OWNER’S/OPERATORSMANUAL

YAMAHA MOTORMANUFACTURING CORP.

OF AMERICA

GOLF CAR

G19E

Printed in U.S.A.KCC

Yamaha Motor Corp., USA

Cypress, California made in

12/01/00

LIT196260076

USA

*LIT196260076*

1PC - G19E O/M

LIT-19626-00-76 JR1-F8199-11

INTRODUCTIONCongratulations on your purchase ofa Yamaha golf car. This manual con-tains information you will need forproper operation, maintenance, andcare of your golf car. A thoroughunderstanding of these simpleinstructions will help you to obtainmaximum enjoyment from your newYamaha.

If you have any questions about theoperation or maintenance of your golfcar, please consult a Yamaha dealer.

TECHNICAL SERVICE DEPTGOLF CAR SALES GROUP

YAMAHA MOTORMANUFACTURING CORP OF

AMERICA

G19EOWNER’S/OPERATOR’S

MANUAL© 2000 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-19626-00-76

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iG19E

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ii G19E

IMPORTANT MANUAL INFORMATION

� 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 fol-lowing 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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iiiG19E

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

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1-1 G19E

WARRANTY

Yamaha Motor Manufacturing Corporation of Americahereby warrants that any new G19E Yamaha Golf Carpurchased from an authorized Yamaha dealer in theUnited States, will be free from defects in material andworkmanship for the period of time stated herein, sub-ject to the stated limitations.

THE PERIOD OF WARRANTY for any G19E will bethree years from date of purchase.

The first year of warranty shall cover the entire carexcept for batteries, battery chargers, tires and rims,which are warranted by their respective manufacturers.

The second year of warranty shall cover the transmis-sion, axles, electrical system, frame, suspension com-ponents, electric motor, control cables, and steeringgear.

Parts excluded from the second year of warranty includethe body parts, seats, mats, bumper assembly, bag car-rier, scorecard holder, and the trim.

The third year of warranty shall cover the transmission,axles, frame, suspension components, steering gear,and electronic speed controller.

Parts excluded from the third year of warranty includethe second year exclusions and the electrical system(except electronic speed controller), electric motor, andcontrol cables.

DURING THE PERIOD OF WARRANTY any authorizedYamaha Golf Car Dealer will, free of charge, repair orreplace, at Yamaha’s option, any part adjudged defectiveby Yamaha due to faulty workmanship or material fromthe factory. Parts used in warranty repairs will be war-ranted for the balance of the machine’s warranty period.All parts replaced under warranty become property ofYamaha Motor Manufacturing Corporation of America.

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 origi-

nal equipment.d. Fading, rust, or deterioration due to exposure or ordi-

nary wear and tear.e. Modification or alteration that affects the car’s condi-

tion, operation, performance, or durability, or whichmakes the car serve a purpose other than use as atwo-person, golf course vehicle.

f. Damage due to improper transportation.g. Acts of God (i.e. lightning, hail damage, flooding, fire,

etc.)

SPECIFIC EXCLUSIONS from this warranty shallinclude any parts replaced due to normal wear or routinemaintenance, such as brake shoes. Any chargesincurred in transporting a golf car to and from an autho-rized Yamaha Golf Car Dealer for service or in perform-ing field service is also excluded 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 and reg-istration fee may be charged for this service.

YAMAHA MOTOR MANUFACTURING CORPORA-TION OF AMERICA MAKES NO OTHER WARRANTYOF ANY KIND, EXPRESSED OR IMPLIED. ALLIMPLIED WARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE WHICHEXCEED THE OBLIGATIONS AND TIME LIMITSSTATED 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 CORPORATION OF AMERICA Newnan, Georgia 30265-1320

Effective Date: 2/1/96LIT-13710-01-96

YAMAHA MOTOR MANUFACTURINGCORPORATION OF AMERICA

G19ELIMITED WARRANTY

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Y-843

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2-1G19E

IMPORTANT LABELS

Y-654

1

2

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5

4

Y-500 Y-655

Y-656

13

4

Y-844

5

SAFETY AND INSTRUCTION LABELS

Please read the followinglabels carefully beforeoperating your golf car, andpromptly replace any labelswhich become damaged orremoved.

