GOLF CAR OWNER’S/ OPERATORS MANUAL G16A G16E 07/12/01 1PC - G16A/E O/M LIT196261600 *LIT196261600* Yamaha Motor Corp., USA Cypress, California USA made in YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA LIT-19626-16-00 Printed in U.S.A.
G21A O_M IFC 8/8/00 7:56 AM Page 1 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
LIT_19626_16_00.qxd 7/13/01 8:42 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.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 2 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: ! The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the golf car occupants, a bystander, or a person inspecting or repairing the golf car.
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LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 4 WARRANTY YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA G16A, G16E LIMITED WARRANTY 1 2 3 4 Yamaha Motor Manufacturing Corporation of America hereby warrants that any new G16 (gas and electric models) Yamaha Golf Car purchased from an authorized Yamaha dealer in the United States will be free from defects in material and workmanship for the period of time stated herein, subject to the stated limitations.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 5 WARRANTY YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA SPECIALTY VEHICLE ENGINES EMISSION CONTROL WARRANTY 1 2 YOUR WARRANTY RIGHTS AND OBLIGATIONS In complance with the California Air Resources Board, Yamaha Motor Manufacturing Corporation of America is pleased to explain the emission control system warranty on your 1996 or later specialty vehicle engine.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 6 WARRANTY 3. Ignition System Spark plugs * Magneto or electronic ignition system Spark advance/retard system 4. Exhaust Gas Recirculation (EGR) System EGR valve body, and carburetor spacer if applicable EGR rate feedback and control system 5. Air Injection System Air pump or pulse valve Valves affecting distribution of flow Distribution manifold 6. Catalyst or Thermal Reactor System Catalytic converter Thermal reactor Exhaust manifold 7.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 7 IMPORTANT LABELS 1 6 G16E 5 G16A 4 G16E 3 G16A SAFETY AND INSTRUCTION LABELS 2 1 2 WARNING Y-505 1 Please read the following labels carefully before operating your golf car, and promptly replace any labels which become damaged or removed.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 8 IMPORTANT LABELS GOLF CAR SERIAL NUMBER 1 The golf car serial number is stamped in the location shown. 2 3 Y-102a 4 NOTE: 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.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 9 ! OPERATOR SAFETY Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following: BEFORE OPERATING THE GOLF CAR 2 ● Read this Owner’s/Operator’s manual and all safety and instruction labels on the golf car before operating. ● Perform the pre-operation checks found in Section 6 of this manual. ● Only authorized people should drive the golf car, from the driver’s side only, and only in designated areas.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 10 ! OPERATOR SAFETY 1 2 3 ● Keep your hands on the steering wheel and your eyes on the path ahead. ● Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully. ● Avoid starting or stopping abruptly. ● Vary the speed of the golf car to match the terrain of the course. ● Avoid turning the steering wheel too sharply at higher speeds. ● Always drive slowly straight up or straight down slopes – never at an angle.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 11 ! MAINTENANCE SAFETY PROGRAM Like all machines, golf cars can cause injury if improperly used or maintained. This section contains broad safety practices required for safe golf car operation. Before golf cars are operated, golf course personnel should establish any additional safety practices that may be required for safe operation. Experience has shown that golf cars are safe when operated in accordance with the safety warnings affixed to every golf car.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 12 ! MAINTENANCE SAFETY PROGRAM 1 ● Loose Terrain. Loose terrain may cause a golf car to lose traction and may affect stability. Repair loose terrain, chain or rope off these areas, or identify loose terrain with a suitable warning. ● Golf Car and Pedestrian Interference. Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent accidents.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 13 ! MAINTENANCE SAFETY PROGRAM 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: ● 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.
