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GOLF CAR G22A

OWNER'S / OPERATOR’SMANUAL

LIT-19626-16-04 JU0-F8199-12YAMAHA MOTOR

MANUFACTURING CORP.OF AMERICA

1000 HWY 34 East Newnan, GA 30265

770-254-4000

Printed in U.S.A2004-KCC

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LIT-CALIF-65-01

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birthdefects or other reproductive harm.

YAMAHA

WARNING

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INTRODUCTIONCongratulations on your purchase of aYamaha golf car. This manual containsinformation you will need for proper operation, maintenance, and care of yourgolf car. A thorough understanding ofthese simple instructions will help you toobtain maximum enjoyment from yournew Yamaha.

If you have any questions about the operation or maintenance of your golf car,please consult a Yamaha dealer.

YAMAHA MOTOR MANUFACTURINGCORP OF AMERICA

G22AOWNER’S/OPERATOR’S

MANUAL© 2004 by Yamaha Motor

Manufacturing Corporationof America1st edition

All rights reserved. Any reprintingor unauthorized use without the

written permission ofYamaha Motor Manufacturing

Corporation of Americais expressly prohibited.

Printed in U.S.A.P/N LIT-19626-16-04

iG22A

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ii G22A

IMPORTANT MANUALINFORMATION

● Yamaha continually seeks ad-vancements in product design andquality; therefore, while this manualcontains the most current productinformation available at the time ofprinting, there may be minor discrepancies between your golf car and this manual. If you have any questions concerning thismanual, please consult yourYamaha dealer.

● This manual should be considereda permanent part of your golf carand should remain with the carwhen resold.

Read and understand this manualcompletely before operating yourgolf car.

WARNING

NOTE:Particularly important information isdistinguished in this manual by the following notations:

The Safety Alert Symbol meansATTENTION! BE ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instruc-tions could result in severe injuryor death to the golf car occupants, a bystander, or a person inspecting or repairing the golf car.

This message describes specialprecautions that must be taken toavoid damage to the golf car.

This message provides additional keyinformation.

NOTE:

CAUTION

WARNING

!

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iiiG22A

1

WARRANTY

CONTENTS

1

IMPORTANT LABELS 2

MAINTENANCE SAFETY PROGRAM 4

MAINTENANCE 8

STORAGE

SPECIFICATIONS

9

WIRING 11

OPERATION 7

PRE-OPERATION CHECKS 6

CONTROLS 5

OPERATOR SAFETY 3

10

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1-1 G22A

WARRANTY

Yamaha Motor Manufacturing of America hereby war-rants that any new Yamaha Golf Car (gas and electricmodels) purchased from an authorized Yamaha dealerin the United States will be free from defects in materialand workmanship for THREE years from date of pur-chase, subject to the stated limitations.

DURING THE PERIOD OF WARRANTY any autho-rized Yamaha Golf Car Dealer will, free of charge, repairor replace, at Yamaha’s option, any part adjudgeddefective by Yamaha due to faulty workmanship ormaterial from the factory. Parts used in warranty repairswill be warranted for the balance of the machine’s war-ranty period. All parts replaced under warranty becomeproperty of Yamaha Motor Manufacturing Corporation ofAmerica.

GENERAL EXCLUSIONS from this warranty shallinclude any failures caused by:a. Abnormal strain, neglect, or abuse, including lack of

proper maintenance, and use contrary to theOwner’s/Operator’s Manual instructions.

b. Accident or collision damage.c. Installation of parts or accessories that are not

original equipment.d. Fading, rust, or deterioration due to exposure or

ordinary wear and tear.e. Modifications or alteration that affects the car’s

condition, operation, performance, or durability, orwhich makes the car serve a purpose other than useas a two-person, golf course vehicle.

f. Damage due to improper transportation.g. Acts of God, ie: lightning, hail damage, flooding, fire,

etc.

SPECIFIC EXCLUSIONS: The first year of warrantyshall cover the entire car except for batteries, batterychargers, tires and rims, which are warranted by theirrespective manufacturers. Parts excluded from the sec-ond year of warranty include the body parts, seats,mats, bumper assembly, bag carrier, scorecard holder,and the trim. Parts excluded from the third year of war-ranty include the second year exclusions, the electricalsystem (except electronic speed controller and electricmotor) and control cables. Other specific exclusionsfrom this warranty shall include any parts replaced dueto normal wear or routine maintenance, including oil, airfilter elements, brake shoes, spark plugs, starter andclutch drive belts. Any charges incurred in transportinga golf car to and from an authorized Yamaha Golf CarDealer for service or in performing field service are alsoexcluded from this warranty.

THE CUSTOMER’S RESPONSIBILITY under this war-ranty shall be to:1. Operate and maintain the golf car as specified in the

appropriate Owner’s/Operator’s Manual;2. Give notice to an authorized Yamaha dealer of any

and all apparent defects within ten (10) days afterdiscovery, and make the machine available at thattime for inspection and repairs by the dealer’s autho-rized representative.

WARRANTY TRANSFER: To transfer any remainingwarranty from the original purchaser to any subsequentpurchaser, it is imperative that the machine be inspect-ed and registered for warranty by an authorized YamahaGolf Car Dealer. In order for this warranty to remain ineffect, this inspection and registration must take placewithin ten (10) days after transfer. An inspection andregistration fee will be charged for this service.