WARNING

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2-2 G19E

IMPORTANT LABELS

Y-102b

JR1

GOLF CAR SERIALNUMBERThe golf car serial number is stampedin 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.

NOTE:

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3-1G19E

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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3-2 G19E

� 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 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-69

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4-1G19E

MAINTENANCE 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 cause agolf car to lose traction and mayaffect stability. Chain or rope off wetareas or identify wet areas with asuitable warning.

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4-2 G19E

MAINTENANCE SAFETY PROGRAM

� Loose Terrain. Loose terrain maycause a golf car to lose traction andmay affect stability. Repair loose ter-rain, chain or rope off these areas,or identify loose terrain with a suit-able 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 hydrogen gas from electricpowered car storage areas duringthe charging process.

For electric powered golf cars, theamount of hydrogen gas emitted dur-ing charging depends on a number offactors, such as the condition of thebatteries, the output rate of the bat-tery charger, and the amount of timethe batteries are on charge. Becauseof the highly volatile nature of hydro-gen gas and its propensity to rise andaccumulate at the ceiling in pockets, aminimum of 5 air changes per hour isrecommended. Consult applicable fireand safety codes for the specific ven-tilation levels requirement, as well asrequirements for the use of explosionproof electrical apparatus.

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4-3G19E

MAINTENANCE 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.

� Avoid fire hazards, and have appro-priate fire protection equipmentavailable.

� 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.

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

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

� Periodically inspect charging facili-ties and procedures to be certainthat applicable safety codes, regu-lations, and procedures are beingfollowed.

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5-1 G19E

CONTROLS

Y-65816 3

Y-659

4

5

6

1

8 7

Y-661

15

13

14

Y-66012

10

2

11

FEATURES1 Steering wheel2 Seat3 Batteries4 Brake pedal5 Parking brake pedal6 Accelerator pedal7 Main switch8 Drive selector switch9 Tow switcha Front cowlb Front tirec Front bumperd Rear cowle Rear bumperf Rear tireg Receptacle

Y-662

9

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5-2G19E

CONTROLS

REV FWD

OFF

ON

Y-663

REV FWD

OFF

ON

Y-664

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.

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5-3 G19E

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

Switch Position Car Movement

FWD FORWARD

REV REVERSE

The back-up buzzer will beep whenthe drive select switch is depressedto the “REV” position.

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.

å Brake pedal

NOTE:

CONTROLS

Y-19

Y-20

A

REV FWD

OFF

ON

Y-665

Y-21

A

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5-4G19E

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

å Parking brake pedal

Release the parking brake bydepressing the accelerator pedal.

TOW SWITCHBefore operating the car, make surethe tow switch is in the “RUN” position.

å Tow switch

Anytime the tow switch is moved fromthe “RUN” position to the “TOW” posi-tion and immediately moved back to“RUN”, there is a delay of approxi-mately 30 seconds before the car willrun.

Make sure the tow switch is in the“TOW” position if towing this vehicle.

NOTE:

NOTE:

CONTROLS

Y-22

A

ATOW

RUN

Y-666

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6-1 G19E

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:✔ Batteries✔ 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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PRE-OPERATION CHECKS

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G19E 6-2

BATTERYCharge batteries before each use.See charging steps in chapter 8,Maintenance.

Check that the batteries are heldsecurely in place to prevent the bat-teries from being damaged fromvibration or jarring. Also check that nobattery caps are missing to preventbattery acid from spilling from the bat-tery. Check the battery terminals forcorrosion.

TIRE CONDITION

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

Tire pressure:

20 psi(137 kPa, 1.4 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.

åWear limit

Y-30

A

Y-31

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G19E6-3

Y-667

REV FWD

OFFON

Y-668

Y-21

A

PRE-OPERATION CHECKS

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 switch to “REV” 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.

å Brake pedal

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G19E 6-4

PRE-OPERATION CHECKS

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

å Parking brake pedal

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.

