Yamaha YTF2E Owner'S/Operator'S Manual Download

Page: 35 / 54

MAINTENANCE

7-2

JW3

Daily

Pre-

Opera-

tion

20 hours

100 miles

160 kms

(Every

Month)

125 hrs

600 mls

1000 kms

(Every 6
months)

250 hrs

1200 mls

2000 kms

(Every

Year)

500 hrs

2500 mls

4000 kms

(Every 2

years)

1000 hrs

5000 mls

8000 kms

(Every 4

years)

Page

Remarks

EVERY
YEAR

7-10/

—

7-9

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.

CS -

CHECK

CA -

CHECK AND ADJUST

R -

REPLACE

S -

SERVICE

CL -

CLEAN AND LUBRICATE

L -

LUBRICATE

Check wheel nut tightness, front
wheel bearing play

Check transaxle oil level and
inspect for leakage

Perform a discharge test

Apply Terminal protectant

Check pedal stop operation and
adjust if necessary

Inspect brake shoes and adjust
or replace if necessary

EVERY 4
YEARS

Replace transaxle oil

Check rear axle bearing play
for roughness or free play

Check steering knuckle
bushing free play / Adjust
wheel alignment

JW3-F8199-00.qxp_LIT_19626_16_05.qxd 2/16/15 4:05 PM Page 34

Summary of Contents for YTF2E

Page 1: ...48 VOLT UTILITY VEHICLE YTF2E LIT 19626 81 13 JW3 F8199 00 OWNER S OPERATOR S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information on USA ...

Page 2: ...tain 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 Motor Corporation USA YTF2E OWNER S OPERATOR S MANUAL 2015 by Yamaha Motor Corporation USA 1st Edition All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation USA is expressly...

Page 3: ...ld be considered a permanent part of your utility vehicle and should remain with the vehicle when resold Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol It is used to alert you to potential person al injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a po...

Page 4: ...iii JW3 WARRANTY CONTENTS IMPORTANT LABELS CONTROLS STORAGE SPECIFICATIONS WIRING MAINTENANCE OPERATION PRE OPERATION CHECKS SAFETY INFORMATION 1 2 4 8 9 7 6 5 3 10 ...

Page 5: ... 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 Yamaha golf car dealer for service or in p...

Page 6: ... 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 TH...

Page 7: ...TRUCTION 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 1 Y 2367 7 6 9 8 ...

Page 8: ... 10 11 IMPORTANT LABELS 2 2 JW3 2 3 G V W 846 5 kg CURB WEIGHT 506 5 kg VEHICLE LOAD CAPACITY 181 kg PER SEAT MAX BATTERY WEIGHT 171 kg NOMINAL SYSTEM VOLTAGE 48V This vehicle complies to SAE J 2258 2010 JP3 F4236 00 4 ...

Page 9: ...IMPORTANT LABELS 1 2 3 4 5 6 7 8 9 10 11 2 3 JW3 6 5 ...

Page 10: ...o prevent it from shifting Never load more than 150 lb 68 kg tongue weight on the towing bracket Do not tow more than 500 lb 227 kg rolling weight trailer plus cargo Read Owner s Operator s Manual before loading towing or pulling objects Improper tire pressure or overloading can cause loss of control To reduce the risk of accidents and injury or DEATH Operating tire pressure set with tires cold Fr...

Page 11: ...ehicle serial number å is identified in the location shown TIP 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 Y 2368 JWX 000000 A ...

Page 12: ...or vehicle license Adults must supervise use by minors Check state laws for minimum age requirements l Do not allow more than two occupants per seat This utility vehicle is restricted to two occupants l Never give a ride to a passenger who is unable to put both feet firmly on the floorboard while seated with his or her back against the back rest l Never carry passengers on the cargo bed l Do not o...

Page 13: ...riving Always go at a speed that is proper for the terrain visibility and operating con ditions and your experience Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when driving the vehicle l Never operate on excessively rough slippery or loose terrain l Use extra care in congested areas or when backing up Always back up slowly and ...

