YDRA/ YDRA 2009: Service Manual

YDRA/ YDRA 2009
SERVICE MANUAL
LIT-19616-29-09
JW1-F8197-11
G29A-E Service Manual.book Page 1 Wednesday, July 16, 2008 9:20 AM
YDRA, YDRE
GOLF CAR SERVICE
MANUAL
YDRA/E SERVICE MANUAL

©2009 by Yamaha Golf-Car Company
3rd edition, June 2009
All rights reserved. Any reprinting
or unauthorized use without the written
permission of Yamaha Golf-Car Company
is expressly prohibited.
Printed in U.S.A.
P/N LIT-19616-29-09
G29A-E Service Manual.book Page -i Wednesday, July 16, 2008 9:20 AM
Chapter 1 – GENERAL INFORMATION 1

Chapter 2 – SPECIFICATIONS 2
Chapter 3 – PERIODIC MAINTENANCE 3
Chapter 4 – BATTERIES 4
Chapter 5 – ENGINE 5
Chapter 6 – DRIVE TRAIN 6
Chapter 7 – CHASSIS 7
Chapter 8 – ELECTRICAL 8
Chapter 9 – TROUBLESHOOTING 9
YDRA/E Service Manual
0 YDRA/E Service Manual

G29A-E Service Manual.book Page i Wednesday, July 16, 2008 9:20 AM
YDRA, YDRE
GOLF CAR SERVICE
MANUAL
1 General Information
Safety Precautions ................................................................................ 1-3
General Information......................................................................... 1-3
Safety Lockout Procedure ............................................................... 1-7
Discharge the Motor Control Unit Capacitor.................................... 1-7
Recommended Jack Points............................................................. 1-7
General Service Information.................................................................. 1-8
Serial Numbers................................................................................ 1-8
Washing and Cleaning .................................................................... 1-9
Correct Tools................................................................................... 1-9
Neatness ......................................................................................... 1-9
Tightening Torque ........................................................................... 1-9
Replacement Parts........................................................................ 1-10
Gaskets, Oil Seals and O-rings ..................................................... 1-10
Lock Washers/Plates and Cotter Pins ........................................... 1-10
Bearings and Oil Seals.................................................................. 1-10
Retaining Rings ............................................................................. 1-11
Disassembly and Assembly Suggestions...................................... 1-11
Special Tools....................................................................................... 1-12
For Tune-Up .................................................................................. 1-12
For Engine Service ........................................................................ 1-12
For Power Train............................................................................. 1-13
For Chassis Service ...................................................................... 1-14
For Electrical Components ............................................................ 1-15
Vehicle Storage ................................................................................... 1-17
Gas-Powered Cars ........................................................................ 1-17
Electric-Powered Cars................................................................... 1-18
2 Specifications
General Specifications .......................................................................... 2-2
General............................................................................................ 2-2
Transmission ................................................................................... 2-2
Batteries .......................................................................................... 2-3
Chassis............................................................................................ 2-3
Paint Codes..................................................................................... 2-3
Torque Specifications............................................................................ 2-4
Engine ............................................................................................. 2-4
Service Specifications (YDRA).............................................................. 2-6
Engine ............................................................................................. 2-6
Primary Sheave Assembly ............................................................ 2-10
Secondary Sheave Assembly ....................................................... 2-10
Cable Routing - YDRA ........................................................................ 2-11
Service Specifications (YDRE)............................................................ 2-13
Cable Routing - YDRE ........................................................................ 2-15
YDRA/E Service Manual i

G29A-E Service Manual.book Page ii Wednesday, July 16, 2008 9:20 AM
3 Periodic Maintenance
— Periodic Maintenance Program —
Inspection and Adjustment Schedule .................................................... 3-5
YDRA - Gas..................................................................................... 3-5
YDRE - Electric ............................................................................... 3-7
Daily Checks - Gas Cars ....................................................................... 3-9
Operational Inspection .................................................................... 3-9
Check the Engine Oil..................................................................... 3-10
Clean the Engine Cooling Inlet Duct ............................................. 3-10
Inspect the Fuel Lines ................................................................... 3-10
Check the Fuel Level..................................................................... 3-10
Check the Battery.......................................................................... 3-10
Check the Brakes .......................................................................... 3-11
Check the Steering........................................................................ 3-11
Inspect Wheels and Tires.............................................................. 3-11
Check the Body and Chassis for Damage .................................... 3-12
Check the Tightness of Bolts, Nuts, Screws and Rivets ............... 3-12
Check Reverse Buzzer Operation................................................. 3-12
Monthly Service - Gas Cars ................................................................ 3-12
Inspect the Fuel Filter and Hoses.................................................. 3-12
Drive Belt....................................................................................... 3-13
Adjust the Shift Cable.................................................................... 3-13
Check the Pedal Group ................................................................. 3-14
Six-Month Service - Gas Cars............................................................. 3-15
Clean the Pre-Filter/Air Filter......................................................... 3-15
Check the Engine Compression Pressure .................................... 3-16
Check and Adjust the Valve Clearance and Spark Plug ............... 3-17
Inspect the Shock Absorbers ........................................................ 3-20
Yearly Service - Gas Cars................................................................... 3-20
Change the Engine Oil .................................................................. 3-20
Adjust the Throttle Cables ............................................................. 3-21
Starter Belt .................................................................................... 3-23
Adjust the Starter Belt ................................................................... 3-24
Check and Adjust the Speed Limiter ............................................. 3-24
Inspect the Wire Harness and Electrical Cables ........................... 3-25
Inspect the Rear Axle Bearing....................................................... 3-25
Inspect the Steering Knuckle......................................................... 3-26
Wheel Alignment ........................................................................... 3-26
Inspect the Front Wheel Bearing................................................... 3-27
Check the Transaxle Oil Level ...................................................... 3-28
Adjust the Parking Brake............................................................... 3-29
Adjust Brake Pedal Free Play ....................................................... 3-29
Adjust Pedal Stop.......................................................................... 3-30
Two-Year Service - Gas Cars ............................................................. 3-30
Inspect the Starter/Generator........................................................ 3-30
Four-Year Service - Gas Cars............................................................. 3-31
Change the Transaxle Oil.............................................................. 3-31
Inspect the Brake Discs................................................................. 3-32
ii YDRA/E Service Manual

G29A-E Service Manual.book Page iii Wednesday, July 16, 2008 9:20 AM
Daily Checks - Electric Cars................................................................ 3-33

Operational Inspection .................................................................. 3-33
Inspect the Batteries...................................................................... 3-33
Inspect the Brakes......................................................................... 3-33
Inspect the Steering System ......................................................... 3-33
Inspect the Wheels and Tires........................................................ 3-33
Check the Reverse Buzzer Operation ........................................... 3-34
Monthly Service - Electric Cars ........................................................... 3-35
Check the Battery Electrolyte Level .............................................. 3-35
Inspect the Charge Receptacle ........................................................... 3-35
Inspect the Electrical Connectors .................................................. 3-35
Six-Month Service - Electric Cars........................................................ 3-36
Yearly Service - Electric Cars.............................................................. 3-37
Perform the Discharge Test .......................................................... 3-37
Apply Battery Terminal Protectant................................................. 3-37
Inspect the Controller Connector................................................... 3-37
Wheel Alignment ........................................................................... 3-38
Adjust the Parking Brake ............................................................... 3-41
Adjust the Pedal Stop.................................................................... 3-42
Four-Year Service - Electric Cars........................................................ 3-43
4 Batteries
— General Information —
Introduction............................................................................................ 4-3
Recommended Equipment.............................................................. 4-3
General Care................................................................................... 4-3
Battery Type .................................................................................... 4-3
Battery Cycle Life ............................................................................ 4-4
— Service Procedures —
Preventive Maintenance........................................................................ 4-5
Battery Cleaning.............................................................................. 4-6
Battery Inspection............................................................................ 4-6
Electrolyte Levels ............................................................................ 4-7
Battery Watering.............................................................................. 4-8
YDRA/E Service Manual iii

G29A-E Service Manual.book Page iv Wednesday, July 16, 2008 9:20 AM
Battery Charging ................................................................................... 4-9