å Accelerator pedal

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

WARNING

NOTE:Y-22

A

Y-20

A

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G19E7-1

REV FWD

OFF

ON

Y-664

REV FWD

OFF

ON

Y-665

Y-20

A

OPERATION

STARTING1. With the parking brake applied,

turn the drive select switch to“FWD” for forward, or “REV” forreverse.

Do not shift from “FWD” forward to“REV” 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. Check that your path is clear inthe direction you plan to go, andslowly depress the acceleratorpedal. The golf car will start tomove.

å Accelerator pedal

The parking brake automaticallyreleases when the accelerator pedalis depressed.

NOTE:

WARNING

CAUTION

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G19E 7-2

OPERATION

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

å Brake pedal

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

∫ Parking brake pedal

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

CAUTION

Y-65

B

A

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G19E8-1

MAINTENANCE

PERIODIC MAINTENANCE CHARTSRegular maintenance is required for the best performance and safe operation ofyour golf car.

Be sure to turn off the main switch and apply the parking brake when you perform maintenance unlessotherwise specified. If the owner is not familiar with machine servicing, this work should be done by aYamaha dealer or other qualified mechanic.

WARNING

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G19E 8-2

MAINTENANCE

Pre-Opera-tion

20 hours100 miles160 kms(EveryMonth)

125 hrs600 mls

1000 kms(Every 6months)

250 hrs1200 mls2000 kms

(EveryYear)

500 hrs2500 mls4000 kms(Every 2years)

1000 hrs5000 mls8000 kms(Every 4years)

PageRemarks

20 rounds 125 rounds 250 rounds 500 rounds 1000 rounds

ChargePRE-OP

EVERYMONTH

EVERY 6MONTHS

EVERYYEAR

EVERY 4YEARS

8-5

6-28-3/

8-9/8-10

*

8-9/*

*

*

*

*

*

*

—

—

6-3

6-3

6-2

6-4

8-3/8-4

8-8

8-8

* Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual doesnot contain these procedures. They are contained in the Service Manual.

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

FOR 19E

Clean battery tops, check fortightness of hold-down screws andterminals

Check brake pedal freeplay andadjust if necessary

Check steering operation

Check tire pressure, tread depth,tire surface for damage

Check body and chassis for damage

Check tightness of all bolts, nuts,and screws

Check for loose or brokenconnections

Check all wire insulation for cracksand/or worn spots

Check wheel nut tightness, frontwheel bearing play

Check gear box oil level andleakage

Check shock absorbers for oil leaksand damaged springs

Clean/Lube pedal control area

Check reverse buzzer operation

Check electrolyte level

Perform a discharge test

Apply Terminal protectant

Check operation and adjust pedal stop if necessary

Check for grease leakage; adjustgear box if necassry

Replace gear box oil

S

S

C

C

C

C

C

C

S

S

CA

CA

CL

C

C

C

C

C

C

S

S

CA

CA

C

C

C

C

C

C

C

C

S

S

S

S

CA

CA

CA

C

C

C

C

C

C

C

C

C

C

S

S

S

S

CA

CA

CA

C

C

C

C

C

C

C

C

C

C

S

S

S

S

CA

CA

CA

CA

C

C

C

C

C

C

C

C

C

C

*

*

Check shoe lining thickness andrear axle bearing play

Check kingpin play, seal, and cap / Adjust wheel alignment

C

CA

C

CA

C

CA

R

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8-3 G19E

MAINTENANCE

Battery Care

Battery electrolyte is poisonous anddangerous, causing severe burns,etc. It contains sulfuric acid. Avoidcontact with skin, eyes, or clothing.Antidote:EXTERNAL: Flush with water.INTERNAL: Drink large quantities ofwater or milk. Follow with milk ofmagnesia, beaten egg, or vegetableoil. Call physician immediately.EYES: Flush with water for 15 minutes and get prompt medical attention.Batteries produce explosive gases.Keep sparks, flame, ciga-rettes, etc.,away.Ventilate when charging or using inenclosed space. Always shield eyeswhen working near batteries.KEEP OUT OF REACH OF CHIL-DREN.

