OWNER’S/OPERATORSMANUAL

YAMAHA MOTORMANUFACTURING CORP.

OF AMERICA

GOLF CAR

G16AG16E

Printed in U.S.A.KCC

Yamaha Motor Corp., USA

Cypress, California made in

07/12/01

LIT196261600

USA

*LIT196261600*

1PC - G16A/E O/M

LIT-19626-16-00 JN6-F8199-13

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

G21A O_M IFC 8/8/00 7:56 AM Page 1

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

G16A, G16EOWNER’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-19626-16-00

iG16A/E

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ii G16A/E

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 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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iiiG16A/E

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 G16A/E

WARRANTY

Yamaha Motor Manufacturing Corporation of Americahereby warrants that any new G16 (gas and electricmodels) Yamaha Golf Car purchased from an authorizedYamaha dealer in the United States will be free fromdefects in material and workmanship for the period oftime stated herein, subject to the stated limitations.

THE PERIOD OF WARRANTY for any G16 (gas andelectric models) will be three years from date of pur-chase.

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 engineassembly, clutch, transmission, axles, electrical system,frame, suspension components, electric motor, controlcables, and steering gear.

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 engine assem-bly, clutch, transmission, axles, frame, suspension com-ponents, steering gear, and (on the G16E) electronicspeed 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; including oil, air filter elements, brakeshoes, spark plugs, starter and clutch drive belts. Anycharges incurred in transporting a golf car to and froman authorized Yamaha Golf Car Dealer for service or inperforming field service is also excluded from this war-ranty.

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-13710-00-96

YAMAHA MOTOR MANUFACTURINGCORPORATION OF AMERICA

G16A, G16ELIMITED WARRANTY

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WARRANTY

1-2G16A/E

� You are responsible for presenting your specialtyvehicle engine to a Yamaha dealer as soon as aproblem exists. The warranty repairs should becompleted in a reasonable time, not to exceed 30days.

If you have any questions regarding your warrantyrights and responsibilities, you should contact theYamaha Customer Relations Department at (770) 254-4164.

Yamaha Motor Manufacturing Corporation ofAmerica warrants to the ultimate purchaser andeach subsequent purchaser thereafter that eachnew 1996 and later model year specialty vehicleengine certified for sale is:

1. Designed, built, and equipped so as to conform,at the time of sale, with all applicable regula-tions adopted by the California Air ResourcesBoard, and

2. All warranted parts are free from defects inmaterial and workmanship for the warranty period of the specialty vehicle engine or theperiod prior to the first scheduled replacementpoint of the warranted part as required by themaintenance schedule, if applicable, whicheveris less. A defect exists when a deficiency inmaterial or workmanship is such that an emis-sion-related warranted part does not function as designed.

The warranty period begins on the date that the specialty vehicle engine is delivered to an ultimatepurchaser or on the date it is first placed in service.

WARRANTED PARTS INCLUDE the following:1. Fuel Metering System

Carburetor and internal parts (or fuel injection)Air/fuel ratio feedback and control systemCold start enrichment system

2. Air Induction SystemControlled hot air intake systemIntake manifold

In complance with the California Air ResourcesBoard, Yamaha Motor Manufacturing Corporation ofAmerica is pleased to explain the emission controlsystem warranty on your 1996 or later specialtyvehicle engine. New Yamaha speciality vehicleengines must be designed, built and equipped tomeet stringent anti-smog standards. Yamaha mustwarrant the emission control system on your spe-ciality vehicle engine for the periods of time listedbelow provided there has been no abuse, neglect orimproper maintenance of your speciality vehicleengine.

Your emission control system may include partssuch as the carburetor or fuel-injection system, theignition system, and catalytic converter. Also includ-ed may be hoses, belts, connectors and other emis-sion-related assemblies.

Where a warrantable condition exists, Yamaha willrepair your specialty vehicle engine at no cost to youincluding diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGEThe 1996 and later specialty vehicle engines arewarranted for two years. If any emissions-relatedpart on your engine is defective, the part will berepaired or replaced by Yamaha.

OWNER’S WARRANTY RESPONSIBILITIES� As the specialty vehicle engine owner, you are

responsible for the performance of the requiredmaintenance listed in your owner’s manual.Yamaha recommends that you retain all receiptscovering maintenance on your specialty vehicleengine, but Yamaha cannot deny warranty solelyfor the lack of receipts or for your failure to ensurethe performance of all scheduled maintenance.

� As the specialty vehicle engine owner, youshould also be aware that Yamaha may deny youwarranty coverage if your specialty vehicleengine or a part has failed due to abuse, neglect,improper maintenance or unapproved modifica-tions.

YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA

SPECIALTY VEHICLE ENGINESEMISSION CONTROL WARRANTY

YOUR WARRANTY RIGHTS AND OBLIGATIONS

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WARRANTY

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1-3 G16A/E

OWNER’S RESPONSIBILITY: The owner of thespecialty vehicle engine is responsible for the per-formance of required maintenance (see yourOwner’s/Operator’s Manual). Receipts and mainte-nance records covering the performance of regularmaintenance should be retained in the event ques-tions arise concerning maintenance. The receiptsshould be transferred to each subsequent owner ofthis specialty vehicle engine.

The emission control systems of your Yamaha spe-cialty vehicle engine were designed, built, tested,and certified as being in conformity with Californiaemission control regulations using genuine Yamahaparts. Accordingly, it is recommended that anyreplacement part(s) used for maintenance, replace-ment, or repair of emission control systems beYamaha parts. The owner may elect to have main-tenance, replacement, or repair of the emission control devices and systems performed by anyrepair establishment or individual, and may elect touse parts other than Yamaha parts for such mainte-nance, replacement, or repair without invalidatingthis warranty. However, the cost of such service orparts will not be covered under the warranty.

EXCLUSIONS: No warranty coverage will beallowed if the part(s) failure was caused byowner/operator abuse, neglect, tampering, improperadjustment unless performed by a dealer duringwarranty repair work, modification, misuse, alter-ation, or improper maintenance (see your Owner’s/Operator’s Manual).

Use of parts which are not qualitatively equivalent togenuine Yamaha parts, improper service, or lack ofrequired maintenance which causes failure of a warranted part may constitute abuse and/or improp-er service, thereby invalidating warranty liabilityhereunder.

This warranty does not cover damage resulting fromaccidents, acts of nature, or other events or occur-rences beyond the control of Yamaha. YamahaMotor Manufacturing Corporation of Americaexpressly disclaims responsibility for any and allconsequential damages, such as loss of time, inconvenience, loss of use of the specialty vehicle,or commercial loss.

Yamaha Motor Manufacturing Corporation ofAmerica1000 Hwy. 34 EastNewnan, GA 30265

3. Ignition SystemSpark plugs *Magneto or electronic ignition systemSpark advance/retard system

4. Exhaust Gas Recirculation (EGR) SystemEGR valve body, and carburetor spacer ifapplicableEGR rate feedback and control system

5. Air Injection SystemAir pump or pulse valveValves affecting distribution of flowDistribution manifold

6. Catalyst or Thermal Reactor SystemCatalytic converterThermal reactorExhaust manifold

7. Particulate ControlsTraps, filters, precipitators, and any other device used to capture particulate emissions

8. Miscellaneous Items Used in Above SystemsVacuum, temperature, and time sensitive valves and switchesElectronic controlsHoses, belts, connectors, and assemblies

9. Engine components damaged due to a failureunder warranty of a warranted part.

* The original spark plug(s) are warranted for theperiod of replacement indicated in theOwner’s/Operator’s Manual and not the useful life ofthe specialty vehicle engine (see your Owner’sManual).

DURING THE PERIOD OF THIS WARRANTY

Yamaha Motor Manufacturing Corporation ofAmerica will repair or replace any warranted partdeemed defective by Yamaha during the scope ofthe warranty without charge to the owner, includingparts, labor, and diagnosis. This work must be doneat an authorized Yamaha dealer. Give notice to anauthorized Yamaha dealer of any apparent defect(s)within a reasonable period of time after discovery.The specialty vehicle engine must be made avail-able for inspection by an authorized Yamaha dealer.

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G16A/E 2-1

IMPORTANT LABELS

Y-505

1

2

56

34

G16AG16E

G16AG16E

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

1

2

3 5

6

4

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G16A/E

Y-851

THIS ENGINE MEETS 2000-2001 CALIFORNIA EMMISSION REGULATIONS FOR OFF-ROAD ENGINES.THIS ENGINE CONFORMSTO **(*****.******) U.S. EPA REGULATIONS FOR SMALL NONROAD ENGINES.

JR3-2179R-04

2-2

IMPORTANT LABELS

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:

Y-102a

Y-852A

C ç Engine Information

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G16A/E 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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G16A/E3-2

� 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(G16A). 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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G16A/E 4-1

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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G16A/E4-2

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 flammable vapors andfumes from gasoline powered carstorage areas. Ventilation is alsorequired to remove hydrogen gasfrom electric powered car storageareas during the 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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G16A/E 4-3

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.

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

� 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.