YAMAHA MOTOR MANUFACTURING CORPORA-TION OF AMERICA MAKES NO OTHER WARRANTYOF ANY KIND, EXPRESSED OR IMPLIED. ALLIMPLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR A PARTICULIAR PURPOSEWHICH EXCEED THE OBLIGATIONS AND TIME LIM-ITS STATED IN THIS WARRANTY ARE HEREBY DIS-CLAIMED BY YAMAHA MOTOR MANUFACTURINGCORPORATION OF AMERICA AND EXCLUDEDFROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG AN IMPLIED WARRANTY LASTS, SOTHE ABOVE LIMITATION MAY NOT APPLY TO YOU.ALSO EXCLUDED FROM THIS WARRANTY AREANY INCIDENTAL OR CONSEQUENTIAL DAMAGESINCLUDING LOSS OF USE. SOME STATES DO NOTALLOW THE EXCLUSION OR LIMITATION OF INCI-DENTAL OR CONSEQUENTIAL DAMAGES, SO THEABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGALRIGHTS, AND YOU MAY ALSO HAVE OTHERRIGHTS, WHICH VARY, FROM STATE TO STATE.

YAMAHA MOTOR MANUFACTURING CORP., NEWNAN, GEORGIA 30265-1320

EFFECTIVE DATE: 06/01/02LIT-13710-03-02

YAMAHA MOTOR MANUFACTURINGCORPORATION OF AMERICA

LIMITED 3-YEARGOLF CAR WARRANTY

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G22A 2-1

IMPORTANT LABELS

Y-505

1

2

4 3

SAFETY AND INSTRUCTION LABELS

Please read the followinglabels carefully beforeoperating your golf car, and promptly replace anylabels which become dam-aged or removed.

WARNING

Y-500

Y-502

WARNINGAVERTISSEMENT

Do not tamperwith governorto increasespeed. Operationat higher speedscan cause lossof control thatcan result insevere injury ordeath.

Ne pas toucher aurégulateur afind’augmenter lavitesse. Unfonctionnementà des vitessessupérieures auréglage initialpeut causer uneperte de contrôlequi peut menerà une blessuregrave, voirefatale.

YAMAHA JN3-K8299-10

1

2

3

4

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G22A

Y-851

THIS ENGINE MEETS **** - **** CALIFORNIA EMISSION REGULATIONS FOR OFF-ROAD ENGINES.THIS ENGINE CONFORMS TO **(*****.******) U.S. EPA REGULATIONS FOR SMALL NONROAD ENGINES.

2-2

IMPORTANT LABELS

GOLF CAR SERIALNUMBERThe golf car serial number 1 isstamped in the location shown.

The first three digits of the serial num-ber are for model identification; theremaining digits are the unit produc-tion number. Keep a record of thesenumbers for reference when orderingparts from a Yamaha dealer.

The engine serial number 2 isaffixed in the location shown.

NOTE:

Y-852A

3 Engine Information

Y-102a

JU

0

1

2

3

IIIII

IIIII

I III

IIII I

I

SM-03-399

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G22A 3-1

OPERATOR SAFETY!

Y-67

Y-68

Y-8

Yamaha golf cars are designed to besimple to operate. However, be sureto observe the following:

BEFORE OPERATINGTHE GOLF CAR● Read this Owner’s/Operator’s man-

ual and all safety and instructionlabels on the golf car before operat-ing.

● Perform the pre-operation checksfound in Section 6 of this manual.

● Only authorized people shoulddrive the golf car, from the driver’sside only, and only in designatedareas.

● Do not allow more than two peopleto ride in the golf car. This golf car isrestricted to two occupants.

● Do not operate the golf car whileunder the influence of alcohol ordrugs; their affect on vision andjudgment make operating a golf cardangerous.

● Do not operate the golf car on pub-lic streets, roads or highways. Suchuse is prohibited by law, and dan-gerous. Operation on public roadscan result in collision with othervehicles.

WHILE OPERATING THEGOLF CAR● Keep your entire body inside the

golf car, remain seated, and hold onwhen the car is in motion.

● Do not start the golf car until alloccupants are seated.

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G22A3-2

● Keep your hands on the steeringwheel and your eyes on the pathahead.

● Use extra care in congested areasor when backing up. Always backup slowly, and watch carefully.

● Avoid starting or stopping abruptly.

● Vary the speed of the golf car tomatch the terrain of the course.

● Avoid turning the steering wheel toosharply at higher speeds.

● Always drive slowly straight up orstraight down slopes – never at anangle.

● Do not run the engine indoors.Exhaust gas is poisonous.

● Do not make any modification oraddition which affects capacity orsafe operation, or make anychanges not in accordance with theowner’s/operator’s manual.

OPERATOR SAFETY!

Y-10

Y-9

Y-69

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G22A 4-1

GOLF COURSE SAFETY PROGRAM!

Like all machines, golf cars cancause injury if improperly used ormaintained. This section containsbroad safety practices required forsafe golf car operation. Before golfcars are operated, golf course per-sonnel should establish any addition-al safety practices that may berequired for safe operation.

Experience has shown that golf carsare safe when operated in accor-dance with the safety warningsaffixed to every golf car. This safeoperation is enhanced when golf carsare used according to the safety rulesand practices established to meet theterrain and conditions of the coursethey are used on.

The information contained here isintended for golf course personnelresponsible for golf car safety. If youare responsible for the operation andmaintenance of this golf car, weencourage you to implement this golfcar safety program.

DRIVER QUALIFICATIONSAllow only authorized people to oper-ate golf cars. It is recommended thatonly people who possess a validmotor vehicle driver’s license beallowed to operate golf cars.