Six 8-volt deep cycle batteries providepower for your electric golf car andmust be properly maintained andrecharged for maximum performanceand service life.

To maintain your batteries:

1. Clean the tops of the batterieswith a solution of baking soda andwater, as necessary, to removecorrosion.

Do not allow cleaning solution toenter battery cells.

2. Check the fluid level before andafter charging.

CAUTION

WARNING

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MAINTENANCE

� Before charging: only add distilledwater if fluid is below the top of theplates, and then add just enough tocover plates.

� After charging: check that the fluidlevel is approximately 1/4 to 1/2inch above the plates and 1/4 to 3/8inch below the level indicator. If thefluid level is low, carefully add dis-tilled water. Adding distilled waterafter charging prevents boil over.

å Battery cap∫ Platesç Maximum fluid level∂ Minimum fluid level

Normal tap water contains miner-als which are harmful to a battery;therefore, refill only with distilledwater.

3. Using a hydrometer, check thespecific gravity of the battery fluidin each cell against the readingson the chart below. Consult aYamaha dealer if any low readingsare found, or if readings vary morethan one point between cells.

Temperature Satisfactory Uncorrected

˚F ˚C Hydrometer Reading

120 48.9 1.244

110 43.3 1.248

100 37.8 1.252

90 32.2 1.256

80 26.7 1.260

70 21.1 1.264

60 15.6 1.268

50 10.0 1.272

40 4.4 1.276

30 -1.1 1.280

CAUTION

Y-47

Y-829

D A

C

B

G19e O_M 9/19/00 3:40 PM Page 25

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8-5 G19E

MAINTENANCE

Battery Charging

Read and understand the owner’smanual provided with your golfcar’s battery charger before charg-ing batteries.

Explosive hydrogen gas is pro-duced while batteries are beingcharged. Only charge batteries inwell ventilated areas (a minimumof 5 air changes per hour is rec-ommended).

To charge the batteries in your golfcar, follow the instructions containedin your battery charger’s owner’smanual.

The following is a summary of thecharging steps. Do not attempt torecharge your golf car’s batterieswithout thoroughly reading andunderstanding the owner’s manualprovided with your charger.

1. Turn main switch key to “OFF”position.

2. With the charger properly con-nected and grounded (see charg-er’s owner’s manual), insert theDC output plug into the golf carreceptacle.

WARNING

WARNING

REV FWD

OFF

ON

Y-663

Y-669

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8-6G19E

MAINTENANCE

Do not disconnect the DC outputcord from the battery receptaclewhen the charger is on or an arccould occur that may cause anexplosion.

3. The charger will turn off automat-ically when the batteries reachfull charge.

4. After the charger has turned off,disconnect the DC output plugfrom the golf car receptacle bygrasping the plug body andpulling the plug straight out of thereceptacle.

Battery Installation

When working with batteries, donot put wrenches or other metalobjects across the battery termi-nals. An arc can occur causingexplosion of the battery.

1. Install the battery holddownplates as shown.

å Forward∫ Batteryç Battery fitting plate

WARNING

WARNING

Y-751

A

B

C

G19e O_M 9/19/00 3:40 PM Page 27

Fuse Type:3 Amp, Blade Style

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8-7 G19E

MAINTENANCE

2. Connect the wire leads as shown.

å Forward∫ To relayç To controller and receptacle∂ Between batteries

When installing batteries:� Carefully place battery cables

and holddowns making sure thatcables don’t lie across vent caps.

� Always remove the negative (–)cable to the motor controller first,and install it last.

Do not overtighten the batteryholddown nuts. Excessive forcewill damage the battery casing.

Fuse Replacement

Be sure to use the specified fuse.Using a wrong fuse can causeelectrical system damage and cre-ate a fire hazard.

When replacing a fuse be sure themain switch is turned off to pre-vent accidental short-circuiting.

å Fuse case∫ Fuse

CAUTION

WARNING

CAUTION

WARNING

Y-672

AC

B

D

D

Y-653

BA

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8-8G19E

MAINTENANCE

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 (A).