Charging Guidelines...................................................................... 4-10
Charging Procedure ...................................................................... 4-10
Battery Charger................................................................................... 4-11
Charger Safety .............................................................................. 4-11
Features and Benefits ................................................................... 4-11
Installation ..................................................................................... 4-12
Grounding...................................................................................... 4-12
Charging (for Western Hemisphere Markets)................................ 4-12
Five-Step Charging Cycle ............................................................. 4-14
Troubleshooting............................................................................. 4-15
Charging (for All Markets Outside of the Western Hemisphere) ... 4-16
Battery Storage ............................................................................. 4-21
Testing and Troubleshooting Batteries ............................................... 4-21
Specific Gravity Test ..................................................................... 4-22
Open-Circuit Voltage Test ............................................................. 4-23
Discharge Load Test ..................................................................... 4-23
Battery Discharge Worksheet........................................................ 4-26
Remove and Replace the Battery ....................................................... 4-27
5 Engine
— Tests and Adjustments —
Engine Tests and Adjustments ............................................................. 5-3
Check the Engine Compression Pressure ...................................... 5-3
Testing the Fuel Pump .................................................................... 5-3
Spark Output Test ........................................................................... 5-4
Test and Adjust Transistor Control Ignition (TCI) ............................ 5-4
Adjust the Choke Cable................................................................... 5-5
— Engine Repair —
Preparation for Engine Repair............................................................... 5-6
Carburetor ............................................................................................. 5-6
Air Filter Housing............................................................................. 5-6
Remove the Carburetor................................................................... 5-7
Repair the Carburetor...................................................................... 5-8
Install the Carburetor..................................................................... 5-11
Muffler ................................................................................................. 5-11
Remove the Engine............................................................................. 5-12
Disassemble the Engine ..................................................................... 5-14
Cylinder Head and Rocker Arm Components ............................... 5-14
Remove the Cylinder Head ........................................................... 5-15
Disassemble the Cylinder Head .................................................... 5-16
Remove the Flywheel Magneto..................................................... 5-18
Remove the Camshaft Components ............................................. 5-20
Remove Piston and Crankshaft..................................................... 5-22
iv YDRA/E Service Manual

G29A-E Service Manual.book Page v Wednesday, July 16, 2008 9:20 AM
Inspect the Engine Components ......................................................... 5-23

Inspect the Cylinder Head ............................................................. 5-23
Check the Cylinder Head .............................................................. 5-24
Inspect the Camshaft .................................................................... 5-29
Check the Valve Lifter ................................................................... 5-30
Check the Balancer Shaft.............................................................. 5-30
Check the Bearings ....................................................................... 5-30
Check the Cylinder and Piston ...................................................... 5-31
Check the Piston Rings ................................................................. 5-32
Check the Piston Pin ..................................................................... 5-33
Check the Crankshaft.................................................................... 5-33
Assemble the Engine .......................................................................... 5-34
Assemble the Piston...................................................................... 5-34
Install Piston and Crankshaft......................................................... 5-35
Install the Camshaft Components ................................................. 5-36
Install the Flywheel Magneto......................................................... 5-37
Assemble the Cylinder Head......................................................... 5-37
Install the Cylinder Head ............................................................... 5-38
Install the Engine................................................................................. 5-39
6 Drive Train
— Drive Train Repair —
Forward and Reverse Shifting Assembly - Gas Cars............................ 6-3
Shift Cables - Gas Cars......................................................................... 6-4
Remove the Shift Cables................................................................. 6-4
Install the Shift Cables..................................................................... 6-4
Replace the Drive Belt........................................................................... 6-5
Primary Sheave Assembly .................................................................... 6-5
Remove the Primary Sheave Assembly.......................................... 6-5
Disassemble and Inspect the Primary Sheave Assembly ............... 6-6
Assemble the Primary Sheave Assembly ....................................... 6-8
Install the Primary Sheave Assembly............................................ 6-10
Secondary Sheave Assembly ............................................................. 6-10
Remove the Secondary Sheave Assembly ................................... 6-10
Install the Secondary Sheave Assembly ....................................... 6-10
Transaxle - YDRA (Gas Car)............................................................... 6-10
Remove the Transaxle - YDRA ..................................................... 6-10
Install the Transaxle - YDRA ......................................................... 6-13
Disassemble the Transaxle - YDRA.............................................. 6-14
Inspect the Transaxle .................................................................... 6-20
Assemble the Transaxle................................................................ 6-21
Transaxle - YDRE (Electric Car) ......................................................... 6-31
Remove the Transaxle - YDRE ..................................................... 6-31
Install the Transaxle - YDRE ......................................................... 6-32
Disassemble the Transaxle - YDRE.............................................. 6-33
YDRA/E Service Manual v

G29A-E Service Manual.book Page vi Wednesday, July 16, 2008 9:20 AM
7 Chassis
— Chassis Repair —
General Repair ...................................................................................... 7-3
Remove and Install the Floor Mat ................................................... 7-3
Front and Rear Bumper ........................................................................ 7-4
Remove the Front Bumper .............................................................. 7-4
Install the Front Bumper .................................................................. 7-4
Remove the Rear Bumper............................................................... 7-4
Install the Rear Bumper................................................................... 7-4
Seat....................................................................................................... 7-5
Remove the Seat............................................................................. 7-5
Install the Seat................................................................................. 7-5
Sun Roof ............................................................................................... 7-5
Remove the Sun Roof ..................................................................... 7-5
Install the Sun Roof ............................................................................... 7-7
Remove the Front Cowling.............................................................. 7-9
Install the Front Cowling................................................................ 7-11
Rear Body ........................................................................................... 7-11
Remove the Rear Body ................................................................. 7-11
Install the Rear Body ..................................................................... 7-14
Front Wheel and Tire Service ............................................................. 7-15
Remove the Wheels ...................................................................... 7-16
Inspect the Wheels........................................................................ 7-17
Brake Cable ........................................................................................ 7-18
Remove ......................................................................................... 7-18
Install ............................................................................................. 7-19
Pedal Group Components................................................................... 7-20
Remove the Pedal Assembly ........................................................ 7-22
Disassemble the Throttle Pedal .................................................... 7-23
Assemble the Throttle Pedal ......................................................... 7-25
Disassemble the Brake Pedal ....................................................... 7-27
Inspect and Repair Springs, O-rings and Bearings ....................... 7-29
Inspect the Parking Brake ............................................................. 7-30
Assemble the Brake Pedal ............................................................ 7-30
Install the Pedal Assembly ............................................................ 7-32
Steering ............................................................................................... 7-34
Remove Steering Assembly .......................................................... 7-36
Disassemble Steering Assembly................................................... 7-38
Inspect the Steering Component................................................... 7-40
Assemble the Steering Assembly.................................................. 7-42
Install the Steering Assembly ........................................................ 7-43
Front Suspension Components........................................................... 7-46
Remove the Front Suspension...................................................... 7-47
Inspect the Front Suspension........................................................ 7-48
Install the Front Suspension.......................................................... 7-50
vi YDRA/E Service Manual

G29A-E Service Manual.book Page vii Wednesday, July 16, 2008 9:20 AM
Rear Suspension Components ........................................................... 7-51

YDRA (Gas Car) Components ...................................................... 7-51
YDRE (Electric Car) Components ................................................. 7-52
Remove the Rear Suspension ...................................................... 7-53
Inspect the Rear Suspension ........................................................ 7-54
Install the Rear Suspension .......................................................... 7-54
Frame Assembly Components ............................................................ 7-55
8 Electrical
— Wiring Diagrams and Electrical Component Location —
YDRA Wiring Diagram........................................................................... 8-4
YDRA Reverse Buzzer Circuit............................................................... 8-5
YDRA Ignition Circuit............................................................................. 8-6
YDRA Component Location .................................................................. 8-7
YDRE Wiring Diagram........................................................................... 8-8
YDRE Reverse Buzzer Circuit............................................................... 8-9
YDRE Component Location ................................................................ 8-10
— Electrical Test and Repair —

Main Switch ......................................................................................... 8-11
Test ............................................................................................... 8-11
Remove ......................................................................................... 8-11
Throttle Stop Switch ............................................................................ 8-12
Test ............................................................................................... 8-12
Remove the Throttle Stop Switch .................................................. 8-12
Install the Throttle Stop Switch ...................................................... 8-12
Reverse Buzzer................................................................................... 8-12
Test the Reverse Buzzer............................................................... 8-12
Remove the Reverse Buzzer ........................................................ 8-13
Install the Reverse Buzzer ............................................................ 8-13
— Repair - YDRA (Gas Car) —

Start Test....................................................................................... 8-15
Charge Test................................................................................... 8-15
Voltage Regulator................................................................................ 8-16
Output Test.................................................................................... 8-16
Remove the Starter/Generator ...................................................... 8-17
Disassemble the Starter/Generator............................................... 8-18
Replace Armature Bearing ....................................................... 8-21
Assemble the Starter/Generator.................................................... 8-22
Install the Starter/Generator .......................................................... 8-22
YDRA/E Service Manual vii

G29A-E Service Manual.book Page viii Wednesday, July 16, 2008 9:20 AM
Start Solenoid Relay ........................................................................... 8-23