Page 14: ... 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 that limits your view l Use extra caution when driving a utility vehicle with accessories The utility vehicle may handle differently than it does without accessories l Never operate on slope...

Page 15: ...ed evenly from side to side Be sure cargo is secured so that it cannot move around during operation l Cargo should always be secured in the trailer Make sure cargo in the trailer cannot move around A shifting load can cause an accident l Make sure the load does not inter fere with controls or your ability to see where you are going l Drive more slowly than you would without a load The more weight ...

Page 16: ...pplicable fire and safety codes for the specific ventilation levels requirement as well as requirements for the use of explosion proof electrical apparatus 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 l Properly immobilize utility vehicle befo...

Page 17: ... l If new nameplates warnings or instructions are needed contact your Yamaha dealer STORAGE AND BATTERY CHARGING Take the following precautions to ensure maintenance worker safety l Only use battery changing and charging facilities and procedures that are in accordance with applic able ordinances and regulations to avoid explosions electrical shock or damage to the electrical system l Periodically...

Page 18: ...h 7 Main headlight switch 8 Battery gauge 9 Batteries a Tow switch b DC charger receptacle c Front body d Seat e Rear body f Rear tire g Front tire h Front bumper i Headlights j Cargo bed k Tailgate l Trailer hitch receiver bracket m Taillights n Cargo bed release lever Y 2372 4 5 6 8 7 1 2 3 10 9 11 Y 2373 Y 2375 21 22 23 19 20 14 15 17 16 18 12 13 Y 2374 ...

Page 19: ...gized The utility vehicle cannot be operated The key can be removed only in this position ON Electrical circuits are switched on The vehicle can be driven ON WITH LIGHTS The functions for this position are the same as for the ON position however this position will activate the headlights and taillights Y 2376 OFF REV FWD ON ON Y 2377 OFF REV FWD ON ON Y 2378 OFF REV FWD ON ON ...

Page 20: ...reverse alarm will sound when the drive select switch is turned to REV BATTERY GAUGE The battery gauge displays how much charge is left in the batteries å When the batteries are at full charge all the LEDs will be lit As the battery energy decreases the LEDs will move to the left toward the E When the LED light below the E is the only one lit the batteries must be charged BEEP Y 2380 CONTROLS Y 23...

Page 21: ...pped PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the utility vehicle ç Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal 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 utility vehicle to move Death or ser...

Page 22: ...i mum before switching again Failure to do so may lead to drive system damage while towing HEADLIGHT TAILLIGHT ON POSITION Turn the main switch all the way to the right to the second ONʳposition This will activate the headlights and taillights HORN SWITCH The horn is located adjacent to the brake pedal and is activated by depressing with your foot Horn switch TIP It is advisable to sound the horn ...

Page 23: ...ND CLOSING THE TAILGATE To open the tailgate unhook the latches and then lower the tailgate To close place the tailgate in its original position and then hook the latches å Tailgate Latch RAISING AND LOWERING THE CARGO BED To raise the cargo bed pull the release lever toward the rear to unlatch the latches The gas spring assists in raising and holding the cargo bed open TIP The gas spring will onl...

Page 24: ...oad capacity for this vehicle l Distribute the load evenly l Secure cargo in cargo bed l Never tow cargo that is not secured l Reduce speed and allow greater distances for braking Fall and Thrown Object Hazard l Do not carry passengers in the cargo bed Crush Hazard l Keep hands and fingers away from cargo bed and seat tracks l Have others back away from vehicle before closing cargo bed l Do not al...

Page 25: ...the ground l Keep fuel nozzle in contact with can inlet while filling l Tighten cap before setting fuel container in cargo bed TRAILER HITCH RECEIVER BRACKET This vehicle is equipped with a 5 cm 2 in receiver bracket for a standard trailer hitch Trailer towing equipment can be obtained at a Yamaha dealer å Trailer hitch receiver bracket Y 2385 A ...

