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1. MAINTENANCE PERIODIC MAINTENANCE CHARTS Regular maintenance is required for the best performance and safe operation of your golf car WARNING 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 servicing the machine death or serious personal injury can result When in doubt the work should be done by a Yamaha dealer or other qualified mechanic CS CHECK CA CHECKANDADJUST R REPLACE S SERVICE CL CLEANANDLUBRICATE L LUBRICATE and damaged springs 40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds Daily 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks Pre 100 miles 600 mis 1200 mis 2500 mis 5000 mis Page Opera 160 kms 1000 kms 2000 kms 4000 kms 8000 kms tion Every Every 6 Every Every 2 Every 4 Month months Year years years PRE OP i Charge S S S S S S E Clean battery tops check for 6 2 tightness of hold down screws and S S S S S S 8 3 terminals Check brake pedal freeplay and 6 4 adjust if necessary cs CA CA CA CA CA 10 Check steering operation cs cs cs cs cs cs Check tire pressure tread depth cs CA CA CA CA CA 6 2 tire surface for damage Check body and chassis for damage cs cs cs cs cs cs 6 4 Check tightness of all bolts nuts screws and rivets cs cs cs cS cs j Check reverse alarm operation cs cs cs cs cs cs 6 3 EV
2. Below Bottom of Fill Well Max Level charged battery ane pO ARNALL Max Level ANN W JW9 e Before charging only add distilled water if fluid is below the top of the plates and then add just enough to cover plates and look inside the fill wells Add distilled water until the electrolyte level is 3 mm 1 8 below the bottom of the fill well A piece of rubber can be used safely as a dipstick to help determine this level Clean replace and tighten all vent caps NOTICE Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water After charging open the vent caps 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 C oF Satisfactory Uncorrected Hydrometer Reading 48 9 120 1 244 43 3 1 248 37 8 100 1 252 32 2 90 1 256 26 7 80 1 260 21 1 70 1 264 15 6 60 1 268 10 0 50 1 272 44 40 1 276 1 1 30 1 280 8 4 MAINTENANCE REV FWD OFF Ny Y 912 Battery Charging Read and understand the owner s manual provided with your golf car s battery charger before charging batteries Death or serious pe
3. ERY Check electrolyte level cs cs cs cs cs 8 3 8 4 MONTH Check for loose or broken cs cs cs cs cs connections Clean Lube pedal control area cL EVERY 6 Check all wire insulation for cracks MONTHS and or worn spots cs cs cs cs Check shock absorbers for oil leak eck shock absorbers for oil leaks cs cs cs cs 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 8 1 Jws MAINTENANCE CS CHECK CA CHECKANDADJUST R REPLACE S SERVICE CL CLEANANDLUBRICATE L LUBRICATE 40 rounds 250 rounds 500 rounds 1000 rounds 2000 rounds Daily 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks Pre 100 miles 600 mis 1200 mls 2500 mis 5000 mis Page Opera 160 kms 1000 kms 2000 kms 4000 kms 8000 kms tion Every Every 6 Every Every 2 Every 4 Month months Year years years EVERY Perform a discharge test S sS S YEAR Apply Terminal protectant S S S Check rear axle bearing play cs cs cs m for roughness or freeplay Check steering knuckle bushing freeplay Adjust CA CA CA wheel alignment Check wheel nut tightness front cs cs cs wheel bearing play Check transaxle oil level and cs cs cs 8 9 inspect for leakage Check pedal stop operation and adjust if necessary GA CA CA i EVERY 2 5 YEARS Replace transaxle oil R EVERY 4 Inspect internal we
4. ctions affixed to the golf car or utility vehicle 1 Install the battery holddown plates and torque to 7 9 Nm 0 7 0 9 m kg 62 80 in Ib as shown Forward Battery Battery holddown plate 2 Connect the wire leads and torque to 9 10 Nm 0 9 1 0 m kg 80 89 in lb as shown WARNING When installing batteries e Carefully place battery cables and hold downs making sure that cables do not lay across vent caps e Always remove the negative cable to the motor controller first and install it last A spark can occur causing an explosion or fire at the battery Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle MAINTENANCE Fuse Type 3 Amp Blade Style JW9 NOTICE Do not overtighten the battery holddown nuts Excessive force will damage the battery casing Fuse Replacement 4 WARNING Be sure to use the specified fuse Using a wrong fuse can cause electrical system damage and create a fire hazard Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle NOTICE When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting and electrical system damage 1 Locate the in line fuse holder on the main wire harness adjacent to the to
5. ing wheel or brake maintenance verify that the main switch is in the OFF position Serious transaxle damage can result Wheel Replacement To remove and install a wheel on your golf car 1 With the wheels blocked to prevent the golf car from moving loosen the wheel nuts 2 Elevate the golf car with a jack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 80 Nm 8 0 mkg 58 ft lb 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 4 WARNING Consult your Yamaha dealer before using your golf car if you suspect brake problems Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle we 8 10 MAINTENANCE Y 62b 8 11 Brake Pedal Free Play Adjustment NOTICE Before adjusting brake pedal free play pump the brake pedal several times to self adjust the brakes To adjust the brake pedal free play 1 Remove the floor mat and service lid from the floor of the golf car 2 Check the brake pedal free play by pressing against the pedal with two fingers using light force and measuring the distance the pedal tra