Function......................................................................................... 8-23
Function Test................................................................................. 8-23
Solenoid Bench Test ................................................................ 8-24
Remove the Solenoid .................................................................... 8-24
Install the Solenoid ........................................................................ 8-24
Oil Level Switch................................................................................... 8-25
Remove the Oil Level Switch ........................................................ 8-25
Test the Oil Level Switch............................................................... 8-25
Engine Stop Relay .............................................................................. 8-25
Test the Engine Stop Relay........................................................... 8-25
Remove the Engine Stop Relay .................................................... 8-26
Install the Engine Stop Relay ........................................................ 8-26
Reverse Buzzer Switch ....................................................................... 8-26
Test Reverse Buzzer Switch ......................................................... 8-26
Remove Reverse Buzzer Switch................................................... 8-26
Install Reverse Buzzer Switch....................................................... 8-27
Fuse .................................................................................................... 8-27
Location......................................................................................... 8-27
Test the Fuse ................................................................................ 8-27
Oil Level Indicator Lamp ..................................................................... 8-27
Test ............................................................................................... 8-27
Remove the Oil Level Warning Lamp............................................ 8-28
Install the Oil Level Warning Lamp................................................ 8-28
Transistor Controlled Ignition (TCI) ..................................................... 8-28
Remove the TCI ............................................................................ 8-28
Install the TCI ................................................................................ 8-28
Spark Plug Cap ................................................................................... 8-29
Test the Spark Plug Cap ............................................................... 8-29
Remove the Spark Plug Cap......................................................... 8-29
Install the Spark Plug Cap............................................................. 8-29
Replacing Starter/Generator Belt ........................................................ 8-29
— Repair - YDRE (Electric Car) —

Traction Motor Components................................................................ 8-30
General Specifications .................................................................. 8-31
Remove the Traction Motor........................................................... 8-31
Disassemble the Traction Motor.................................................... 8-32
Inspect and Test the Traction Motor.............................................. 8-34
Replace the Armature Bearing ................................................. 8-36
Assemble the Traction Motor ........................................................ 8-37
Install the Traction Motor............................................................... 8-40
Motor Control Unit ............................................................................... 8-41
Remove the Motor Control Unit..................................................... 8-41
Install the Motor Control Unit......................................................... 8-41
viii YDRA/E Service Manual

G29A-E Service Manual.book Page ix Wednesday, July 16, 2008 9:20 AM
Speed Sensor...................................................................................... 8-41

Test the Speed Sensor.................................................................. 8-41
Remove the Speed Sensor ........................................................... 8-42
Install the Speed Sensor ............................................................... 8-42
Throttle Position Sensor ...................................................................... 8-43
Test the Throttle Position Sensor .................................................. 8-43
Remove the Throttle Position Sensor............................................ 8-43
Install the Throttle Position Sensor................................................ 8-43
Directional Switch - YDRE................................................................... 8-44
Test the Directional Switch - YDRE............................................... 8-44
Remove the Directional Switch - YDRE ........................................ 8-44
Install the Directional Switch - YDRE ............................................ 8-44
Solenoid .............................................................................................. 8-45
Test the Solenoid .......................................................................... 8-45
Fuse .................................................................................................... 8-46
Location......................................................................................... 8-46
Test the Fuse ................................................................................ 8-46
Tow Switch - YDRE............................................................................. 8-46
Test the Tow Switch - YDRE......................................................... 8-46
Remove the Tow Switch - YDRE .................................................. 8-46
Install the Tow Switch - YDRE ...................................................... 8-46
Charge Receptacle - YDRE ................................................................ 8-47
Remove the Charge Receptacle - YDRE ...................................... 8-47
Install the Charge Receptacle - YDRE .......................................... 8-48
9 Troubleshooting
— Troubleshooting - YDRA (Gas Car) —
Starter Will Not Turn.............................................................................. 9-3
Engine Cranks and Has Spark But Will Not Start.................................. 9-4
Engine Cranks But is Weak or Has No Spark ....................................... 9-5
Engine Backfires ................................................................................... 9-5
Engine Intermittently Cuts Out .............................................................. 9-6
Engine Will Not Stop Running ............................................................... 9-6
Loss of Power or Speed ........................................................................ 9-7
Carburetor Floods ................................................................................. 9-8
Transaxle Will Not Shift Into Forward or Reverse ................................. 9-8
Transaxle is Noisy ................................................................................. 9-9
Transaxle is Leaking Oil ........................................................................ 9-9
Car Will Not Move Forward or Reverse................................................. 9-9
Excessive Vibration ............................................................................. 9-10
Engine is Seized; Will Not Turn Over .................................................. 9-10
YDRA/E Service Manual ix

G29A-E Service Manual.book Page x Wednesday, July 16, 2008 9:20 AM
— Troubleshooting - YDRE (Electric Car) —

Traction Motor ..................................................................................... 9-12
Resetting Motor Control Unit ............................................................... 9-13
MCU Main Harness Connector ........................................................... 9-13
Reverse Warning Buzzer Does Not Work ........................................... 9-14
Car Will Not Run at Rated Speed ....................................................... 9-14
Car Will Not Operate in Either Direction - Solenoid Does Not Click.... 9-15
Car Will Not Operate in Either Direction - Solenoid Does Click .......... 9-16
No Regenerative Braking or Rollaway Protection ............................... 9-18
— Z-2 Diagnostic Tester —

Z-2 Harness Connections ................................................................... 9-19
Z-2 Tester...................................................................................... 9-19
Z-2 Tester Harness Adapter.......................................................... 9-19
Preliminary Checks and Guidelines .............................................. 9-19
Operating Instructions ......................................................................... 9-20
Z-2 Tester Failure Chart ...................................................................... 9-21
— Genius Diagnostic System —

Introduction ......................................................................................... 9-23
Genius Diagnostic System .................................................................. 9-23
Personal Digital Assistant (PDA)................................................... 9-23
Transmitter Unit............................................................................. 9-23
Software Installation ...................................................................... 9-23
Transmitter Unit Installation ................................................................ 9-24
Diagnostic Mode ................................................................................. 9-26
PDA Operation Procedures........................................................... 9-26
Data Screen .................................................................................. 9-27
Read Tab.................................................................................. 9-28
Set Car # Tab ........................................................................... 9-29
Faults Screen ................................................................................ 9-30
Faults:....................................................................................... 9-30
Help .......................................................................................... 9-31
About Application ..................................................................... 9-31
Read Tab.................................................................................. 9-31
Erase Tab ................................................................................. 9-32
Troubleshooting Using Genius ............................................................ 9-33
Golf Car Programming Mode .............................................................. 9-40
Mode Select Screen ...................................................................... 9-41
Read Mode ............................................................................... 9-41
x YDRA/E Service Manual

1
GENERAL
INFORMATION
Table of Contents
Safety Precautions ................................................................................ 1-3
General Information......................................................................... 1-3
Prepare for Emergencies........................................................... 1-3
Safety Lockout Procedure ............................................................... 1-7
Discharge the Motor Control Unit Capacitor.................................... 1-7
Recommended Jack Points............................................................. 1-7
General Service Information.................................................................. 1-8
Serial Numbers................................................................................ 1-8
YDRA/YDRE Chassis................................................................ 1-8
YDRA Engine ............................................................................ 1-8
YDRE Traction Motor ................................................................ 1-9
YDRE Motor Control Unit .......................................................... 1-9
Washing and Cleaning .................................................................... 1-9
Correct Tools................................................................................... 1-9
Neatness ......................................................................................... 1-9
Tightening Torque ........................................................................... 1-9
Replacement Parts........................................................................ 1-10
Gaskets, Oil Seals and O-rings ..................................................... 1-10
Lock Washers/Plates and Cotter Pins ........................................... 1-10
Bearings and Oil Seals.................................................................. 1-10
Retaining Rings ............................................................................. 1-11
Disassembly and Assembly Suggestions...................................... 1-11
Special Tools....................................................................................... 1-12
For Tune-Up .................................................................................. 1-12
For Engine Service ........................................................................ 1-12
For Power Train............................................................................. 1-13
For Chassis Service ...................................................................... 1-14
For Electrical Components ............................................................ 1-15
YDRA/E Service Manual 1-1

GENERAL INFORMATION
Vehicle Storage ................................................................................... 1-17
Gas-Powered Cars........................................................................ 1-17
Preparation for Storage ........................................................... 1-17
Returning Car to Service ......................................................... 1-18
Electric-Powered Cars................................................................... 1-18
Preparation for Storage ........................................................... 1-18
Returning Car to Service ......................................................... 1-19
1-2 YDRA/E Service Manual