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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G16A/E5-1

CONTROLS

Y-50618

710

Y-12

4

5

6

1

9 8

Y-507

16

17

15

14 3

Y-1313

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2

12

FEATURES1 Steering wheel2 Seat3 Fuel cap (for G16A)4 Brake pedal5 Parking brake pedal6 Accelerator pedal7 Drive selector lever8 Main switch9 Oil warning light (for G16A)a Choke knob (for G16A)b Front cowlc Front tired Front bumpere Rear cowlf Rear bumperg Rear tireh Battery (for G16A)i Receptacle (for G16E)

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G16A/E 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(G16A)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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G16A/E5-3

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.

å Brake pedal

NOTE:

CONTROLS

Y-19

Y-20

A

Y-18

Y-21

A

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G16A/E 5-4

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

å Parking brake pedal

Release the parking brake bydepressing the accelerator pedal.

CHOKE KNOB (G16A)Pull and hold out choke knob whenstarting a cold engine. Release theknob after the engine starts.

å Choke knob

NOTE:

CONTROLS

Y-22

A

Y-23

ACHOKE

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G16A/E6-1

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.

� For the G16A: During the pre-operation checks, avoid touch-ing engine parts or the mufflerwhile they are still hot.

PRE-OPERATIONCHECKLISTBefore each use check the following:

✔ Fuel system (G16A)✔ Engine oil level (G16A)✔ 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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G16A/E 6-2

PRE-OPERATION CHECKS

Y-513

B

A

FUEL SYSTEM (G16A)Make 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 get gaso-line in your eyes, get immediatemedical 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:6.3 US gal(24.0 L, 5.3 Imp gal)

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G16A/E6-3

ENGINE OIL (G16A)With 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

PRE-OPERATION CHECKS

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

Engine oil capacity:1.16 US qt(1.0 L, 0.24 Imp gal)

Oil change quantity:1.0 US qt(0.9 L, 0.19 Imp gal)

Y-514

MIN MAX

Y-28

A

B

C

Y-515

A

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G16A/E 6-4

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

å Engine cooling inlet duct

BATTERYCharge G16E batteries before eachuse. See charging steps in chapter 8,Maintenance.

Check that the battery (G16A) or bat-teries (G16E) are held securely inplace to prevent the batteries 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 G16A: 16 psi(108 kPa, 1.1 kgf/cm2)

For G16E: 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

PRE-OPERATION CHECKS

Y-30

A

Y-31

A

G16A1

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G16A/E6-5

Y-32

Y-33

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 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.

å Brake pedal

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G16A/E 6-6

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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G16A/E7-1

Y-16

OFF

ON

Y-18

Y-23

ACHOKE

Y-20

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 (G16A). Releasethe choke 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.

å Accelerator pedal

The parking brake automaticallyreleases when the accelerator pedalis depressed.

NOTE:

NOTE:

WARNING

CAUTION

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G16A/E 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

TROUBLESHOOTINGG16AIf G16A’s gas 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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G16A/E8-1

PERIODIC MAINTENANCE CHARTSRegular maintenance is required for the best performance and safe operation of your 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

MAINTENANCE

FOR G16A

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 8-18and 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 8-9

Check operation ofC C C C C —Forward / 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 8-5/*condition** / 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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G16A/E 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 8-6

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 8-8wear or scratches

Check sliding sheave andCL CL CL *ramp shoes; Grease secondary

sheave bearing.

Grease primary sheave L L L *

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 kingpin play, seal, andCA CA CA *cap / Adjust wheel alignment

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

Check gear box oil levelC C C 8-16and leakage

Check operation and adjustCA CA CA *pedal stop if necessary

EVERY Check brushes for wear andC S *2 YEARS commutator for dirt

EVERY Replace fuel filter andR *4 YEARS 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 G16A (continued)

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G16A/E8-3

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 rds 250 rds 500 rds 1000 rds

ChargePRE-OP

EVERYMONTH

EVERY 6MONTHS

EVERYYEAR

EVERY 4YEARS

8-13

8-11

8-18

*

*

*

*

*

*

*

*

6-5

6-5

6-4

6-6

8-12

8-16

*

* Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic. This manual does not contain these procedures. They are contained in the Service Manual.

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

FOR 16E

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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G16A/E

MAINTENANCE

8-4

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.

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G16A/E

MAINTENANCE - G16A

8-5

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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G16A/E

MAINTENANCE - G16A

8-6

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(1.0 L, 0.24 Imp gal)

Oil change quantity:1.0 US qt(0.9 L, 0.19 Imp gal)

Y-624

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G16A/E

MAINTENANCE - G16A

8-7

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 - G16A

8-8

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

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G16A/E8-9

MAINTENANCE - G16A

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, ciga-rettes, 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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G16A/E 8-10

MAINTENANCE - G16A

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

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MAINTENANCE - G16E

8-11

Battery Care

Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuric acid.Avoid contact with skin, eyes, orclothing.Antidote:EXTERNAL: Flush with water.INTERNAL: Drink large quantitiesof water 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 6-volt deep cycle batteries pro-vide power for your electric golf carand must be properly maintained andrecharged for maximum performanceand service life.