Place operation and safety instruc-tions recommended by the golf carmanufacturer, along with the golfcourse safety rules, in a conspicuousplace near the golf car rental area orgolf car pick-up area. It is also rec-ommended that the following warningbe posted in a conspicuous location:

Do Not Operate Golf Cars WhenUnder The Influence Of Alcohol OrDrugs

GOLF COURSE SAFETYSURVEYPerform safety surveys regularly toidentify hazardous areas where golfcars should not be operated.

GOLF COURSE HAZARDPREVENTIONThe following golf course hazardsmust be made safe:

● Steep Grades. Where steepgrades exist, restrict golf cars todesignated golf car pathwayswhere possible. In addition, identifysteep grades with a suitable warn-ing like:

Warning: Steep Grade, DescendSlowly With Foot On Brake

● Sharp Turns, Blind Corners,Bridge Approaches. Chain orrope off these potentially haz-ardous areas or identify them witha suitable warning describing thenature of the hazard and the prop-er precautions to be taken to avoidthe hazard.

● Wet Areas. Wet grass may causea golf car to lose traction and mayaffect stability. Chain or rope off wetareas or identify wet areas with asuitable warning.

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G22A4-2

GOLF COURSE SAFETY PROGRAM

● Loose Terrain. Loose terrain maycause a golf car to lose traction andmay affect stability. Repair looseterrain, chain or rope off theseareas, or identify loose terrain witha suitable warning.

● Golf Car and Pedestrian Interfer-ence. Reroute golf car traffic orpedestrian traffic in congestedareas wherever possible to preventaccidents. If it is impractical toreroute traffic, erect warning signsto warn pedestrians of golf car traf-fic, and to warn golf car operators todrive slowly, use caution, and watchfor pedestrians.

MAINTENANCE REQUIRED FOR GOLFCAR SAFETYPractice the following to help ensurethe safety of golf car operators:

● Preventative Maintenance. Per-form all scheduled maintenance inaccordance with manufacturer’srecommendations to provide thegolfing patron with a safe, properlyoperating golf car.

● Personnel. Allow only qualified,trained, and authorized personnelto inspect, adjust, and maintain golfcars.

● Parts and Materials. Use onlyreplacement parts and materialsrecommended by the manufacturer.

● Ventilation. Properly ventilate allmaintenance and storage areas inaccordance with applicable firecodes and ordinances to avoid firehazards. Ventilation is required toremove flammable vapors andfumes from gasoline powered carstorage areas. Ventilation is alsorequired to remove hydrogen gasfrom the car storage areas duringthe battery charging process.

!

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G22A 4-3

GOLF COURSE SAFETY PROGRAM

SAFETY PRECAUTIONSDURING MAINTENANCEWhen performing maintenance, fol-low all safety instructions containedin the manufacturer’s operation andservice manuals, as well as the fol-lowing safety procedures:

● Properly immobilize golf car beforebeginning any maintenance.

● Properly block chassis beforeworking underneath golf car.

● Before disconnecting any part ofthe fuel system, drain the applica-ble part of the system to preventfuel leaks.

● Avoid fire hazards, and haveappropriate fire protection equip-ment available.

● Before working on an electric golfcar, disable the car’s electrical sys-tem in accordance with the manu-facturer’s instructions.

● Use only properly insulated toolswhen working on electrically pow-ered golf cars or around batteries.

● Maintain all safety devices includ-ing brakes, steering mechanisms,warning devices, and governors, ina safe operating condition. Do notmodify these safety devices assupplied by the manufacturer.

● After each maintenance or repair,the car must be driven by a quali-fied, trained, and authorized per-son – in an area free of pedestriantraffic – to ensure proper operationand adjustment.

● Record all maintenance performedin a maintenance record log bydate, name of person performingmaintenance, and type of mainte-nance. Periodically inspect mainte-nance log to ensure accurate andcomplete entries.

● Provide operator comment cards toassist in identifying non-periodicmaintenance needs for specific golfcars.

● Maintain in a legible condition allnameplates, warnings, and instruc-tions provided by the manufacturer.

● If new nameplates, warnings, orinstructions are needed, contactyour Yamaha dealer.

FUEL HANDLING/STORAGE AND BATTERY CHARGINGTake the following precautions toensure maintenance worker safety:

● Supervise the storage and han-dling of liquid fuels in accordancewith applicable fire and safetyrequirements.

● Only use battery changing andcharging facilities and proceduresthat are in accordance with applic-able ordinances and regulations.

● Periodically inspect fueling andcharging facilities and proceduresto be certain that applicable safetycodes, regulations, and proceduresare being followed.

!

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G22A5-1

CONTROLS

Y-12a

19 8

6

5

4

P

Y-506

710

Y-507

16

17

15

14 3

Y-1313

11

2

12

FEATURES1 Steering wheel2 Seat3 Fuel cap4 Brake pedal5 Parking brake pedal6 Accelerator pedal7 Drive selector lever8 Main switch9 Oil warning lighta Choke knobb Front cowlc Front tired Front bumpere Rear cowlf Rear bumperg Rear tireh Battery

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G22A 5-2

CONTROLS

Y-15

OFF

ON

Y-16

OFF

ON

OFFOILWARNING

ON

Y-17

A

MAIN SWITCHThe main switch controls the follow-ing items:

OFFIgnition circuit is switched off.The key can be removed only in thisposition.

ONElectrical circuits are switched on.The golf car can be driven.