Safety Precautions GENERAL INFORMATION
SAFETY PRECAUTIONS
WARNING
General Information The safety messages that follow have
There is no substitute for common sense and
careful practices. Improper practices or
carelessness can cause burns, cuts, mutilation,
WARNING level hazards.
ALWAYS follow the recommended safety
messages. Such messages affect the safe
1
asphyxiation, other bodily injury or death. This operation of the equipment and the safety of
information contains general safety precautions you and/or others.
and guidelines that must be followed to reduce Failure to comply could result in death or
risk to personal safety. Special safety precautions serious injury.
are listed in specific procedures. Read and
understand all of the safety precautions before
operating or performing repairs or maintenance.
WARNING
NEVER permit anyone to operate the
! golf car without proper training.
This safety alert symbol appears with most safety Read and understand this Service
statements. It means attention, become alert, Manual before you service the golf
your safety is involved! Please read and abide by car to ensure that you follow safe
the message that follows the safety alert symbol. operating practices and maintenance
procedures.
Prepare for Emergencies
• Safety signs and decals are additional
Be prepared for possible injury or fire. Keep the reminders for safe operating and
following items handy: maintenance techniques.
• First aid kit • See your authorized Yamaha dealer or
• Fire extinguisher distributor for additional training.
• Emergency phone numbers
WARNING WARNING
Failure to follow WARNING instructions could Crush Hazard
result in death or severe injury to golf car
NEVER stand under hoisted golf
occupants, a bystander, or a person
car. If the hoist mechanism fails,
inspecting or repairing the golf car.
the golf car can fall on you.
CAUTION
This message describes special precautions
that must be taken to avoid damage to the golf
car.
NOTE:
This message provides additional key
information.

GENERAL INFORMATION Safety Precautions
WARNING WARNING
Fire Hazard Entanglement Hazard
Keep fire extinguishers handy in NEVER leave the key in the key
case of fire. Clearly indicate the switch when you are servicing the
location of the fire extinguishers engine. Someone may accidentally
with a safety sign. start the engine and not realize you
Ensure that the types of fire extinguishers are are servicing it.
appropriate for materials that might catch fire.
Check with local authorities.
Have all fire extinguishers checked WARNING
periodically for proper operation and/or
readiness. Personal Injury Hazard
Post evacuation routes prominently. Avoid personal injury. NEVER operate the golf
Periodically conduct fire drills. car while wearing a headset. Doing so would
result in difficulty hearing abnormal noises or
Ensure that appropriate fire detection and a warning from another golfer.
extinguishing equipment are installed and
checked periodically for proper operation.
Check with local authorities.
Avoid injury or equipment damage from fire. WARNING
Undersized wiring systems can cause an
electrical fire. Flying Object Hazard
ALWAYS wear eye protection when
servicing the engine and batteries
or when using compressed air or
WARNING high-pressure water. Dust, flying
debris, compressed air,
Sever Hazard pressurized water or steam may
NEVER wear jewelry, unbuttoned injure your eyes.
cuffs, ties or loose-fitting clothing
and ALWAYS tie long hair back
when working near moving/
rotating parts such as the WARNING
flywheel. Keep hands, feet and
tools away from all moving parts. Burn Hazard
Some of the engine surfaces
become very hot during operation
and shortly after shutdown. Keep
WARNING hands and other body parts away
from hot engine surfaces.
Alcohol and Drug Hazard
NEVER operate the golf car while
under the influence of alcohol or
drugs, or when feeling ill.

WARNING WARNING
Sudden Movement Hazard Exposure Hazard
ALWAYS stop the engine before beginning
service.
Wear protective clothing.
Many permanent injuries can be
1
Follow these safety precautions. Exercise prevented by wearing
caution when performing service work to appropriate Personal Protective
prevent serious accidents. Equipment (PPE) during work.
Secure the vehicle: Whenever applicable, ALWAYS use the
following:
• Block the front wheels.
• Safety glasses with side shields or goggles
• Raise both rear wheels off the ground to a when performing work like grinding,
freewheeling position. chiseling, spraying or any other activity that
• NEVER allow anyone to stand in front of or could result in an object or chemical striking
behind the vehicle during service. the eye.
• Hearing protection when performing loud
work that could cause hearing loss.
WARNING • Safety shoes when working with heavy
objects that could be dropped.
Exhaust Hazard • Respiratory protection when performing
NEVER block windows, vents or work involving dust, vapors or gases that
other means of ventilation if the could cause respiratory problems.
engine is operating in an enclosed
area. All internal combustion
engines create carbon monoxide
gas during operation and special CAUTION
precautions are required to avoid
The safety messages that follow have
carbon monoxide poisoning.
CAUTION level hazards.
Properly ventilate work area to prevent
ALWAYS follow the recommended safety
buildup of dangerous gases and keep the
messages. Such messages affect the safe
oxygen level above OSHA’s 19.5% minimum
operation of the equipment and the safety of
level.
you and/or others.
Failure to comply could result in minor or
moderate injury.

GENERAL INFORMATION Safety Precautions
CAUTION CAUTION
Poor Lighting Hazard It is important to perform daily checks as
listed in the Operation Manual.
Ensure that the work area is properly
illuminated. ALWAYS install wire cages on Periodic maintenance prevents unexpected
portable safety lamps. downtime, reduces the number of accidents
due to poor performance and helps extend the
life of the engine or batteries.
ALWAYS be environmentally
CAUTION responsible.
Tool Hazard Follow the guidelines of the EPA or
ALWAYS use tools appropriate for the task at other governmental agencies for
hand and use the correct size tool for the proper disposal of hazardous
loosening or tightening machine parts. materials such as engine oil,
gasoline and gear oil. Consult the
local authorities or reclamation
facility.
CAUTION NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground or
Slip Hazard into groundwater or waterways.
Keep shop floor clean and dry to prevent
Before operating the engine, check oil level.
accidents due to slips.
If the ambient temperature falls below -15°C
(+5°F) rubber components such as gaskets
and seals will harden, causing premature golf
car wear and damage.
Contact your authorized Yamaha dealer or
distributor if the golf car will be operated in
either temperature extreme.
NEVER attempt to modify the golf car’s
design or safety features.
Observe the following environmental
operating conditions to maintain golf car
performance and avoid premature wear:
• Avoid operating in extremely dusty
conditions.
• Avoid operating in the presence of chemical
gases or fumes.
If the golf car engine temperature is too high,
stop engine immediately and check the oil
level and the air cooling system.
When jacking the rear of golf car, NEVER let
the jack contact the rear suspension
connecting rod or damage to the rod may
result.


Safety Lockout Procedure Recommended Jack Points
1. Turn the key switch to the OFF position and
remove the key.
2. Depress the brake pedal and lock the park
brake to the ON position. 1
3. For YDRE move the tow switch to the TOW
position.
4. For YDRA move the shift lever to the
NEUTRAL position.
Discharge the Motor Control Unit

Capacitor
Y-1243
Figure 1-2
1
• Front: Under the lower arm to frame pivot
Y-1535
Figure 1-1
1. Turn the main switch to OFF.
2. Turn the tow switch to the TOW position.
When turned to TOW, the controller capacitor
should discharge within five seconds. Y-1244
3. Disconnect the black wire leads at the Figure 1-3
negative (-) battery terminal.
• Rear: Frame crossmember
4. Wait 30 seconds and attach a 48-volt test light
between the positive (Figure 1-1, (1)) and
negative (Figure 1-1, (2)) controller terminals
to confirm that the capacitor is discharged.
(Test light will not illuminate.)
5. If required for component testing, reconnect
the battery and turn on main and tow switch
for specific measurements after required
meters are in place.

GENERAL INFORMATION General Service Information
GENERAL SERVICE
INFORMATION
Serial Numbers
JWX-000000
Y-1245
Figure 1-4
• Side: Main frame rail Y-910b
Figure 1-5
YDRA/YDRE Chassis
The frame serial number is attached in the
location shown (Figure 1-5).
I
II
III
III
II
I II
IIII
II
SM-03-399
Figure 1-6
YDRA Engine
The engine serial number is attached in the
location shown (Figure 1-6).