To maintain your batteries:

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

Do not allow cleaning solution toenter battery cells.

2. Check the fluid level before andafter charging.

CAUTION

WARNING

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G16A/E

MAINTENANCE - G16E

8-12

Y-47

Y-829

D A

C

B

� 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

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G16A/E

MAINTENANCE - G16E

8-13

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.

3. Monitor the ammeter on thecharger according to instructionsfound in the charger’s owner’smanual.

WARNING

WARNING

Y-15

OFF

ON

Y-49

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G16A/E

MAINTENANCE - G16E

8-14

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

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

5. 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-50

A

B

C

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G16A/E

MAINTENANCE - G16E

8-15

Y-51

C A

B

D

DD

Y-52

Y-653

BA

2. Connect the wire leads as shown.

å Forward∫ To relayç To controller∂ 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

Fuse Type:10 Amp, Blade Style

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G16A/E

95%

MAINTENANCE - G16A & G16E

8-16

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. 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).

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

Do not allow foreign material toenter the gear box.

5. 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:G16A: 0.44 US qt(0.42 L, 0.09 Imp gal)

G16E: 0.32 US qt(0.3 L, 0.06 Imp gal)

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 41

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G16A/E

MAINTENANCE - G16A & G16E

8-17

Wheel ReplacementTo remove and install a wheel on yourgolf 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

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 42

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G16A/E

95%

8-18

MAINTENANCE - G16A & G16E

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

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 43

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 (G16A GAS CAR)

Gasoline and its vapors are highlyflammable and explosive.

� Do not smoke when refuelingand keep away from sparks,flames, or other sources of igni-tion.

� Stop engine and allow it to coolfor several minutes before refu-eling.

� 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.

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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9-1 G16A/E

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95%

9-2G16A/E

STORAGE

ENGINE PREPARATION(G16A GAS CAR)

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.

BATTERY PREPARATIONFor G16A:

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.

For G16E:

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

Do not allow cleaning solution toenter battery cells.

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

CAUTION

NOTE:

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 45

SPECIFICATIONS

GENERAL SPECIFICATIONS

Items G16A G16EDimensions:

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 64.0 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) 653 lb (296 kg) 560 lb (254 kg)

Performance:

Maximum speed 12 mph 12-15 mph

(19 km/h) (19-24 km/h)

Minimum turning radius 113.0 in. (2.8 m) 113.0 in. (2.8 m)

Seating capacity 2 persons 2 persons

Hill climbing ability 27˚ (50% grade) 20˚ (38% grade)on pavement on pavement

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10-2G16A/E

SPECIFICATIONS

ENGINEItems G16A

Description:Engine type 4-stroke, Gasoline, OHVNumber of cylinders SingleDisplacement 301 cm3

Bore x stroke 3.07 x 2.48 in. (78 x 63 mm)Compression ratio 8.1:1Rated output 9.5 hp (7.1 kw)/4000 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 (1.0 L, 0.24 Imp gal)Oil change quantity 1.0 US qt (0.9 L, 0.19 Imp gal)

TRANSMISSIONItems G16A

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: G16A G16EDifferential type Bevel gear Bevel gearLubricant/capacity SAE 90 gear oil/ SAE 90 gear oil/

0.44 US qt (0.42 L, 0.32 US qt (0.3 L,0.09 Imp qt) 0.26 Imp qt)

BATTERIESItems G16A G16E

Battery: BCI group 24, BCI group GC-2RC: minimum 75 min RC: minimum 105 minCCA: minimum 400A

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 47

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G16A/E10-3

SPECIFICATIONS

CHASSISItems G16A and G16E

Steering system:Type Worm and pinSteering angle (L.H.) 1.5 turnSteering angle (R.H.) 1.5 turnLubricant/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: For G16A:

16 psi (108 kPa, 1.1 kgf/cm2)For G16E:

20 psi (137 kPa, 1.4 kgf/cm2)

LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 48

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G16A/E

WIRING

11-1

G16A WIRING DIAGRAM

RB

RB

P

B RR

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FW

DR P

BB

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LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 49

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G16A/E

WIRING

11-2

G16E WIRING DIAGRAM

Br

B/R

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LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 50

OWNER’S/OPERATORSMANUAL

YAMAHA MOTORMANUFACTURING CORP.

OF AMERICA

GOLF CAR

G16AG16E

Printed in U.S.A.KCC

Yamaha Motor Corp., USA

Cypress, California made in

07/12/01

LIT196261600

USA

*LIT196261600*

1PC - G16A/E O/M

LIT-19626-16-00 JN6-F8199-13