OIL WARNING LIGHT When the engine oil level falls belowan acceptable level, this light comeson. If the light comes on, stop theengine, check the engine oil level,and add oil as necessary. (Seepage 6-3).

å Oil warning light

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G22A5-3

DRIVE SELECT LEVERThe drive select lever is used to shiftthe golf car into forward or reverse.After coming to a complete stop,move the lever to the desired posi-tion.

Lever Position Car Movement

F FORWARD

R REVERSE

The back-up buzzer will beep whenthe drive select lever is turned to “R.”

ACCELERATOR PEDALThe accelerator pedal controls thegolf car’s speed.

Action Car Speed

Depress pedal Increase

Release pedal Decrease

å Accelerator pedal

BRAKE PEDALPress down on the brake pedal tostop the golf car.

∫ Brake pedal

NOTE:

CONTROLS

Y-19

Y-20A

A

Y-18

Y-21a

B

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G22A 5-4

PARKING BRAKEPEDALPress down on the parking brakepedal whenever parking the golf car.

ç Parking brake pedal

Release the parking brake bydepressing the accelerator pedal.

The parking brake will automaticallyrelease when the accelerator pedalis depressed. If the main switch is inthe “ON” position, depressing theaccelerator may suddenly cause thegolf car to move.

CHOKE KNOBPull and hold out choke knob whenstarting a cold engine. Release theknob after the engine starts.

å Choke knob

WARNING

NOTE:

CONTROLS

Y-22a

C

Y-23

A

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G22A6-1

PRE-OPERATION CHECKS

Y-512

Pre-operation checks should bemade each time you use your golfcar. Get in the habit of performing thefollowing checks in the same way sothat they become second nature.

● Be sure the main switch key isremoved before performing thepre-operation checks to preventaccidental starting, and applythe parking brake to keep the carfrom moving.

PRE-OPERATIONCHECKLISTBefore each use check the following:

✔ Fuel system✔ Engine oil level✔ Battery✔ Tire condition✔ Steering system✔ Back-up buzzer✔ Pedal operation✔ Body and chassis

SEATOpen the seat for checking and ser-vicing.

WARNING

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G22A 6-2


Y-513

B

A

FUEL SYSTEMMake sure there is sufficient fuel inthe tank, and check fuel line and con-nections for leakage.

å Fuel tank∫ Fuel cap

Gasoline and its vapors are highlyflammable and explosive.● Do not smoke when refueling

and keep away from sparks,flames, or other sources of igni-tion.

● Stop engine and allow it to coolfor several minutes before refuel-ing.

● Refuel in a well-ventilated area.● Take care not to spill gasoline. If

gasoline spills, wipe it up imme-diately with dry rags. Always dis-pose of gasoline-soaked ragsproperly.

● Tighten the filler cap securelyafter refueling.

● If you swallow gasoline, inhale alot of gasoline vapor, or getgasoline in your eyes, get imme-diate medical attention.

● If any gasoline gets on your skin,immediately wash with soap andwater. Change clothing if gaso-line spills on it.

Avoid using gasoline blended withmethyl alcohol which can damagefuel system parts.

CAUTION

WARNING

Recommended fuel:Unleaded gasoline

Fuel tank capacity:6.1 US gal(23.0 L)

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G22A6-3

ENGINE OILWith the golf car parked on levelground, remove the dipstick andmake sure the engine oil is betweenthe MIN and MAX marks (the cross-hatched area on the end of the dip-stick).

å Oil level dipstick∫ Maximum oil levelç Safe operating range

If the oil level is below the MIN markon the dipstick, add oil through the oilfiller hole until the oil level is betweenthe MIN and MAX marks.

å Oil filler hole

● Use care not to fill past the MAXdipstick mark, and be sure noforeign material enters thecrankcase.

● Use care not to get oil on thestarter belt.

The distance between the dipstickmarks represents approx. 1/2 US qt(1/2 L) of oil.

Recommended engine oil classifica-tion: API Service SE, SF, or SG.Engine oils labeled “Energy Con-serving II” are recommended.

NOTE:

NOTE:

CAUTION


Recommended oil:YAMALUBE 4-cycle oil orSAE 10W-30

Engine oil capacity:1.16 US qt(1.1 L, 1100 cc)

Oil change quantity:1.0 US qt(0.9 L, 900 cc)

Y-514

MIN MAX

Y-28

A

B

C

Y-515

A

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G22A 6-4

Engine Cooling Inlet DuctCheck the engine cooling inlet duct fordebris. Remove any debris present.

å Engine cooling inlet duct

BATTERYCheck that the battery is held secure-ly in place to prevent the battery frombeing damaged from vibration or jar-ring. Also check that no battery capsare missing to prevent battery acidfrom spilling from the battery. Checkthe battery terminals for corrosion.

TIRE CONDITION

Tire Air PressureCheck the tire air pressure beforeoperating the golf car.

Tire pressure:

For G22A: 16 psi(110 kPa, 1.1 kgf/cm2)

Tire Wear LimitCheck the tire surface for damage,cracks or embedded objects. Whentire tread wears down to 0.04 in. (1mm), replace the tire.

å Wear limit


Y-30

A

Y-31

A

G22A1

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G22A6-5

Y-32

Y-33

Y-21a

B


STEERING SYSTEMCheck the steering system for exces-sive freeplay by:

● 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 hearrattling sounds which may indicateloose steering components, consult aYamaha dealer.

BACK-UP BUZZERCheck the back up buzzer by movingthe drive select lever to “R” forreverse. The buzzer should sound.