General Service Information GENERAL INFORMATION

Washing and Cleaning
NOTE:
Yamaha Golf-Car Company does not approve
the use of high-pressure washers to clean the
products they manufacture. Doing so may
1
damage the finish on the body or result in doing
other damage not covered by warranty.
Before servicing, thoroughly clean the exterior of

the car body and engine. While cleaning, take
care to protect the electrical parts, such as relay
switches, motor resistors and controllers, from
Y-1206B
high-pressure water splashes.
Figure 1-7 Correct Tools
YDRE Traction Motor Be sure to use the appropriate tool for the
The traction motor serial number is attached in intended part in order to protect the part and
the location shown (Figure 1-7). vehicle from damage.
Neatness
Keep the removed parts organized in separate
groups so that they will not be misplaced.
Tightening Torque
1
6
4 3
7
Y-1485
8
Figure 1-8
2 5
YDRE Motor Control Unit
The motor control unit serial number is attached Figure 1-9
in the location shown (Figure 1-8). Be sure to follow tightening torque specifications.
When tightening nuts and bolts, start with
larger-diameter ones and work from
inner-positioned ones to outer-positioned ones in
a crisscross pattern (Figure 1-9). See
Specifications on page 2-1.

GENERAL INFORMATION General Service Information
Replacement Parts Bearings and Oil Seals
NOTE:
Never use compressed air to spin the bearings
dry. This causes damage to the bearing
surfaces.
Oil
SM-03-160
Figure 1-10
Only use Yamaha genuine replacement parts, 3
lubricants and sealants (Figure 1-10) when
performing maintenance or repairs. Use of
products or parts other than genuine Yamaha
may void warranty coverage. 2
Gaskets, Oil Seals and O-rings

All gaskets, seals and O-rings should be replaced
when an engine is overhauled. All gasket
surfaces, oil-seal lips and O-rings must be
cleaned prior to installation. Lubricate O-rings as
indicated in procedures.
Lock Washers/Plates and Cotter

Pins Y-1439
Figure 1-12
SM-03-162
Figure 1-11
All lock washers/plates (Figure 1-11, (1)) and
cotter pins must be replaced when they are
removed. Lock tabs should be bent along the bolt
or nut flats after the bolt or nut has been properly
tightened.

General Service Information GENERAL INFORMATION

Retaining Rings
1
1
2
SM-03-166
3
Figure 1-14
All retaining rings should be inspected carefully
before assembly. Always replace piston pin
retaining rings after one use. Replace distorted
retaining rings. When installing a retaining ring
(Figure 1-14, (1)), ensure the sharp-edged
corner (Figure 1-14, (2)) is positioned in the
groove (Figure 1-14, (4)) opposite to the thrust
(Figure 1-14, (3)) it receives.
Y-1440
Disassembly and Assembly
Figure 1-13 Suggestions
Install bearings and seals (Figure 1-12, (3)) and Follow these guidelines when disassembling and
(Figure 1-13, (3)) with stamped letters or assembling parts:
numbers facing outward. Use a press
(Figure 1-12, (1)) and (Figure 1-13, (1)) and a • Clean and dry parts whenever they are
tool (Figure 1-12, (2)) and (Figure 1-13, (2)) that disassembled.
presses against the diameter that contacts the
housing or shaft. • Apply oil to contact surfaces of moving parts
prior to assembly. After parts are assembled,
Apply a light coat of lightweight, lithium-based make sure each moving part operates normally.
grease to the seal lip(s). Oil bearings liberally.

GENERAL INFORMATION Special Tools
SPECIAL TOOLS For Engine Service

The proper special tools are necessary for Valve Spring Compressor
complete and accurate tune-up, disassembly and
assembly. Using the correct special tool will help
prevent damage caused by the use of improper
tools or improvised techniques. To order the tools
specified on the following pages, please contact
K&L Tool at: 800-708-3184, FAX 408-727-4305
for pricing and availability.
For Tune-Up
Inductive Tachometer
SM-03-173
Figure 1-17
P/N YM-01253
• This tool is needed to remove and install the
valve springs (Figure 1-17).
• YM-01253-1 Compressor Replacement
Adapter - 26 mm
• YM-01253-2 Compressor Replacement
SM-03-170 Adapter - 32 mm
Figure 1-15 Valve Seat Cutter Set
P/N YU-8036-C
• This tool is for measuring engine rpm
(Figure 1-15).
Compression Gauge
SM-03-174
Figure 1-18
P/N YG-91046
• This tool is used to resurface the valve seat
SM-03-171 (Figure 1-18).
Figure 1-16
P/N YU-33223
• This gauge is used to measure the engine
compression (Figure 1-16).

Special Tools GENERAL INFORMATION

Valve Adjuster For Power Train
Primary Sheave Assembly Holder
SM-03-175
Figure 1-19
P/N YM-08035-A
• This tool is used to adjust the valve clearance
(Figure 1-19). Y-1326
Figure 1-21
Piston Ring Compressor
P/N YGCC-001
• This tool is used to hold the primary sheave
assembly fixed sheave when removing or
installing the spider assembly (Figure 1-21).
Primary Sheave Assembly Puller
SM-03-176
Figure 1-20
P/N YU-33294
• This tool is used to squeeze piston ring ends
together while piston is pushed into cylinder
(Figure 1-20).
Y-1321
Figure 1-22
P/N YGCC-002
• This tool is used for removing the primary
sheave assembly from engine (Figure 1-22).

Primary Sheave Assembly Spider Separator Drift Punch (6 mm) or Guide Driver (Spindle
Pin)
SM-03-180
Figure 1-25
Y-1322 P/N YM-04064-A

Figure 1-23 • This tool is used to remove the spring pins for
P/N YGCC-003 the steering knuckle (Figure 1-25).
• This tool is used to remove spider assembly Mityvac® Vacuum and Pressure Tester
from fixed sheave of primary sheave assembly
(Figure 1-23).
For Chassis Service

Plastic Rivet Remover
Acquire locally.
SM-03-181
Figure 1-26
P/N YS-42423
• This tool is used for vacuum pressure testing
(Figure 1-26).
Y-1263
Figure 1-24
• This tool is used to remove plastic rivets
(Figure 1-24).

Special Tools GENERAL INFORMATION

Toe-In Measuring Gauge For Electrical Components
Digital Multimeter
1
SM-03-402
Figure 1-27
P/N YC-39526-A
• This tool is used to check toe-in alignment of
the front tires (Figure 1-27).
Brake Cable Removal Tool
Y-1438
Figure 1-29
P/N YU-A1927
• This instrument is invaluable for checking the
electrical system (Figure 1-29).
Battery Hydrometer
Y-1460
Figure 1-28
P/N YGCC-006
• This tool is used to compress the retainer on
the end of the brake cable to remove it from the
bracket on the transaxle (Figure 1-28). SM-03-183
Figure 1-30
P/N YU-03036
• This gauge is used to measure the specific
gravity of battery electrolyte (Figure 1-30).

Dynamic Spark Tester Z-2 Tester
SM-03-436
Figure 1-31
P/N YM-34487
• This tester is necessary for checking the Y-1324A
ignition system components (Figure 1-31). Figure 1-33

Traction Motor Cradle P/N YGCC-008 - Available at
www.grainger.com/yamaha.
• This instrument allows you to quickly check the
electrical functions of the MCU and electrical
system (Figure 1-33).
Z-2 Tester Breakout Harness
Y-1325
Figure 1-32
P/N YGCC-004
• This tool is used to support the traction motor
during removal and installation (Figure 1-32).
Y-1323A
Figure 1-34
P/N YGCC-008 - Available at
www.grainger.com/yamaha.
• This harness (Figure 1-34) allows the Z-2
tester to be plugged into the main wire harness.

Vehicle Storage GENERAL INFORMATION

Speed Sensor Test Cord VEHICLE STORAGE
When a golf car is to be stored during the
off-season, certain steps must be taken to
prevent deterioration and to extend the life of the
car. Likewise, steps must be taken when
returning the car to service after storage.
1
Gas-Powered Cars
Y-1486 Preparation for Storage
Figure 1-35
WARNING
P/N YG-42221-A
Gasoline is highly flammable. Use
• This tool is needed to test the traction motor extreme care! Clean any spills
speed sensor voltage output (Figure 1-35). immediately. Storage area must
have adequate ventilation.
Transaxle Fixture
NOTE:
Running the engine until it stops does not use
all the fuel. Remove the float bowl if not
equipped with a drain.
1. Drain fuel from the carburetor float bowl. (Use

bowl drain, if equipped.)
2. Fill the fuel tank completely, leaving no air
space. This will help prevent gumming or
other deterioration of the fuel. Use Yamaha
fuel conditioner and stabilizer
P/N ACC-11001-45-00 or equivalent if the car
will be stored for six months or longer.
3. Remove the spark plug and pour a
tablespoon of motor oil into the hole. Bring the
piston to top dead center (TDC) of the
compression stroke and install the spark plug.
Tighten spark plug to specification.
Specification:
Spark Plug Torque.................................. 20 N·m
(2.0 m·kg; 14 lb-ft)
4. With the engine off, check the battery with a
Y-1396 voltmeter. If the reading is below 12 volts,
charge or replace the battery.
Figure 1-36
5. Inflate the tires to 110 kPa (16 psi).
P/N YGCC-005
6. Wash and dry the entire car thoroughly,
• This fixture is needed to hold the transaxle in a including the chassis. For best protection,
vertical position during assembly or wax the body with Yamaha SILICONE WAX
disassembly (Figure 1-36). P/N ACC-1000-15-02 or equivalent.
7. Avoid storing in humid or damp areas to
prevent rust and corrosion.

