Yamaha YDRE 2007 Owner'S/Operator'S Manual Download

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48 VOLT GOLF CAR

YDRE

OWNER’S / OPERATOR’S
MANUAL

LI T -19626-21-07

JW2-F8199-10

YAMAHA GOLF-CAR

COMPANY

1000 HWY 34 East

Newnan, GA 30265

770-254-4000

Printed in U .S. A

2006-KCC

LIT_19626_21_07 cover.qxd 9/18/06 8:10 AM Page 1

Summary of Contents for YDRE 2007

Page 1: ...LF CAR YDRE OWNER S OPERATOR S MANUAL LIT 19626 21 07 JW2 F8199 10 YAMAHA GOLF CAR COMPANY 1000 HWY 34 East Newnan GA 30265 770 254 4000 Printed in U S A 2006 KCC LIT_19626_21_07 cover qxd 9 18 06 8 10 AM Page 1 ...

Page 2: ...m enjoyment from your new Yamaha If you have any questions about the operation or maintenance of your golf car please consult a Yamaha dealer YAMAHA GOLF CAR COMPANY YDRE OWNER S OPERATOR S MANUAL 2006 by Yamaha Golf Car Company 1st Edition All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Golf Car Company is expressly prohibited Printed in U S A LIT 1...

Page 3: ...r and should remain with the car when resold Read and understand this manual completely before operating your golf car Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the golf car occupants a bystande...

Page 4: ...NTY CONTENTS 1 IMPORTANT LABELS 2 SAFETY CONSIDERATIONS 4 MAINTENANCE 8 STORAGE SPECIFICATIONS 9 WIRING 11 OPERATION 7 PRE OPERATION CHECKS 6 CONTROLS 5 OPERATOR SAFETY 3 10 LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 3 ...

Page 5: ... any parts replaced due to normal wear or routine maintenance including oil and air filter ele ments tire wear spark plugs starter and clutch drive belts Any charges incurred in transporting a golf car or charger to and from an authorized Yamaha golf car dealer for service or in performing field service is also excluded from this warranty THE CUSTOMER S RESPONSIBILITY under this warranty shall be ...

Page 6: ... in any way and as part of its limited warranty exclusion YAMAHA does not warrant that its battery is suitable for use in any application other than in a golf car or utility vehicle As in the use of any battery a prudent owner will read and study the charger owner s manual the vehicle owner s manual the operator s instructions and the battery warning labels and will exercise due care in working on...

Page 7: ...JW2 Y 924 4 3 1 2 SAFETY AND INSTRUCTION LABELS Please read the following labels carefully before operating your golf car and promptly replace any labels which become damaged or removed Y 500a 2 4 Y 844a LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 6 ...

Page 8: ...1 2 3 4 5 6 7 8 9 10 11 IMPORTANT LABELS 2 2 JW2 1 3 LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 7 ...

Page 9: ...d in the location shown The first three digits of the serial number are for model identification the remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha Golf Car Company dealer Y 910b JWX 000000 1 LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 8 ...

Page 10: ...allow more than two occupants per seat This golf car is restricted to two occupants unless equipped with a rear seat G Do not operate the golf car while under the influence of alcohol or drugs their affect on vision and judgment make operating a golf car dangerous G Do not operate the golf car on public streets roads or highways unless allowed by law or local regulating authority WHILE OPERATING T...

Page 11: ...rain of the course G Avoid turning the steering wheel too sharply at higher speeds G Always drive slowly straight up or straight down slopes never at an angle G Do not run the engine indoors Exhaust gas is poisonous G Do not make any modification or addition which affects capacity or safe operation or make any changes not in accordance with the owner s operator s manual Y 921 Y 922 Y 923 LIT_19626...

Page 12: ...icense be allowed to operate golf cars Place operation and safety instructions recommended by the golf car manufacturer along with the golf course safety rules in a conspicuous place near the golf car rental area or golf car pick up area It is also recommended that the following warning be posted in a conspicuous location Do Not Operate Golf Cars When Under The Influence Of Alcohol Or Drugs GOLF C...

Page 13: ...ersonnel to inspect adjust and maintain golf cars G Parts and Materials Use only replacement parts and materials recommended by the manufacturer G Ventilation Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards Ventilation is required to remove flammable vapors and fumes from gasoline powered car storage areas Ventilati...