6. rom the battery receptacle when the charger is on or an arc could occur that may cause an explosion Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle Power ON Light Red Error Light 1 Red Error Light 2 Red Charging Light Yellow Charged Light Green 4 When the charger is plugged into the AC power the Power ON Light illuminates continuously 5 If Error 1 or Error 2 light is blinking there is a problem with the batteries or the charger Contact your Yamaha Dealer 6 During normal charging the Charging Light blinks or continually illuminates 7 The charger turns off automatically when the batteries reach full charge 8 6 MAINTENANCE BATTERY INSTALLATION AND WIRE LEAD CONNECTION TO RELAY TO MOTOR CONTROL UNIT ASSY RECEPTACLE FORWARD Y 672h 8 After the charger has turned off disconnect the DC output plug from the golf car receptacle by grasping the plug body and pulling the plug straight out of the receptacle Battery Installation WARNING When working with batteries do not put wrenches or other metal objects across the battery terminals An arc can occur causing an explosion or fire at the battery Death or serious personal injury can result from failing to comply with the safety and warning instru
7. rsonal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle WARNING Explosive hydrogen gas is produced while batteries are being charged Only charge batteries in well ventilated areas a minimum of five air changes per hour is recommended Death or serious personal injury can result from failing to comply with the safety and warning instructions affixed to the golf car or utility vehicle To charge the batteries in your golf car follow the instructions contained in your battery charger s owner s manual The following is a summary of the charging steps 1 Turn main switch key to OFF position NOTICE Always put the tow switch in the TOW position before charging battery or damage to the electrical system may result 2 Lift up the seat and move the tow switch to the TOW position MAINTENANCE POWER ON ERROR1 ERROR2 CHARGING Foo DOOOG Y 1559 JW9 NOTICE Use only battery chargers that are rated for use with 48 volt Yamaha Golf Cars Serious battery damage can result Thoroughly read and understand the user manual supplied with your 48 volt charger 3 With the charger properly connected and grounded see charger s owner s manual insert the DC output into the golf car receptacle WARNING Do not disconnect the DC output cord f
8. t brake and CA YEARS replace pads if necessary Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual JW9 8 2 MAINTENANCE Battery Care Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with waiter INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Six 8 volt deep cycle batteries provide power for your electric golf car and must be properly maintained and recharged for maximum performance and service life To maintain your batteries 1 Clean the tops of the batteries with a solution of baking soda and water as necessary to remove corrosion NOTICE Do not allow cleaning solution to enter battery cells Serious battery damage can result 2 Check the fluid level before and after charging MAINTENANCE Fill Well Electrolyte 1 8
9. vels before resistance is felt Brake pedal free play a 45 50 mm 1 77 1 96 in 3 If the free play distance needs adjusting loosen the lock nut under rubber bushing and turn the adjusting nut in or out until free play specification is met Then tighten the lock nut in place NOTICE Do not over tighten the brake cables Over tightening will increase brake wear and affect overall performance of car Premature brake wear can result Jws
10. w switch 2 Pull fuse holder cover off 3 Pull fuse out inspect and replace if necessary Fuse holder Fuse MAINTENANCE Y 1994 Transaxle Oil To check transaxle oil level 1 Place the golf car on a flat level surface 2 Remove seven plastic rivets and two bolts and remove the bag holder insert 3 Place an oil pan under the transaxle case 4 Clean area around servicing plug 5 Using an 8 mm hex wrench remove transaxle oil servicing plug located on the rear of the transaxle case 6 Transaxle oil should be at the top of the oil servicing hole or just beginning to run out of hole NOTICE Do not allow foreign material to enter transaxle Serious transaxle damage can result 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 servicing hole TIP The YDRE Golf Car is equipped with an internal wet brake Use of oil other than Yamalube Friction Modified Shaft Drive Gear Oil will cause brake noise 8 Install the transaxle servicing plug and tighten to 14 19 Nm 1 4 1 9 m kg 120 168 in lb 9 Install the bag holder insert and secure with two bolts and seven plastic rivets 1 MAINTENANCE TIP For transaxle oil replacement consult a Yamaha dealer or other qualified mechanic NOTICE Before perform

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