GENERAL INFORMATION Vehicle Storage
Returning Car to Service Electric-Powered Cars

1. Adjust tire pressure to 110 kPa (16 psi).
Preparation for Storage
2. With the key turned off, check the operation of
the brakes, parking brake, throttle, steering
mechanism and choke. WARNING
3. Start and run engine long enough to reach • Battery electrolyte is dangerous; it contains
normal operating temperature. sulfuric acid and is therefore poisonous and
highly caustic.
NOTE: • ALWAYS follow these precautionary
Because of the oil that was added to the upper measures:
engine prior to storage, the engine will smoke ◆ Avoid bodily contact with electrolyte as it
for a few minutes after starting. can cause severe burns or permanent eye
injury.
◆ Wear protective eye gear when handling
4. Drive the car and note any problems with the or working near batteries.
items listed in step 2.
• Antidote (EXTERNAL)
5. Wash and dry the car thoroughly before
returning it to service. ◆ SKIN – flush with water.
◆ EYES – flush with water for 15 minutes
and get immediate medical attention.
• Antidote (INTERNAL)
◆ Drink large quantities of water or milk;
follow with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
• Batteries generate explosive hydrogen gas.
Always follow these precautionary
measures:
◆ Charge batteries in a well-ventilated area.
◆ Keep batteries away from fire, sparks or
open flames (e.g., welding equipment, lit
cigarettes, etc.).
◆ Do not smoke when charging or handling
batteries.
• KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
• Remove all metal jewelry before working on
the electrical system or batteries. Failure to
do so may result in personal injury from a
short circuit.
• ALWAYS wear protective clothing, gloves
and goggles when handling batteries and
electrolyte, and when charging your battery.
NOTE:
See Battery Storage on page 4-21 for further
information about battery preparation for
storage.

Vehicle Storage GENERAL INFORMATION

1. Charge the batteries until all cells reach a Returning Car to Service
specific gravity of 1.260 ± 0.010 at an acid
1. Adjust tire pressure to 138 kPa (20 psi).
temperature of 26.6°C (80°F).
2. With the key turned off, check the operation of
2. Add distilled water to each battery cell until
the proper level is reached.
3. Check the electrolyte using a hydrometer
the brakes, parking brake, throttle, steering
mechanism and choke.
3. Drive the car and note any problems with the
1
every 8-10 weeks and charge the batteries as
items listed in step 2.
necessary. Be sure the batteries maintain a
specific gravity of 1.260 at 26.6°C (80°F). 4. Check all batteries for a complete charge.
Charge as necessary. Test batteries when
4. Inflate the tires to 138 kPa (20 psi).
they are fully charged. See Discharge Load
5. Protect the tires from moisture and ozone Test on page 4-23.
from the battery charging area by providing
5. Wash and dry the car thoroughly before
adequate ventilation.
returning it to service.
6. Wash and dry the entire car thoroughly,
including the chassis. For best protection,
wax the body with Yamaha SILICONE WAX
P/N ACC-1000-15-02 or equivalent.
7. Avoid storing in humid or damp areas to
prevent rust and corrosion.
8. Ensure the key is in the OFF position.
IMPORTANT
If the key is left on, the batteries will
discharge, resulting in the possibility of
damage due to freezing.
9. Turn the tow switch to the TOW position.

GENERAL INFORMATION Vehicle Storage
This Page Intentionally Left Blank

SPECIFICATIONS 2
Table of Contents
General Specifications .......................................................................... 2-2
General............................................................................................ 2-2
Transmission ................................................................................... 2-2
Batteries .......................................................................................... 2-3
Chassis............................................................................................ 2-3
Paint Codes..................................................................................... 2-3
Torque Specifications............................................................................ 2-4
Engine ............................................................................................. 2-4
Service Specifications (YDRA).............................................................. 2-6
Engine ............................................................................................. 2-6
Primary Sheave Assembly ............................................................ 2-10
Secondary Sheave Assembly ....................................................... 2-10
Cable Routing - YDRA ........................................................................ 2-11
Service Specifications (YDRE)............................................................ 2-13
Cable Routing - YDRE ........................................................................ 2-15

SPECIFICATIONS General Specifications
GENERAL SPECIFICATIONS
General
Item YDRA YDRE
Model Code JW1 JW2
Frame Serial Number JW1-000101 - JW2-000101 -
Length Overall 2395 mm (94.4 in.)
Width Overall 1200 mm (47.2 in.)
Height Overall (without canopy) 1190 mm (46.9 in.)
Height of Floor 310 mm (12.2 in.)
Wheelbase 1640 mm (64.6 in.)
Tread, Front 870 mm (34.3 in.)
Tread, Rear 980 mm (38.6 in.)
Ground Clearance (minimum) 110 mm (4.3 in.)
Weight, Dry 255 kg (562 lb) 243 kg (535 lb)
Factory Speed Setting 19 km/h (12 mph)
Maximum Speed Setting 24 km/h (15 mph)
Turning Radius (minimum) 2.9 m (114.2 in.)
Seating Capacity Two People
Maximum Grade 27° on pavement 20° on pavement
Fuel Capacity 6.6 U.S. gallons (25 L) –
Transmission
Item YDRA YDRE
Transmission Transaxle with Differential
Final Drive V-Belt Automatic Centrifugal Direct Coupled Traction Motor
Engagement
New Belt Pitch Height 4.1 mm (0.16 in.) –
New Belt Top Width 29.5 mm (1.16 in.) –
New Belt Thickness 12.0 mm (0.47 in.) –
New Belt Pitch Length 1031 mm (40.59 in.) –
New Belt Outer Length 1057 mm (41.61 in.) –
New Belt Angle 30° –
Belt Top Width Wear Limit 27.8 mm (1.09 in.) –
Speed Limiter Oil Bath Flyweight –
Recommended Gear Lubricant SAE 80W-90 API GL-5 Limited Slip High Performance Gear Oil
Lubrication Capacity 1750 cc (59 oz) 1350 cc (46 oz)

General Specifications SPECIFICATIONS

Batteries
Item YDRA YDRE
Type BCI Group 24 - 12V Trojan T-1275 12V Deep Cycle
Quantity 1 4
Reserve Capacity (minimum) 75 Minutes 102 Minutes at 56A at 27°C (80°F)
Cold Cranking Amps (CCA) 400 –
System Voltage 12V 48V
Chassis 2
Item YDRA YDRE
Steering System Type Rack and Pinion
Steering Angle (left/right) 1.85 turn
Brake System Type Mechanical Wet Brakes with Internal Expanding Pads
Brake Location Integrated into Transaxle
Brake Pedal Free Play 45 - 50 mm (1.77 - 1.97 in.)
Brake Cable End Play 0.1 - 0.5 mm (0.004 - 0.020 in.)
Parking Brake Type Foot Type with Automatic Release
Tire Size (front and rear) 18 x 8.50–8.00/4 ply rated
Rim Size 7.00–I–8.00
Tire Pressure 2
110 kPa (1.1 kg/cm ; 16 psi) 138 kPa (1.4 kg/cm2; 20 psi)
Paint Codes
OEM Code Name Ditzler Number
SPU60185 Glacier 918519
W44145 Emerald 48748
W49874 Garnet 701739
AH2039 Onyx Metallic 918520
AH5068 Cobalt Metallic 918521
AH5080 Anthracite Metallic 918522
AH9064 Sandstone Metallic 918523