Page 14: ...intenance or repair the car must be driven by a qualified trained and authorized person in an area free of pedestrian traffic to ensure proper operation and adjustment G Record all maintenance performed in a maintenance record log by date name of person performing maintenance and type of maintenance Periodically inspect maintenance log to ensure accurate and complete entries G Provide operator com...

Page 15: ...ATURES 1 Brake pedal 2 Parking brake pedal 3 Accelerator pedal 4 Steering wheel 5 Main switch 6 Receptacle 7 Batteries 8 Seat 9 Front cowl a Front tire b Front bumper c Rear cowl d Rear tire e Rear bumper f Tow switch g FWD REV switch Y 930a 15 Y 935 7 6 LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 14 ...

Page 16: ... ON Y 913 REV FWD MAIN SWITCH The main switch controls the following items OFF Ignition circuit is switched off The key can be removed only in this position ON Electrical circuits are switched on The golf car can be driven LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 15 ...

Page 17: ...r Movement FWD FORWARD REV REVERSE The back up buzzer will beep when the drive select switch is turned to REV ACCELERATOR PEDAL The accelerator pedal controls the golf car s speed Action Car Speed Depress pedal Increase Release pedal Decrease å Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the golf car Brake pedal Y 920 BEEP Y 20A A OFF ON Y 904 REV FWD Y 21a B LIT_19626_21_0...

Page 18: ... ç Parking brake pedal 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 golf car to move Y 22a C LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 17 ...

Page 19: ...he tow switch is in the RUN position å Tow switch Ensure that the Drive Select Switch is in the FWD position and then move the TOW Switch to TOW before towing Failure to do so may lead to drive system damage CAUTION AVERTISSEMENT TOW RUN A Y 666a LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 18 ...

Page 20: ...ond nature G Be sure the main switch key is removed before performing the pre operation checks to prevent accidental starting and apply the parking brake to keep the car from moving PRE OPERATION CHECKLIST Before each use check the following Batteries Tire condition Steering system Back up buzzer Pedal operation Body and chassis SEAT Open the seat for checking and servicing LIT_19626_21_07 qxd 9 1...

Page 21: ...battery acid from spilling from the batteries Check the battery terminals for corrosion TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the golf car Tire pressure For JW2 20 psi 138 kPa 1 4 kgf cm2 Tire Wear Limit Check the tire surface for damage cracks or embedded objects When tire tread wears down to 0 04 in 1 mm replace the tire å Wear limit Y 30 A Y 31 LIT_19626_...

Page 22: ... may indicate loose steering components consult a Yamaha dealer BACK UP BUZZER Check the back up buzzer by moving the drive select switch to REV for reverse The buzzer should sound PEDAL OPERATION Check the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha dealer Accelerator Pedal Before checking operation of the accelerator pedal be sure the main swi...

Page 23: ...rake Pedal Make sure the parking brake pedal locks in place with a positive click and releases when the accelerator pedal is pressed ç Parking brake pedal Release the parking brake by depressing the accelerator pedal BODY AND CHASSIS Before each use visually inspect the golf car body and chassis for damage and or missing parts Y 22a C Y 21a B LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 22 ...

Page 24: ...hile the golf car is moving 2 Turn the main switch to ON Do not depress the accelerator pedal when turning on the main switch or the golf car may suddenly start moving 3 Check that your path is clear in the direction you plan to go and slowly depress the accelerator pedal The golf car will start to move å Accelerator pedal The parking brake automatically releases when the accelerator pedal is depr...

Page 25: ...ress down on the brake pedal å Brake pedal When the car has come to a stop apply the parking brake pedal and turn the main switch to OFF Parking brake pedal Do not hold the golf car on an incline with the accelerator use the brake Y 65b A B LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 24 ...

Page 26: ...nce and safe operation of your golf car Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified If the owner is not familiar with machine servicing this work should be done by a Yamaha dealer or other qualified mechanic LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 25 ...

Page 27: ...cessary Check steering operation Check tire pressure tread depth tire surface for damage Check body and chassis for damage Check tightness of all bolts nuts screws and rivets Check for loose or broken connections Check all wire insulation for cracks and or worn spots Check wheel nut tightness front wheel bearing play Check transaxle oil level and inspect for leakage Check shock absorbers for oil l...

Page 28: ...eries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Four 12 volt deep cycle batteries provide power for your electric golf car and must be properly maintained and recharged for maximum performance and service life To maintain your batteries 1 Clean the top...

Page 29: ... 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 F C Hydrometer Reading 120 48 9 1 244 110 43 3 1 248 100 37 8 1 ...