Page 26: ...erly increases the possibility of an accident or equipment damage Do not oper ate the vehicle if you find any problem If a problem cannot be corrected by the procedure in this manual have the vehicle inspect ed by a Yamaha dealer PRE OPERATION CHECKLIST Before each use check the following o Batteries o Tire condition o Steering system o Reverse alarm o Pedal operation o Headlights Taillights o Hor...

Page 27: ...rolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Ventilate when charg ing or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the utility vehicle Tire pressure Front 68 82 kPa 0 69 0 84 kgf cm2...

Page 28: ...g sounds which may indicate loose steering components consult a Yamaha dealer REVERSE ALARM Check the reverse alarm by moving the drive select switch to REV for reverse The alarm 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 With the main switch in the OFF position make sure the accel...

Page 29: ...l 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 TIP 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 the cargo bed is lowered completely and is latche...

Page 30: ...s Taillights Ensure the headlights and taillights are operational Never operate the utility vehicle at night or during inclement weather without properly working head lights taillights Horn Switch Make sure the horn operates correctly å Horn switch Y 1650 Y 901A A ...

Page 31: ... result 2 Turn the main switch to ON Do not depress the accelerator pedal when turning on the main switch or the vehicle may start moving unexpectedly 3 Check that your path is clear in the direction you plan to go and slowly depress the accelerator pedal The vehicle will start to move å Accelerator pedal TIP The parking brake automatically releases when the accelerator pedal is depressed NOTICE Y...

Page 32: ...mission 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 follow ing points in mind l Never exceed the weight limits shown An overloaded vehicle can be unstable NOTICE Y 65c A B MAXIMUM LOADING LIMIT l Vehicle Rated Capacity 590 kg 1300 lb l Maximum Cargo Bed ...

Page 33: ...to see where you are going l Drive more slowly than you would without a load The more weight you carry the slower you should go l Allow more braking distance A heavier vehicle takes longer to stop l Avoid making sharp turns unless at very slow speeds to avoid tipping or rolling the vehicle l Avoid hills and rough terrain Choose terrain carefully Added weight affects the stability and handling of t...

Page 34: ... 4 7 3 7 4 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 CS CHECK CA CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE Clean battery tops check for tightness of hold down screws and terminals Check brake pedal freeplay and adjust if ...

Page 35: ...ntain these procedures They are contained in the Service Manual CS CHECK CA CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE Check wheel nut tightness front wheel bearing play Check transaxle oil level and inspect for leakage Perform a discharge test Apply Terminal protectant Check pedal stop operation and adjust if necessary Inspect brake shoes and adjust or replace if nece...

Page 36: ...s produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Eight 6 volt deep cycle batteries provide power for your electric utility vehicle and must be properly main tained and recharged for maximum performance and service life To maintain your batteries 1 Clean ...

Page 37: ...ontains 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 Satisfactory Uncorrected C F Hydrometer Reading 48 9 120 1 244 43 3...

Page 38: ...us per sonal injury can result from failing to comply with the instructions and warnings in this manual To charge the batteries in your utility vehicle 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 utility vehicle s batteries without thoroughly reading and under standing the owner s manual...

Page 39: ... cord from the DC charger recep tacle when the charger is on or an arc could occur that may cause an explosion 1 Red Power ON LED 2 Yellow Charging LED 3 Green Charged LED 4 When the charger is plugged into the AC power the Power ON LED illuminates continuously 5 If any of the LEDs blink for sev eral minutes after the charger is turned on there is a problem with the batteries or the charger Contac...

Page 40: ...s the battery terminals An arc can occur causing explosion of the battery 1 Install the battery hold down plates and torque to 7 9 Nm 0 7 0 9 m kg 62 80 in lb as shown å Forward Battery ç Battery hold down plate 2 Connect the wire leads and torque to 9 10 Nm 0 9 1 0 m kg 80 89 in lb as shown When installing batteries l Carefully place battery cables and hold downs making sure that cables do not la...

Page 41: ...e electrical system damage and cre ate a fire hazard When replacing a fuse be sure the main switch is turned off to pre vent accidental short circuiting and electrical system damage 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 NOTICE NOTICE Fuse Type 10 Amp Blade...