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LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 15 CONTROLS MAIN SWITCH 1 The main switch controls the following items: OFF Ignition circuit is switched off. The key can be removed only in this position. OF F 2 3 ON 4 Y-15 5 ON Electrical circuits are switched on. The golf car can be driven. OF F 6 ON 7 Y-16 W AO I L RN ING ON A OF F Y-17 OIL WARNING LIGHT (G16A) 8 When the engine oil level falls below an acceptable level, this light comes on.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 16 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, move the lever to the desired position. 2 3 Y-18 Lever Position Car Movement F FORWARD R REVERSE 4 NOTE: The back-up buzzer will beep when the drive select lever is turned to “R.” 5 6 Y-19 7 ACCELERATOR PEDAL A 8 The accelerator pedal controls the golf car’s speed.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 17 CONTROLS PARKING BRAKE PEDAL 1 A Press down on the parking brake pedal whenever parking the golf car. 2 å Parking brake pedal Y-22 NOTE: Release the parking brake by depressing the accelerator pedal. 3 4 CHOKE KNOB (G16A) A Pull and hold out choke knob when starting a cold engine. Release the knob after the engine starts.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 18 PRE-OPERATION CHECKS Pre-operation checks should be 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 nature. 1 2 WARNING 3 ● 4 ● 5 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.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 19 PRE-OPERATION CHECKS FUEL SYSTEM (G16A) 1 Make sure there is sufficient fuel in the tank, and check fuel line and connections for leakage. B 2 å Fuel tank ∫ Fuel cap A 3 Y-513 WARNING Gasoline and its vapors are highly flammable and explosive. ● Do not smoke when refueling and keep away from sparks, flames, or other sources of ignition. ● Stop engine and allow it to cool for several minutes before refueling. ● Refuel in a well-ventilated area.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 20 PRE-OPERATION CHECKS ENGINE OIL (G16A) 1 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 crosshatched area on the end of the dipstick). 2 3 Y-514 å Oil level dipstick ∫ Maximum oil level ç Safe operating range B 4 MIN If the oil level is below the MIN mark on the dipstick, add oil through the oil filler hole until the oil level is between the MIN and MAX marks.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 21 PRE-OPERATION CHECKS Engine Cooling Inlet Duct 1 Check the engine cooling inlet duct for debris. Remove any debris present. A 2 å Engine cooling inlet duct BATTERY Charge G16E batteries before each use. See charging steps in chapter 8, Maintenance. G16A1 Check that the battery (G16A) or batteries (G16E) are held securely in place to prevent the batteries from being damaged from vibration or jarring.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 22 PRE-OPERATION CHECKS STEERING SYSTEM 1 Check the steering system for excessive freeplay by: 2 3 4 Y-32 5 ● moving the steering wheel up and down, and back and forth. ● turning the steering wheel slightly to the right and left. If you feel excessive freeplay, or hear rattling sounds which may indicate loose steering components, consult a Yamaha dealer. BACK-UP BUZZER Check the back up buzzer by moving the drive select lever to “R” for reverse.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 23 PRE-OPERATION CHECKS Parking Brake Pedal 1 Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed. A 2 å Parking brake pedal Y-22 NOTE: Release the parking brake by depressing the accelerator pedal. 3 4 Accelerator Pedal 5 WARNING Before checking operation of the accelerator pedal, be sure the main switch is in the “OFF” position. Make sure the accelerator pedal operates smoothly.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 24 OPERATION STARTING 1 1. With the parking brake applied, turn the drive select lever to “F” for forward, or “R” for reverse. 2 CAUTION 3 Y-18 Do not shift from “F” forward to “R” reverse while the golf car is moving. 2. Turn the main switch to “ON.” 4 WARNING OF F Do not depress the accelerator pedal when turning on the main switch or the golf car may suddenly start moving. 5 ON 6 Y-16 3. Pull the choke knob out and hold it while starting (G16A).
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 25 OPERATION STOPPING 1 To stop the golf car, gradually press down on the brake pedal. B å Brake pedal 2 When the car has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.” 3 ∫ Parking brake pedal 4 CAUTION A Y-65 Do not hold the golf car on an incline with the accelerator – use the brake.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 26 MAINTENANCE 1 PERIODIC MAINTENANCE CHARTS Regular maintenance is required for the best performance and safe operation of your golf car. WARNING 2 3 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_16_00.qxd 7/13/01 8:42 AM Page 27 MAINTENANCE FOR G16A (continued) C - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE 500 rds 500 hrs 2500 mls 4000 kms (Every 2 years) 1000 rds 1000 hrs 5000mls 8000 kms (Every 4 years) Page R R R 8-6 CA CA CA * Check starter V-belt for damage and tension C C C * Check drive belt for slippage, wear or scratches C C C 8-8 Check sliding sheave and ramp shoes; Grease secondary sheave bearing.