PEDAL OPERATIONCheck the following pedal controls forproper operation. If a pedal does notwork properly, consult a Yamahadealer.

Brake PedalMake sure the brake pedal feels firmwhen pressed and returns to its orig-inal position when released.

∫ Brake pedal

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G22A 6-6


Parking Brake PedalMake sure the parking brake pedallocks in place with a positive click,and releases when the acceleratorpedal is pressed.


Release the parking brake bydepressing the accelerator pedal.

Accelerator Pedal

Before checking operation of theaccelerator pedal, be sure themain switch is in the “OFF” posi-tion.

Make sure the accelerator pedaloperates smoothly.


BODY AND CHASSISBefore each use, visually inspect thegolf car body and chassis for damageand/or missing parts.

WARNING

NOTE:Y-22a

C

Y-20A

A

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G22A7-1

Y-16

OFF

ON

Y-18

Y-23

A

Y-20A

A

OPERATION

STARTING1. With the parking brake applied,

turn the drive select lever to “F”for forward, or “R” for reverse.

Do not shift from “F” forward to“R” reverse while the golf car ismoving.

2. Turn the main switch to “ON.”

Do not depress the acceleratorpedal when turning on the mainswitch or the golf car may sudden-ly start moving.

3. Pull the choke knob out and holdit while starting. Release thechoke knob after the enginestarts.

å Choke knob

The choke is not required when theengine is warm.

4. Check that your path is clear inthe direction you plan to go, andslowly depress the acceleratorpedal. The golf car will start tomove.


The parking brake automaticallyreleases when the accelerator pedalis depressed.

NOTE:

NOTE:

WARNING

CAUTION

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G22A 7-2

OPERATION

STOPPINGTo stop the golf car, gradually pressdown on the brake pedal.

∫ Brake pedal

When the car has come to a stop,apply the parking brake pedal andturn the main switch to “OFF.”


Do not hold the golf car on anincline with the accelerator – usethe brake.

CAUTION

Y-65aB

C

TROUBLESHOOTINGIf the vehicle’s engine won’t start, usethe following chart:

Cause Remedy

Fuel System

No fuel in tank Fill fuel tankClogged fuel Clean fuel line line – Consult

Yamaha dealerForeign matter Clean fuel in fuel filter fiter – Consult

Yamaha dealerClogged Clean carburetorcarburetor – Consult

Yamaha dealerElectrical System

Spark plug dirty Clean carbonwith carbon, or or wipe sparkwet plug dryFaulty ignition Consultsystem Yamaha

dealer

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G22A8-1

PERIODIC MAINTENANCE CHARTSRegular maintenance is required for the best performance and safe operation of yourgolf car.

Be sure to turn off the main switch and apply the parking brake when you performmaintenance unless otherwise specified. If the owner is not familiar with machine ser-vicing, this work should be done by a Yamaha dealer or other qualified mechanic.

WARNING

MAINTENANCE

FOR G22A

C - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE

20 Rounds 125 rds 250 rds 500 rds 1000 rdsPre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs

Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mlstion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms

(Every (Every 6 (Every (Every (Everymonth) months) year) 2 years) 4 years) Page

PRE- Check engine oil C C C 6-3

OPER- Check air cooling duct C C C C C C *

ATION Check fuel lines for leakage C C C C C C 6-2

CHECKS Check fuel level C C C C C C 6-2

Check for loosenessand corrosion of battery C C C C C C 6-4terminals and hold downs

Check brake pedal freeplayC CA CA CA CA CA 8-12and adjust if necessary

Check steering operation C C C C C 6-5

Check tire pressure, treadC CA CA CA CA CA 6-4depth, tire surface for damage

Check body and chassis forC C C C C C

6-6damage

Check tightness of all bolts,C C C C C C *nuts, and screws

Check reverse buzzerC C C C C C 6-5operation

EVERY Check fuel filter for clogging C C C C C *

MONTH Check wear of drive belt C C C C C 8-8

Check operation ofC C C C C 6-5Forward / Reverse shifting

Clean / Lube pedal control area CL –

EVERY 6 Wash pre-filter, check airS S S S 8-7MONTHS cleaner element

Check spark plug and plug capC C C C 8-4condition** / Check compression

Check shock absorbers for oilC C C *leaks and damaged springs

* Items with out 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.

**Related to emission control system.

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G22A 8-2

MAINTENANCE

C - CHECK CA - CHECK AND ADJUST R - REPLACE S - SERVICE CL - CLEAN AND LUBRICATE L - LUBRICATE

20 Rounds 125 rds 250 rds 500 rds 1000 rdsPre- 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs

Remarks Opera- 100 miles 600 mls 1200 mls 2500 mls 5000mlstion 160 kms 1000 kms 2000 kms 4000 kms 8000 kms

(Every (Every 6 (Every (Every (Everymonth) months) year) 2 years) 4 years) Page

EVERY Replace engine oil R R R 8-5

YEAR Adjust throttle cables,**choke cable, check carburetor CA CA CA *throttle shaft for wear**

Check starter V-belt forC C C *damage and tension

Check drive belt for slippage,C C C

CL CL CL

8-8wear or scratches

Check sliding sheave and*ramp shoes; Grease secondary

Check operation of speed limiter C C C *

Apply battery terminal protectant S S S –

Check wiring connectionsC C C –and insulation

Check shoe lining thicknessC C C *and rear axle bearing play

Check steering knucklebushing freeplay / Adjustwheel alignment

CA CA CA *

Check wheel nut tightness,C C C *front wheel bearing play

Check gear box oil levelC C C 8-10and leakage

Check operation and adjustCA CA CA *pedal stop if necessary

EVERY2 YEARS

Check brushes for wear andC S *commutator for dirt

EVERY4 YEARS

Replace fuel filter andR *fuel hoses

Check tightness of cylinder CA *head / Adjust valves

Replace gear box oil R *Check for grease leakage;

CA *adjust gearbox if necessary

* Items with out 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.