Page 30: ...y charger s owner s manual The following is a summary of the charging steps Do not attempt to recharge your golf car s batteries without thor oughly reading and understanding the owner s manual provided with your charger 1 Turn main switch key to OFF position 2 With the charger properly connected and grounded see charger s owner s manual insert the DC output plug into the golf car receptacle Use o...

Page 31: ... grasping the plug body and pulling the plug straight out of the receptacle Battery Installation When working with batteries do not put wrenches or other metal objects across the battery terminals An arc can occur causing explosion of the battery 1 Install the battery holddown plates and torque to 7 9 Nm 0 7 0 9 m kg 62 80 in lb as shown å Forward Battery ç Battery holddown plate 2 Connect the wir...

Page 32: ... damage the battery casing Fuse Replacement Be sure to use the specified fuse Using a wrong fuse can cause electrical system damage and create a fire hazard When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting 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 re...

Page 33: ... hole or just beginning to run out of hole Do not allow foreign material to enter transaxle 7 If needed add SAE80 W90 API GL 5 limited slip high 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 YDRE Golf Car is equipped with an internal wet brake Use of oil other than SAE80 W90 API GL 5 limited slip high performance gear oil will cau...

Page 34: ...he wheel nuts 2 Elevate the golf car with a jack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 58 ft lb 80 Nm 8 0 m kg Brake Adjustment The brakes on your golf car are self adjusting Before you operate the car press down on the brake pedal several times to make sure the brakes are functioning properly Consult your Yamaha d...

Page 35: ... with two fingers using light force and measuring the distance the pedal travels before resistance is felt Brake pedal free play Å 45 50 mm 1 77 1 96 in 3 If the free play distance needs adjusting loosen the lock nut å and turn the adjusting nut in or out until the free play specification is met Then tighten the lock nut in place Do not over tighten the brake cables Over tightening will increase b...

Page 36: ...eparations when storing your golf car for extended periods of time Turn main switch key to OFF position remove key and store key in a safe place CHASSIS PREPARATION 1 Verify the tire pressure is set to 20 psi 138 kPa 1 4 kgf cm2 2 Clean exterior of the golf car and apply a rust inhibitor 3 Cover the golf car with a breathable cover and store it in a dry well ventilated area BATTERY PREPARATION 1 R...

Page 37: ...ttery 535 lb 243 kg Vibration Level Vibration on seat EN1032 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 radius 114 2 in 2 9 m Seating capacity 2 persons per seat TRANSMISSION Items YDRE Differential reduction gear Differential...

Page 38: ...ype of brake Internal wet Brake pedal freeplay linkage adjustment 45 50 mm 1 77 1 96 in Brake cable end play 0 004 0 02 in 0 1 0 5 mm Parking brake Type Foot type parking brake with automatic release Release timing With pedal segment in second notch Bolt heads round parallel to arm 0 000 0 001 in 0 0 0 3 mm Wheel Tire size Front 18 x 8 50 8 00 4 PR Rear 18 x 8 50 8 00 4 PR Rim size 7 00 I 8 00 Tir...

Page 39: ...r W RY Y BATTERY 4x12v RECEPTACLE CONTROLLER 3 5 6 7 13 2 Y R G CHARGER DATA RECEIVE14 24 26 25 REV FWD RY Y W NOTE 1 DIRECTIONAL SW TACH A1 F1 A2 A1 A2 F2 D C MOTOR F2 F1 P N MOSFET BOARD ASSY CONTROL BOARD ASSY R R RELAY FUSE 3 AMP MAIN SW NOTE 1 OFF ON R RY RW RW Br OFF ON Br RW NOTE 1 ACCEL SW RY RB RW RB RW RY RY RY RY O O G B R R G B R G B TOW STORAGE SW RY R 22 21 20 19 B W I R TRANSCEIVER ...

Page 40: ...1 2 3 4 5 6 7 8 9 10 11 JW2 NOTES LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 39 ...

Page 41: ...NOTES 1 2 3 4 5 6 7 8 9 10 11 JW2 LIT_19626_21_07 qxd 9 18 06 9 24 AM Page 40 ...

Page 42: ...LF CAR YDRE OWNER S OPERATOR S MANUAL LIT 19626 21 07 JW2 F8199 10 YAMAHA GOLF CAR COMPANY 1000 HWY 34 East Newnan GA 30265 770 254 4000 Printed in U S A 2006 KCC LIT_19626_21_07 cover qxd 9 18 06 8 10 AM Page 1 ...

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