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LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 29 MAINTENANCE EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS • • • • • Item CARB. ASSY., LH., JT., CARBURETOR 2 & JT., CARBURETOR 1 T.C.I. MAGNETO ASSY. & PLUG, SPARK CRANKCASE 1 & HEAD, CYLINDER 1 AIR FILTER ASSY. MUFF., 2 1 Acronym CARB (Carburetor) 2 El (Electronic Ignition) 3 PCV (Positive Crankcase Ventilation) ACL (Air Cleaner) 4 5 The above items and the corresponding acronyms are provided in accordance with U.S.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 30 MAINTENANCE - G16A Spark Plug Inspection 1 2 You should periodically remove and inspect the spark plug. Dirty or worn spark plugs can cause poor performance. B å Spark plug ∫ Spark plug cap 3 A Y-516 4 1. Check for discoloration and remove carbon deposits with a spark plug cleaner or wire brush. The normal electrode color will be tan. 2. Check the spark plug type, and check the spark plug gap with a feeler gauge.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 31 MAINTENANCE - G16A Engine Oil Replacement 1. Warm up the engine for several minutes, place the golf car on a level surface, then stop the engine. WARNING 1 2 3 Use caution not to touch hot engine oil or hot engine parts, during the following procedure. 4 2. Place an oil pan under the engine drain plug. 3. Remove the oil drain plug and let the oil drain completely.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 32 MAINTENANCE - G16A 1 å Oil filler hole A CAUTION 2 3 Y-515 4 Air Filter To remove the air filter elements: A 5 B 6 7 A 1. Unlatch the air filter cover clips and remove cover. A å Air filter cover clips ∫ Air filter cover Y-518 2. Lift the air filter and pre-filter out of the air filter case. å Air filter ∫ Pre-filter 8 9 Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the crankcase.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 33 MAINTENANCE - G16A Inspection and cleaning: A 1 3. Wash the foam pre-filter in soap and water. Allow it to dry. B å Soap and water ∫ Foam element 2 4. Check the filter element. If damaged or dirty, replace it. 3 Y-508 CAUTION 4 Do not wring out the foam pre-filter, this could cause it to tear. 5. To replace the elements, reverse the above steps. 5 6 CAUTION The pre-filter has a notch on one side. It will only fit in the case one way.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 34 MAINTENANCE - G16A Inspection: 1 To inspect the drive belt, check for frayed edges or tears, and measure drive belt against the following specification. If the belt shows excessive wear or damage, replace the belt with a new one. A 2 B 3 Y-44 4 å New: 1.22 in. (31.0 mm) ∫ Replace when belt reaches: 1.06 in. (27 mm) 5. To install the drive belt, reverse the above steps, rolling the belt back over the secondary sheave.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 35 MAINTENANCE - G16A The 12-volt battery that provides starting power to your gas car normally doesn’t require the addition of water during the one year period provided by the battery manufacturer. If the battery loses its charge, have an experienced mechanic charge it. ++ – – 1 2 3 Fuse Replacement Y-45 4 WARNING Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and create a fire hazard.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 36 MAINTENANCE - G16E Battery Care 1 WARNING 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 water. 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.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 37 MAINTENANCE - G16E D ● Before charging: only add distilled water if fluid is below the top of the plates, and then add just enough to cover plates. ● After charging: check that the fluid level is approximately 1/4 to 1/2 inch above the plates and 1/4 to 3/8 inch below the level indicator. If the fluid level is low, carefully add distilled water. Adding distilled water after charging prevents boil over.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 38 MAINTENANCE - G16E Battery Charging 1 WARNING Read and understand the owner’s manual provided with your golf car’s battery charger before charging batteries. 2 3 WARNING Explosive hydrogen gas is produced while batteries are being charged. Only charge batteries in well ventilated areas (a minimum of 5 air changes per hour is recommended).