**Related to emission control system.

FOR G22A

sheave bearing

Grease primary sheave L L L *

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G22A

EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS

Item Acronym• CARB. ASSY., LH., JT., CARB (Carburetor)

CARBURETOR 2 & JT.,CARBURETOR 1

• T.C.I. MAGNETO ASSY. & El (Electronic Ignition)PLUG, SPARK

• CRANKCASE 1 & HEAD, PCV (Positive Crankcase CYLINDER 1 Ventilation)

• AIR FILTER ASSY. ACL (Air Cleaner)

• MUFF., 2

The above items and the correspond-ing acronyms are provided in accor-dance with U.S. EPA REGULATIONSFOR SMALL NONROAD ENGINESand the CALIFORNIA REGULA-TIONS FOR NEW 1995 AND LATEROFF-HIGHWAY RECREATIONALVEHICLES AND ENGINES.

The acronyms conform to the latestversion of the SAE’s recommendedpractice document J1930, “DiagnosticAcronyms, Terms, and Definitions ForElectrical/Electronic System”.

It is recommended that these itemsbe serviced by a Yamaha dealer orother qualified mechanic.

8-3

MAINTENANCE

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G22A 8-4

MAINTENANCE

Spark Plug InspectionYou should periodically remove andinspect the spark plug. Dirty or wornspark plugs can cause poor perfor-mance.

å Spark plug∫ Spark plug cap

1. Check for discoloration andremove carbon deposits with aspark plug cleaner or wire brush.The normal electrode color willbe tan.

2. Check the spark plug type, andcheck the spark plug gap with afeeler gauge.

Standard spark plug: BPR2ES

Spark plug gap:0.028 ˜ 0.031 in (0.7 ˜ 0.8 mm)

å Gap

3. Clean the gasket and plug sur-faces and install the spark plugfinger tight before tightening tothe following torque:

Spark plug torque:14.5 ft.lb(20 Nm, 2.0 m.kg)

When removing or installing thespark plug, be careful not to dam-age the insulator. A damaged insu-lator could allow external sparks,which could lead to explosion orfire.

WARNING

Y-516A

B

A

Y-37

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MAINTENANCE

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G22A

Engine Oil Replacement

1. Warm up the engine for severalminutes, place the golf car on alevel surface, then stop theengine.

Use caution not to touch hotengine oil or hot engine parts, dur-ing the following procedure.

2. Place an oil pan under the enginedrain plug.

3. Remove the oil drain plug and letthe oil drain completely.

Dispose of used oil in an environmen-tally safe way, such as taking oil to anoil collection station.

4. Install the drain plug, along with anew drain plug gasket, finger tightbefore tightening to the followingtorque:

Drain plug torque:23 ft.lb(31 Nm, 3.1 m.kg)

5. Add the correct quantity of oilthrough the oil filler hole.

Recommended engine oil classifica-tion: API Service SE, SF, or SG.Engine oils labeled “Energy Con-serving II” are recommended.

NOTE:

NOTE:

WARNING

Recommended oil:YAMALUBE 4-cycle oil orSAE 10W-30

Engine oil capacity:1.16 US qt(1.1 L, 1100 cc)

Oil change quantity:1.0 US qt(0.9 L, 900 cc)

Y-624

8-5

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MAINTENANCE

G22A 8-6

Y-515

A

Y-518

A

A

A

B

Y-519

A

B

å Oil filler hole

Use care not to fill past the MAXdipstick mark, and be sure no for-eign material enters the crank-case. After replacing engine oil,check for oil leaks around thedrain plug. If oil leaks are found,consult a Yamaha dealer.

Air FilterTo remove the air filter elements:

1. Unlatch the air filter cover clipsand remove cover.

å Air filter cover clips∫ Air filter cover

2. Lift the air filter and pre-filter outof the air filter case.

å Air filter∫ Pre-filter

Be careful not to drop anythinginto the air inlet.

CAUTION

CAUTION

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MAINTENANCE

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G22A

Y-60

BA

Y-508

Inspection and cleaning:

3. Wash the foam pre-filter in soapand water. Allow it to dry.

å Soap and water∫ Foam element

4. Check the filter element. If dam-aged or dirty, replace it.

Do not wring out the foam pre-fil-ter, this could cause it to tear.

5. To replace the elements, reversethe above steps.

The pre-filter has a notch on oneside. It will only fit in the case oneway.

Drive BeltTo remove the drive belt:

1. Set the drive select lever halfwaybetween forward and reverse.

2. Pull up on the drive belt and pushit outward over the edge of thesecondary sheave.

3. Turn the secondary sheave clock-wise and the drive belt will roll offthe sheave.

4. Remove the drive belt from theprimary sheave.

CAUTION

CAUTION

8-7

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MAINTENANCE

G22A 8-8

B

A

Y-44

Inspection:

To inspect the drive belt, check forfrayed edges or tears, and measuredrive belt against the following speci-fication. If the belt shows excessivewear or damage, replace the belt witha new one.