SPECIFICATIONS Torque Specifications
TORQUE SPECIFICATIONS
Engine
ENGINE
Air Filter Case Bolt Torque 7 N·m (0.7 m·kg; 62 lb-in.)
Carburetor Stud Nut Torque 7 N·m (0.7 m·kg; 62 lb-in.)
Connecting Rod Cap Bolt Torque 20 N·m (2.0 m·kg; 168 lb-in.)
Crankcase Cover Bolt Torque (M10) 43 N·m (4.3 m·kg; 31 lb-ft)
Crankcase Cover Bolt Torque (M8) 26 N·m (2.6 m·kg; 19 lb-ft)*
Cylinder Head Bolt Torque 44 N·m (4.4 m·kg; 32 lb-ft)*
Cylinder Head Cover Bolt Torque 11 N·m (1.1 m·kg; 72 lb-in.)
Engine Mounting Bolts and Nuts Torque 32 N·m (3.2 m·kg; 23 lb-ft)
Float Chamber Bolt Torque 9 N·m (0.9 m·kg; 80 lb-in.)
Flywheel Nut Torque 120 N·m (12.0 m·kg; 85 lb-ft)
Muffler Flange Mounting Nuts Torque 19 N·m (1.9 m·kg; 13 lb-ft)
Muffler Mounting Bracket Nut and Bolts Torque 16 N·m (1.6 m·kg; 11 lb-ft)
Spark Plug Torque 20 N·m (2.0 m·kg; 168 lb-in.)
Valve Adjusting Locknut Torque 7 N·m (0.7 m·kg; 62 lb-in.)
* Refer to procedure for correct tightening sequence
DRIVE TRAIN
Rear Arm-to-Transaxle Bolt Torque 64 N·m (6.5 m·kg; 47 lb-ft)
Transaxle Drain and Service Plug Torque 16 N·m (1.66 m·kg; 142 lb-in.)
Rear Axle Nut Torque 88 - 102 N·m (9.0 - 10.0 m·kg; 65 - 75 lb-ft)
Brake Assembly Top Plate Screw Torque 24 - 29 N·m (2.5 - 3.0 m·kg; 18 - 21 lb-ft)
Transaxle Case Bolt Torque 27 - 34 N·m (2.8 - 3.5 m·kg; 20 - 25 lb-ft)
Motor Flange-to-Case Bolt Torque 27 - 34 N·m (2.8 - 3.5 m·kg; 20 - 25 lb-ft)
Brake Cable Bracket-to-Case Bolt Torque 23 - 27 N·m (2.3 - 2.8 m·kg; 204 - 240 lb-in.)
Primary Sheave Assembly Bolt Torque 70 - 100 N·m (7.1 - 10.2 m·kg; 52 - 74 lb-ft)
Secondary Sheave Assembly Bolt Torque 33 - 52 N·m (3.4 - 5.3 m·kg; 24 - 38 lb-ft)
*

Torque Specifications SPECIFICATIONS
CHASSIS
Front Bumper Bolt Torque 22 N·m (2.2 m·kg; 194 lb-in.)
Front Hub Flange Nut Torque 14 N·m (11.6 m·kg; 84 lb-ft)
Front Mount Center Bolt and Nut Torque 135 N·m (13.8 m·kg; 100 lb-ft)
Front Mount-to-Frame Bolt Torque 32 N·m (3.3 m·kg; 24 lb-ft)
Knuckle Arm-to-Steering Knuckle Bolt Torque 48 N·m (4.9 m·kg; 35 lb-ft)
Lower Arm-to-Frame Bolt Torque 53 N·m (5.4 m·kg; 39 lb-ft)
Lower Front Shock Absorber Bolt Torque 75 - 85 N·m (7.6 - 8.6 m·kg; 55 - 62 lb-ft)
Upper Front Shock Absorber Bolt Torque
Upper and Lower Rear Shock Absorber Bolt Torque
40 - 50 N·m (4.0 - 5.0 m·kg; 30 - 37 lb-ft)
24 - 39 N·m (2.4 - 3.8 m·kg; 17 - 28 lb-ft)
2
Pedal Base Locknut Torque 19 N·m (1.9 m·kg; 168 lb-in.)
Brake Pedal Screw 52 N·m (5.3 m·kg; 38.4 lb-ft)
Brake Cable to Pedal Assembly Jam Nuts 13 N·m (1.3 m·kg; 115 lb-in.)
Throttle Cable to Pedal Assembly Locknut 3 N·m (0.3 m·kg; 27 lb-in.)
Throttle Pedal Clamp Screw 8 - 11 N·m (0.8 - 1.1 m·kg; 71 - 97 lb-in.)
Seat Back Support Bolt Torque 30 N·m (3.1 m·kg; 22 lb-ft)
Steering Column Bolt Torque 21 N·m (2.1 m·kg; 186 lb-in.)
Steering Gear Box Bolt Torque 48 N·m (4.9 m·kg; 35 lb-ft)
Steering Knuckle King Pin Bolt Torque 35 N·m (3.6 m·kg; 26 lb-ft)
Steering U-Joint Pinch Bolt Torque 22 N·m (2.2 m·kg; 194 lb-in.)
Steering Wheel Nut Torque 35 N·m (3.6 m·kg; 26 lb-ft)
Suspension Connecting Rod Nut Torque 90 N·m (9.2 m·kg; 66 lb-ft)
Tie Rod End-to-Knuckle Arm Torque 39 N·m (4.0 m·kg; 29 lb-ft)
Tie Rod Jam Nut Torque 40 N·m (4.1 m·kg; 29.5 lb-ft)
Tie Rod-to-Rack Gear Torque 79 N·m (8.1 m·kg; 58 lb-ft)
Upper Shock Absorber Bolt Torque 45 N·m (4.6 m·kg; 33 lb-ft)
Wheel Lug Nut Torque 80 N·m (8.2 m·kg; 59 lb-ft)
Sun Top-to-Support Nut Torque 5 - 8 N·m (0.5 - 0.8 m·kg; 45 - 71 lb-in.)
Sun Top Support Bolt Torque 12 - 19 N·m (1.2 - 2.0 m·kg; 106 - 168 lb-in.)
ELECTRICAL
Battery Terminal Nut Torque 9 N·m (0.92 m·kg; 80 lb-in.)
Solenoid Terminal Post Nut Torque 6 N·m (0.6 m·kg; 53 lb-in.)
Starter/Generator Pulley Nut Torque 91 N·m (9.3 m·kg; 67 lb-ft)
Starter Adjusting Bolt Locknut Torque 7 N·m (0.7 m·kg; 62 lb-in.)
Starter Attaching Bolt (12 mm) Torque 59 N·m (6.0 m·kg; 43.5 lb-ft)
Starter Lower Tensioner Locknut Torque 21 N·m (2.1 m·kg; 186 lb-in.)
TCI Bolt Torque 10 N·m (1.0 m·kg; 86 lb-in.)
TCI Bolt Torque 11 N·m (0.1 m·kg; 97 lb-in.)
Traction Motor Bolt Torque 12 N·m (1.2 m·kg; 106 lb-in.)
Traction Motor Cable Nut “A” Torque 6 N·m (0.6 m·kg; 53 lb-in.)
Traction Motor Cable Nut “F” Torque 5 N·m (0.5 m·kg; 44 lb-in.)

SPECIFICATIONS Service Specifications (YDRA)
SERVICE SPECIFICATIONS (YDRA)

Engine
Description Specification
Engine Type 4-Stroke, 60° incline OHV
Fuel Unleaded Regular Gasoline - 87 octane minimum
Number of Cylinders Single
Displacement 357 cm3
Bore x Stroke 85 x 63 mm (3.30 x 2.48 in.)
Compression Ratio 8.1:1
Compression Relief Automatic camshaft activated
Rated Output 8.5 kw (11.4 hp) @ 3500 rpm
Cooling Forced Air
Starting System Starter/Generator
Ignition System TCI Magneto
Spark Plug Type NGK BPR2ES or BPR4ES
Compression Pressure (at sea level) Standard: 785.0 ± 98.0 kPa
(7.85 ± 0.98 kg/cm2; 114 psi)
Lubrication System Splash-style positive oil lubrication
Engine Oil Type YAMALUBE ACC-Shaft-LU-00
Engine Oil Capacity 1.0 L (1.16 qt)
Oil Change Quantity 0.9 L (1.0 qt)
Ignition System
Specifications
Type TCI
Manufacturer/Model Moric/JR7
Dynamic Timing 28° BTDC at 3000 rpm
Ignition timing (BTDC)
20
10
0
1 2 3 4
Engine speed (x 103 rpm)
Y-780
Ignition Advance Curve

Primary Winding Resistance at 20°C (68°F) 0.9 - 1.5 ohms
Secondary Winding Resistance at 20°C (68°F) 10.5 - 12.9 k-ohms (spark plug cap removed)
Spark Plug Cap Resistance at 20°C (68°F) 4 - 6 k-ohms ± 10%
Spark Plug Type NGK BPR2ES or BPR4ES
Spark Plug Gap 0.7 - 0.8 mm (0.028 - 0.031 in.)