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 39 MAINTENANCE - G16E WARNING Do not disconnect the DC output cord from the battery receptacle when the charger is on or an arc could occur that may cause an explosion. 1 2 4. The charger will turn off automatically when the batteries reach full charge. 3 5. 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.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 40 MAINTENANCE - G16E 1 C 2. Connect the wire leads as shown. A å Forward ∫ To relay ç To controller ∂ Between batteries B D 2 D 3 D Y-51 WARNING 4 When installing batteries: ● Carefully place battery cables and holddowns making sure that cables don’t lie across vent caps. ● Always remove the negative (–) cable to the motor controller first, and install it last. 5 6 Y-52 CAUTION Do not overtighten the battery holddown nuts.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 41 MAINTENANCE - G16A & G16E Gear Box Oil 1 To check gear box oil level: 1. Place the golf car on a level surface. 2. Remove the access panel by removing the screws in the two lower corners of the panel and pulling the panel from the car. 2 3 4 Y-48 5 3. For G16A and G16E Remove the oil level plug (A). Add gear oil little by little until oil flows from the level plug hole (B). 6 4. Allow excess gear oil to flow out until it stops.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 42 MAINTENANCE - G16A & G16E Wheel Replacement 1 To remove and install a wheel on your golf car: 2 1. With the wheels blocked to prevent the golf car from moving, loosen the wheel nuts. 3 2. Elevate the golf car with a jack and remove the wheel nuts and the wheel. 4 Y-57 3. Reverse the removal steps when installing the wheel. 5 Wheel nut tightening torque: 58 ft.lb (80 Nm, 8.0 m.kg) 6 Brake Adjustment The brakes on your golf car are selfadjusting.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 43 MAINTENANCE - G16A & G16E Brake Pedal Free Play Adjustment CAUTION 1 2 Before adjusting brake pedal free play, pump the brake pedal several times to self-adjust the brakes. 3 To adjust the brake pedal free play: 1. Remove the service lid from the floor of the golf car. 4 5 Y-61 6 25 -30 2.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 44 STORAGE Perform the following preparations when storing your golf car for extended periods of time: 1 NOTE: Turn main switch key to “OFF” position, remove key, and store key in a safe place. 2 3 DRAINING FUEL (G16A GAS CAR) 4 WARNING Gasoline and its vapors are highly flammable and explosive. 5 ● 6 ● ● 7 ● 8 ● 9 ● 10 ● 11 Do not smoke when refueling and keep away from sparks, flames, or other sources of ignition.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 45 STORAGE ENGINE PREPARATION (G16A GAS CAR) With the key removed and the spark plug lead disconnected, turn the clutch by hand until compression is felt. This puts the valves in the closed position. CHASSIS PREPARATION 1. Increase the tire pressure to 20 psi (137 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. 2.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 46 SPECIFICATIONS 1 2 3 4 GENERAL SPECIFICATIONS Items Dimensions: Overall length Overall width Overall height (steering height) Height of floor Wheelbase Tread: Front Rear Min. ground clearance G16A G16E 93.9 in. (2385 mm) 47.2 in. (1200 mm) 46.8 in. (1190 mm) 11.8 in. (300 mm) 64.0 in. (1629 mm) 34.3 in. (870 mm) 38.6 in. (980 mm) 3.8 in.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 47 SPECIFICATIONS ENGINE 1 Items G16A Description: Engine type Number of cylinders Displacement Bore x stroke Compression ratio Rated output Cooling system Starting system Ignition system Spark plug type Spark plug gap Lubrication system Engine oil type Engine oil capacity Oil change quantity 4-stroke, Gasoline, OHV Single 301 cm3 3.07 x 2.48 in. (78 x 63 mm) 8.1:1 9.5 hp (7.1 kw)/4000 rpm Forced air cooled Starter TCI Magneto BPR2ES 0.028-0.031 in. (0.7-0.
LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 48 SPECIFICATIONS 1 CHASSIS Items 2 3 Steering system: Type Steering angle (L.H.) Steering angle (R.H.) Lubricant/capacity Brakes: Brake system 4 5 Type of brake Brake pedal freeplay linkage adjustment (Brake cable end play) 6 Parking brake: Type 7 Release timing (Bolt heads round parallel to arm) 8 9 Wheel: Tire size: Front Rear Rim size: Tire pressure: G16A and G16E Worm and pin 1.5 turn 1.5 turn Grease/3.0 US oz (0.09 L, 3.
G16A/E 1 Engine stop relay 2 Engine ground 3 Pickup 4 Rotor 5 Oil level gauge 6 Blade fuse (10A) 7 Voltage regulator 8 Starter generator ON Br Br 9 a b c d e f g Relay Battery Pilot lamp (12V, 3.4W) Main switch Accelerator stop switch Back switch Buzzer Body ground G Br G Br Br R R/W R/W G Br P P Br R Br RY R R P B – 10 + 9 RW B RW B B L B B B R/W L R/W F2 8 G G G G R/W RW R R A1 L B L B 2 B RW G B G 7 B B B 6 B Br 5 Y-509 B.........................
11-2 9 + R + – – + – – R R 8 L W G – + R/Y 10 Br R/Y L G W W L G L W G Y/B Y Br Y Y/B Br Y Y/B Br Y/B Y Br – P 11 + Br R/W FD B B Br R/W P P P A1 A2 P S1 S2 R BACKWARD 12 Y/B R F1 F2 S S F2 F1 R 13 FORWARD Y/B Y Y P R Y/B R P R P Y Y/B Y Y-59 COLOR CODE B.........................Black L...........................Blue G .......................Green Y .......................Yellow R...........................Red P ..........................
GOLF CAR OWNER’S/ OPERATORS MANUAL G16A G16E 07/12/01 1PC - G16A/E O/M LIT196261600 *LIT196261600* Yamaha Motor Corp., USA Cypress, California USA made in YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA LIT-19626-16-00 Printed in U.S.A.