å New: 1.22 in. (31.0 mm)∫ Replace when belt reaches:

1.06 in. (27 mm)

5. To install the drive belt, reversethe above steps, rolling the beltback over the secondary sheave.

Battery

Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuricacid. Avoid contact with skin,eyes, or clothing.Antidote:EXTERNAL: Flush with water. INTERNAL: Drink large quantitiesof water or milk. Follow with milkof magnesia, beaten egg, or veg-etable oil. Call physician immedi-ately.EYES: Flush with water for 15 minutes and get prompt medical attention.Batteries produce explosivegases. Keep sparks, flame, cigarettes, etc., away.Ventilate when charging or usingin enclosed space. Always shieldeyes when working near batteries.KEEP OUT OF REACH OF CHIL-DREN.

WARNING

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MAINTENANCE

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G22A

Y-45

++

––

The 12-volt battery that provides start-ing power to your gas car normallydoesn’t require the addition of waterduring the one year period provided bythe battery manufacturer. If the bat-tery loses its charge, have an experi-enced mechanic charge it.

Fuse Replacement

Be sure to use the specified fuse.Using a wrong fuse can cause elec-trical system damage and create afire hazard.

When replacing a fuse be sure themain switch is turned off to preventaccidental short circuiting.

1. Remove cap screw on cover. Pullfuse case cover forward.

å Cap screw∫ Fuse case cover

You do not have to remove the cover.

2. Pull cap off fuse. Pull fuse out andreplace if necessary.

ç Fuse cap∂ Fuse

Replacement Fuse:10 Amp, Blade Style

NOTE:

CAUTION

WARNING

Y-522

BA

Y-523CD

8-9

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MAINTENANCE

G22A 8-10

Gear Box OilTo check gear box oil level:

1. Place the golf car on a level sur-face.

2. Remove the access panel byremoving the screws in the twolower corners of the panel andpulling the panel from the car.

3. Remove the oil level plug å.

4. Add gear oil little by little until oilflows from the level plug hole ∫.

5. Allow excess gear oil to flow outuntil it stops.

Do not allow foreign material toenter the gear box.

6. Reinstall the oil level plug.

For gear oil replacement, consult aYamaha dealer or other qualifiedmechanic.

NOTE:

CAUTION

Y-48

Y-520

A

B

Recommended oil:SAE 90 gear oil

Gearcase capacity:G22A: 0.44 US qt(415 mL, 415 cc)

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MAINTENANCE

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G22A8-11

Before performing wheel or brakemaintenance, verify that the mainswitch is in the “OFF” position.

Wheel ReplacementTo remove and install a wheel onyour golf car:

1. With the wheels blocked to pre-vent the golf car from moving,loosen the wheel nuts.

2. Elevate the golf car with a jackand remove the wheel nuts andthe wheel.

3. Reverse the removal steps wheninstalling the wheel.

Wheel nut tightening torque:58 ft.lb (80 Nm, 8.0 m.kg)

Brake AdjustmentThe brakes on your golf car are self-adjusting.

Before you operate the car, pressdown on the brake pedal severaltimes to make sure the brakes arefunctioning properly.

Consult your Yamaha dealerbefore using your golf car if yoususpect brake problems. Brakefailure could result in a seriousaccident.

WARNING

CAUTION

Y-57

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MAINTENANCE

G22A 8-12

Brake Pedal Free PlayAdjustment

Before adjusting brake pedal freeplay, pump the brake pedal severaltimes to self-adjust the brakes.

To adjust the brake pedal free play:

1. Remove the service lid from thefloor of the golf car.

2. Check the brake pedal free playby pressing against the pedalwith two fingers (using light force)and measuring the distance thepedal travels before resistance isfelt.

Brake pedal free play Å:20-25 mm (0.79-0.98 in.)

3. If the free play distance needsadjusting, loosen the lock nut andturn the adjusting nut in or outuntil the free play specification ismet. Then tighten the lock nut inplace.

Do not overtighten the brakecables. The self adjusters may notoperate properly, reducing brakingperformance.

WARNING

CAUTION

Y-61a

Y-63

Y-62b

7

1817

1615

1413

1211

109

8

a

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G22A

STORAGE

Perform the following preparationswhen storing your golf car for extend-ed periods of time:

Turn main switch key to “OFF” posi-tion, remove key, and store key in asafe place.

DRAINING FUEL

Gasoline and its vapors are highlyflammable and explosive.

● Do not smoke when draining fueland keep away from sparks,flames, or other sources of igni-tion.

● Stop engine and allow it to coolfor several minutes before drain-ing fuel.

● Drain fuel in a well-ventilatedarea.

● Take care not to spill gasoline. Ifgasoline spills, wipe it up imme-diately with dry rags. Always dis-pose of gasoline-soaked ragsproperly.

● Tighten the filler cap securelyafter checking fuel level.

● If you inhale a lot of gasolinevapor, or get gasoline in youreyes, get immediate medicalattention.

● If any gasoline gets on your skin,immediately wash with soap andwater. Change clothing if gaso-line spills on it.

1. Fill the fuel tank.

å Float bowl drain screw

2. Drain the carburetor float bowl intoa suitable container by turning thescrew located on the bottom of thecarburetor.

WARNING

NOTE:

Y-521

A

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STORAGE

G22A 9-2

ENGINE PREPARATION With the key removed and the sparkplug lead disconnected, turn theclutch by hand until compression isfelt. This puts the valves in the closedposition.

