linkage adjustment 1 77 1 96 in 45 50 mm Brake cable end play 0 004 0 02 in 0 1 0 5 mm Parking brake Type Foot type parking brake with automatic release Release timing With pedal segment in second notch Bolt heads round parallel to arm 0 000 0 001 in 0 0 0 3 mm Wheel Tire size Front 18 x 8 50 8 00 4 PR Rear 18 x 8 50 8 00 4 PR Rim size 7 00...

Page 55: ... GAUGE HORN HORN SWITCH W W B B B R P P HEAD LIGHT L H HEAD LIGHT R H G G TAIL LIGHT L H TAIL LIGHT R H OFF ON HEAD TAIL LIGHT MAIN SW TCI BW B C A D TERMINAL TERMINAL B R B B B R RW R RW Br RW RY ENG STOP RELAY RW B ENG EARTH LIGHT FUSE 10A NOTES 1 OPTION A AND B ARE REPRESENTED BY DOT LINE 2 WIRE COLOR OF OPTIONAL CIRCUITS ARE TBD 3 WIRE COLORS FOR TAIL STOP LIGHTS ARE LOCATED ON WIRE HARNESS SI...

Page 56: ...EAD LIGHT L H HEAD LIGHT R H G G TAIL LIGHT L H STOP REAR SIGNAL LIGHTS L H TAIL LIGHT R H TO GROUND BATTERY TO MAIN SW TERMINAL D STOP REAR SIGNAL LIGHTS R H FUSE 10A NOTES 1 OPTION A AND B ARE REPRESENTED BY DOT LINE 2 WIRE COLOR OF OPTIONAL CIRCUITS ARE TBD 3 WIRE COLORS FOR TAIL STOP LIGHTS ARE LOCATED ON WIRE HARNESS SIDE ...

Page 57: ...VER VIA TURN SIGNAL BODY TAIL LIGHT L H B G G B B W W RY B HEAD LIGHT R H HEAD LIGHT L H BATTERY TO GROUND TO MAIN SW TERMINAL D STOP REAR SIGNAL LIGHTS L H STOP REAR SIGNAL LIGHTS R H O RY FUSE 10A B NOTES 1 OPTION A AND B ARE REPRESENTED BY DOT LINE 2 WIRE COLOR OF OPTIONAL CIRCUITS ARE TBD 3 WIRE COLORS FOR TAIL STOP LIGHTS ARE LOCATED ON WIRE HARNESS SIDE WIRING YTF1 WIRING DIAGRAM ...

Page 58: ...NOTES 1 2 3 4 5 6 7 8 9 10 11 JW6 ...

Page 59: ......

Page 60: ...YAMAHA GOLF CAR COMPANY 1000 HWY 34 East Newnan GA 30265 770 254 4000 Printed in U S A 2008 KCC ...

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