4. Add gear oil little by little until oilflows from the level plug hole (B).

Recommended oil:SAE 90 gear oil

Gearcase capacity:0.32 US qt(0.3 L, 0.06 Imp gal)

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

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8-9 G19E

MAINTENANCE

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 dealer beforeusing your golf car if you suspectbrake problems. Brake failurecould result in a serious accident.

WARNING

Y-57

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8-10G19E

MAINTENANCE

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:25-30 mm (0.98-1.18 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-61

7

1817

1615

1413

1211

109

8

Y-62

25-30 mm

Y-63

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9-1 G19E

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. Move the tow switch intothe “TOW” position.

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.

NOTE:

95%

BATTERY PREPARATION

1. Recharge the batteries and checkthe fluid levels at least once amonth.

Do not allow cleaning solution toenter battery cells.

2. Clean the tops of the batterieswith a solution of baking sodaand water, as necessary, toremove corrosion.

CAUTION

G19e O_M 9/19/00 3:41 PM Page 32

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10-1G19E

SPECIFICATIONS

GENERAL SPECIFICATIONS

Items G19EDimensions:

Overall length 93.9 in. (2385 mm)Overall width 47.2 in. (1200 mm)Overall height (steering height) 46.9 in. (1190 mm)Height of floor 11.8 in. (300 mm)Wheelbase 64.1 in. (1629 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) 560 lb (254 kg)

Performance:

Maximum speed 12-15 mph

(19-24 km/h)

Minimum turning radius 113.0 in. (2.8 m)

Seating capacity 2 persons

Hill climbing ability 24˚ (44% grade)on pavement

TRANSMISSION

Items G19E

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

0.32 US qt (0.3 L,0.26 Imp qt)

BATTERIES

Items G19E

Battery: BCI group GC-2HRC: minimum 105 min

G19e O_M 9/19/00 3:41 PM Page 33

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10-2 G19E

SPECIFICATIONS

CHASSISItems G19E

Steering system:Type Worm and pinSteering angle (L.H.) 1.5 turnSteering angle (R.H.) 1.5 turn

Lubricant/capacity Grease/3.0 US oz (0.09 L, 3.17 Imp oz)

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 25-30 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

(Bolt heads round parallel to arm) 0.04 in. (1 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: 20 psi (137 kPa, 1.4 kgf/cm2)

G19e O_M 9/19/00 3:41 PM Page 34

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WIRING

11-1G19E

G19E WIRING DIAGRAM

OF

FO

N

RR

/WR

W RY

R/W

R

OF

FO

N

R/WBr

OF

FO

N

R/YR

+

–

––

+

–

++

––

++

Br

Br

R/W

R/W

A1

A2

F1

F2

PB

PB

WR

/Y

W

Y YR

/Y

PB

R/B

Y

R/Y

R/BR

/B

R/W

RR

RR

LL

OO

BB

L O B

L O B

B

5K

111

23

1

9 8 7

23

64

515 14 16

10

R

BG

CO

NT

RO

LB

OA

RD

AS

SY

MO

SF

ET

BO

AR

DA

SS

Y

(N)

(P)

(A1)

(A2)

(F2)

(F1)

3/4

RE

C

RE

VF

WD

YR/Y W

R/W

R/W

R/Y

R/Y

R

R/Y

R/Y

WR

/YY

WR

/YY

Br

32

1

Y-6

71

T A C H

R/W R/Y

54

32

1

8

97

6

10

11

12

Mai

n sw

itch

Tow

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sw

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Acc

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1 2 3 4 5 6 7 8 9 10 11 12

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/Whi

te

G19e O_M 9/19/00 3:41 PM Page 35

OWNER’S/OPERATORSMANUAL

YAMAHA MOTORMANUFACTURING CORP.

OF AMERICA

GOLF CAR

G19E

Printed in U.S.A.KCC

Yamaha Motor Corp., USA

Cypress, California made in

12/01/00

LIT196260076

USA

*LIT196260076*

1PC - G19E O/M

LIT-19626-00-76 JR1-F8199-11