Page 42: ...llow foreign material to enter transaxle Serious transaxle damage can result 5 The oil level should be right at the bottom of the oil level plug hole or just starting to flow out of the hole 6 If needed add SAE 90 gear oil until it starts to flow from the oil level plug hole 7 Allow excess gear oil to flow out of the hole until it stops 8 Install the oil level plug 9 Lower the cargo bed TIP For tr...

Page 43: ... 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 dealer...

Page 44: ...d service lid from the floor of the utility vehicle 2 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 affect the overall performance of the vehicle Premature brake wear can result Death or ...

Page 45: ... 4 2 Disconnect the wire connectors from the bulb 3 Remove the two screws 5 locat ed on the side of the bulb holder 1 to gain access to the headlight bulb 2 4 Insert a new bulb 2 into the bulb holder 1 and secure with the two bulb holder screws 5 Torque to 3 4 5 Nm 0 3 0 45 m kg 27 40 in lb 5 Reattach the bulb holder 1 to the bezel 4 and torque to 3 4 5 Nm 0 3 0 45 m kg 27 40 in lb Y 1969 1 5 Y 19...

Page 46: ... lower the beam and turning the screw counterclock wise will raise the beam 3 Once the correct adjustment has been made tighten the screws 1 to 3 4 5 Nm 0 3 0 45 m kg 27 40 in lb Replacing a Taillight Bulb 1 Disconnect the wire connector from the taillight 2 Pull the rubber seal 1 away from the body while pushing on the back of the taillight 2 3 Remove the seal 1 and the taillight 2 4 Install the ...

Page 47: ...ecessary to remove corrosion NOTICE Perform the following preparations when storing your utility vehicle for extended periods of time TIP Turn the main switch key to the OFF position remove the key and store the key in a safe place CHASSIS PREPARATION 1 Verify the tire pressure is set to Front 68 82 kPa 10 12 psi Rear 241 255 kPa 35 37 psi 2 Clean exterior of the utility vehicle and apply a rust i...

Page 48: ...bed size Overall length 1209 mm 47 5 in Overall width 1243 mm 48 9 in Overall height 356 mm 14 0 in Minimum ground clearance 115 mm 4 5 in Weight Dry weight with suntop without batteries 372 kg 819 lb Performance Factory speed setting 25 0 km h 15 5 mph Maximum speed 31 5 km h 19 6 mph Minimum turning radius 2 8 m 9 2 ft Seating capacity Two occupants per seat Vehicle rated capacity 590 kg 1300 lb...

Page 49: ... reduction gear Secondary reduction system helical gear Secondary reduction ratio Forward 11 34 1 Reverse 15 25 1 Differential type bevel gear Lubricant capacity SAE 90 gear oil 355 cc 355 mL 0 38 US qt BATTERIES Items YTF2E UTILITY VEHICLE Battery Trojan Golf Car Type T 105 8x6volt RC minimum 117 min ...

Page 50: ...t and rear Dual mechanical drum Type of brake Cable activated drum brake Brake pedal free play linkage adjustment 20 25 mm 0 79 0 99 in Brake cable end play 0 1 0 5 mm 0 004 0 02 in 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 0 0 3 mm 0 000 0 001 in Wheel Tire size Front 18 x 8 50 8 00 4 ply ...

Page 51: ...WIRING 1 2 3 4 5 6 7 8 9 10 11 10 1 JW3 YTF2E WIRING DIAGRAM Y 2394 ...

Page 52: ...1 2 3 4 5 6 7 8 9 10 11 WIRING 10 2 JW3 Y 2395 YTF2E WIRING DIAGRAM ...

Page 53: ...NOTES 1 2 3 4 5 6 7 8 9 10 11 JW3 ...

Page 54: ...Printed in U S A 2015 KCC 48 U Y LIT OW MA Yamaha Motor Corporation USA 800 962 7926 JW3 F8199 00 ...

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