CHASSIS PREPARATION1. Increase the tire pressure to 20

psi (137 kPa, 1.4 kgf/cm2).

2. Clean exterior of the golf car andapply a rust inhibitor.

3. Cover the golf car with a breath-able cover and store it in a dry,well-ventilated area.

BATTERYPREPARATION

1. Remove the battery from the golfcar and store it in a cool, dryplace that stays between 32˚F(0˚C) and 90˚F (30˚C).

2. Have the battery recharged every60-90 days to keep it fullycharged. The battery must bekept fully charged to avoid dam-age.

Batteries like the one supplied withyour car normally do not require youto check the water level inside thebattery for the one year warrantyperiod provided by the manufacturer.

3. Clean the top of the battery witha solution of baking soda andwater, as necessary, to removecorrosion.

Do not allow cleaning solution toenter battery cells.

CAUTION

NOTE:

LIT_19626_16_03.qxd 5/26/04 12:42 PM Page 37

SPECIFICATIONS

GENERAL SPECIFICATIONS

Items G22ADimensions:

Overall length 93.9 in. (2385 mm)Overall width 47.2 in. (1200 mm)Overall height (steering height) 46.8 in. (1190 mm)Height of floor 11.8 in. (300 mm)Wheelbase 64.3 in. (1632 mm)Tread:

Front 34.3 in. (870 mm)Rear 38.6 in. (980 mm)

Min. ground clearance 3.8 in. (97 mm)

Weight:

Dry weight (without battery) 670 lb (304 kg)

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

Hill climbing ability 27˚ (50% grade)on pavement

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10-1 G22A

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SPECIFICATIONS

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10-2G22A

ENGINEItems G22A

Description:Engine type 4-stroke, Gasoline, OHVNumber of cylinders SingleDisplacement 357 cm3

Bore x stroke 3.30 x 2.48 in. (85 x 63 mm)Compression ratio 8.1:1Rated output 11.4 hp (8.5 kw)/3500 rpmCooling system Forced air cooledStarting system StarterIgnition system TCI MagnetoSpark plug type BPR2ESSpark plug gap 0.028-0.031 in. (0.7-0.8 mm)Lubrication system SplashEngine oil type YAMALUBE 4 cycle oil or SAE 10W30Engine oil capacity 1.16 US qt (1.1 L, 1100 cc)Oil change quantity 1.0 US qt (0.9 L, 900 cc)

TRANSMISSIONItems G22A

Transmission:Type V-belt automatic centrifugal engagementV-belt width and outer line length 1.22 x 39.76 in. (31 x 1010 mm)V-belt wear limit 1.06 in. (27 mm)

Governor:Type Oil bath flyweightFactory speed setting 12 mph (19 km/h)

Differential/reduction gear: G22ADifferential type Bevel gearLubricant/capacity SAE 90 gear oil/

0.44 US qt (415 mL,415 cc)

BATTERIESItems G22A

Battery: BCI group 24,RC: minimum 75 minCCA: minimum 400A

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SPECIFICATIONS

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G22A10-3

CHASSISItems G22A

Steering system:Type Rack and PinionSteering angle (L.H.) 1.55 turnSteering angle (R.H.) 1.55 turn

Brakes:Brake system Mechanical drum brake on each rear wheel

with self-adjusters.Type of brake Dual internal expanding shoe.

Leading/trailing shoes (self-adjusting)Brake pedal freeplay linkageadjustment 20-25 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 secondnotch)(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 PRRear 18 x 8.50–8.00/4 PRRim size: 7.00–I–8.00Tire pressure: For G16A:

16 psi (110 kPa, 1.1 kgf/cm2)

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WIRING

G22A 11-1

G22A WIRING DIAGRAM

RB

RB

P

B RR

EV

FW

DR P

BB

PP

B P

Br

R/W

Br

R/W

Br

A1

F2

BB

RW

RW

R R

RR

R/W

R/W

GB

RW

G G G

G

G

B

Br

B B

R/W

Br

R/W

OF

FO

N

Br

R/Y

LBB L

G Br

B

R/W R

/W

L L

L

BB

B

B

B

–+

Y-5

09

GG Br

Br

BR

W

R Br

RR

Y

Br

Br

16

12

3

4

5

67

8

910

1415 13 12 11

19 10

211

312

413

514

615

716

8

Eng

ine

stop

rel

ayE

ngin

e gr

ound

Pic

kup

Rot

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il Le

vel g

auge

Bla

de F

use

(10A

)V

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egul

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Sta

rter

gen

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Rel

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atte

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ilot l

amp

(12V

, 3.4

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Mai

n sw

itch

Acc

eler

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p sw

itch

Bac

k sw

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Buz

zer

Bod

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9R

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top

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......

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edP

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kB

r....

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......

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/B...

......

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R/Y

......

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ello

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/W...

......

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/Whi

te

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G22A

NOTES

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NOTES

G22A

LIT_19626_16_03.qxd 5/26/04 12:42 PM Page 43

NOTES

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G22A

LIT_19626_16_03.qxd 5/26/04 12:42 PM Page 44

GOLF CAR G22A

OWNER'S / OPERATOR’SMANUAL

LIT-19626-16-04 JU0-F8199-12YAMAHA MOTOR

MANUFACTURING CORP.OF AMERICA

1000 HWY 34 East Newnan, GA 30265

770-254-4000

Printed in U.S.A2004-KCC

LIT_19626_16_03 cover.qxd 5/26/04 9:40 AM Page 1

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