Service Specifications (YDRA) SPECIFICATIONS

Cylinder Head
Specifications
Valve Clearance Intake Cold 0.08 - 0.12 mm (0.00315 - 0.00472 in.)
Valve Clearance Exhaust Cold 0.08 - 0.12 mm (0.00315 - 0.00472 in.)
Combustion Chamber Volume (with spark plug) 38.1 ± 0.4 cc
Head Gasket Thickness 0.27 ± 0.05 mm (0.01 ± 0.001 in.)
Rocker Arm Shaft Bore ID 12.000 - 12.018 mm (0.4724 - 0.4731 in.)
Rocker Arm Shaft OD
Shaft-to-Rocker Arm Clearance
Shaft-to-Rocker Arm Service <Limit>
11.981 - 11.991 mm (0.4717 - 0.4721 in.)
0.009 - 0.037 mm (0.0004 - 0.0015 in.)
0.08 mm (0.0031 in.)
2
Y-742
Head Diameter (A)

• Intake 32 mm (1.259 in.)
• Exhaust 27 mm (1.062 in.)
Face Width (B)
• Intake 2.6 mm (0.102 in.)
• Exhaust 1.6 mm (0.063 in.)
Seat Width (C)
• Intake 1.0 mm (0.039 in.)
• Exhaust 1.0 mm (0.039 in.)
Valve Margin Thickness (D) <Limit>
• Intake 1.2 mm (0.047 in.)
• Exhaust 0.5 - 0.8 mm (0.019 - 0.031 in.)
Valve Spring Free Length 36.2 mm (1.43 in.)
Valve Spring Service <Limit> 35.0 mm (1.38 in.)
Valve Spring Tilt 2.5° or 1.6 mm (0.063 in.)
Valve Spring Force at Installed Height 91.1 - 104.9 N (9.30 - 10.70 kg; 20.50 - 23.60 lb)
Cylinder
Specifications
Material Cast iron sleeve in aluminum cylinder
Bore 85.00 - 85.02 mm (3.346 - 3.347 in.)
Bore Service <Limit> 85.05 mm (3.348 in.)
• Oversize 1 Plus 0.25 mm (0.010 in.)
• Oversize 2 Plus 0.50 mm (0.020 in.)

Piston
Specifications
Diameter (standard) 84.96 - 84.98 mm (3.345 - 3.346 in.)
• Oversize 1 85.25 mm (3.356 in.)
• Oversize 2 85.50 mm (3.366 in.)
Piston-to-Cylinder Clearance 0.03 - 0.05 mm (0.0012 - 0.002 in.)
Piston Pin Diameter 19.995 - 20.000 mm (0.7872 - 0.7874 in.)
Pin-to-Piston Clearance 0.004 - 0.015 mm (0.0002 - 0.0005 in.)
Piston Ring
Specifications
Top Piston Ring Type Barrel
• Cross Section 1.5 x 3.6 mm (0.059 x 0.141 in.)
• Installed End Gap 0.25 - 0.40 mm (0.010 - 0.016 in.)
• <Limit> 1.0 mm (0.040 in.)
• Side Clearance 0.04 - 0.08 mm (0.0015 - 0.0030 in.)
• <Limit> 0.10 mm (0.004 in.)
Second Piston Ring Type Taper
• <Limit> 1.0 mm (0.040 in.)
• Side Clearance 0.03 - 0.07 mm (0.0012 - 0.0028 in.)
• <Limit> 0.10 mm (0.004 in.)
Oil Ring
Connecting Rod
Specifications
Small End Bearing None
Big End Bearing None

Service Specifications (YDRA) SPECIFICATIONS

Crankshaft
Specifications
2
Y-740
Assembly Width (A) 107.2 - 107.5 mm (4.220 - 4.232 in.)

Crankshaft Runout (B) <Limit> 0.05 mm (0.002 in.)
Connecting Rod Big End Side Clearance (C) 0.20 - 0.65 mm (0.008 - 0.025 in.)
Crank Pin OD 35.969 - 35.984 mm (1.4161 - 1.4167 in.)
Crankshaft Oil Seal (both ends) SD 35 50 8
Camshaft
Specifications
B
Y-741
Method Gear
Camshaft Journal OD 15.90 - 15.97 mm (0.625 - 0.628 in.)
Camshaft Bearing Bore ID 16.00 - 16.05 mm (0.630 - 0.632 in.)
Camshaft Bearing Clearance <Limit> 0.03 - 0.15 mm (0.001 - 0.005 in.)
Lobe Major Diameter (A) (intake and exhaust) 32.495 - 32.595 mm (1.279 - 1.283 in.)
<Limit> 32.395 mm (1.2754 in.)
Lobe Minor Diameter (B) (intake and exhaust) 26.029 - 26.129 mm (1.024 - 1.028 in.)
<Limit> 25.929 mm (1.0208 in.)

Carburetor
Specifications
Make/Model Mikuni/BV26-21-83
Identification Mark JR700
Venturi Diameter 21 mm (0.826 in.)
Main Jet #87.5
Main Air Jet Diameter 1.6 mm (0.063 in.)
Pilot Jet #65.0
Pilot Air Jet Diameter 0.9 mm (0.035 in.)
Throttle Valve #150
Float Valve Seat Diameter 1.0 mm (0.039 in.)
Bypass (1) Diameter 0.7 mm (0.027 in.)
Pilot Outlet Diameter 1.0 mm (0.39 in.)
Pilot Screw Adjustment Preset at factory
Float Height 14.5 mm (0.56 in)
Cable Adjustment
Specifications
Throttle Cable No. 1 Free Play 1.0 - 2.0 mm (0.04 - 0.08 in.)
Throttle Cable No. 2 Free Play 0.5 mm (0.020 in.)
Choke Cable Free Play 1.0 mm (0.040 in.)
Primary Sheave Assembly

Type V-belt automatic centrifugal engagement
Reduction Ratio - Constantly Variable 3.1:1 to 0.8:1
Sheave Assembly Center-to-Center Distance 270.5 mm (10.65 in.)
Sheave Assembly Offset 24.3 mm (0.96 in.)
Belt Width and Length 29.5 x 1010 mm (1.16 x 39.76 in.)
<Width Wear Limit> 27.7 mm (1.09 in.)
Secondary Sheave Assembly

Type V-belt automatic centrifugal engagement
Reduction Ratio - Constantly Variable 3.1:1 to 0.8:1
Torque Cam Angle 37.5°
Sheave Assembly Center-to-Center Distance 270.5 mm (10.65 in.)
Sheave Assembly Offset 24.3 mm (0.96 in.)
Belt Width and Length 27.6 x 1010 mm (1.09 x 39.76 in.)
<Width Wear Limit> 24 mm (0.95 in.)

Cable Routing - YDRA SPECIFICATIONS
CABLE ROUTING - YDRA
2
1
A
5 3 8
12
6
4 10
11
7
9
Y-1509
Figure 2-1
1. Main Switch Wire 7. Positive Battery Cable

2. Stop Switch Wire 8. Shift Lever
3. Throttle Cable 9. Solenoid
4. Brake Cable 10. Spark Plug Lead
5. Main Harness 11. Battery
6. Negative Battery Cable 12. TCI Unit Wire

SPECIFICATIONS Cable Routing - YDRA
2 3 4
6 5
10
12
11
Y-1510
Figure 2-2
1. Reverse Buzzer Switch 7. Solenoid

2. Forward Shift Cable 8. Positive Cable to Starter/Generator
3. Fuel Hose to Carburetor 9. Positive Cable to Battery
4. Fuel Hose from Fuel Tank 10. Starter/Generator Leads
5. Fuel Hose to Engine Crankcase 11. Low Oil Warning Switch Lead
6. Reverse Shift Cable 12. Starter/Generator

Service Specifications (YDRE) SPECIFICATIONS
SERVICE SPECIFICATIONS (YDRE)

Operating Voltage 48V DC
Batteries 12V x 4
Traction Motor
Model DM430-06
Rated Output 2.6 kW (3.5 hp) for 30 minutes
Operating Voltage
Operating Current
Set Torque
48V DC
10 A
13.42 N·m (1.4 m·kg; 9.9 lb-ft)
2
Speed 2475 rpm
(maximum allowable) 2905 rpm
Weight 22 kg (48.5 lb)
Direction of Rotation Clockwise and Counterclockwise
Brush Length
• Standard 29 mm (1.14 in.)
• Wear Limit 13 mm (0.5 in.)
Brush Spring Pressure - Maximum/Minimum 1000 gf (35.27 ozf)/500 gf (17.7 ozf)
Mica Undercut - Standard/Minimum 1 mm (0.040 in.)/0.25 mm (0.010 in.)
Armature Winding Resistance 0.0176 ohm at 24°C (75°F)
Field Coil Resistance 0.716 ohm at 24°C (75°F)
Insulation Resistance (all measurements) >1 M-ohm
Motor Controller
Operating Amperage Minimum/Maximum 0 - 290 A
Solenoid Relay
Amperage Rating 100 A
• Peak Rating for 3 minutes 300 A
Coil Resistance 336 ohms at 20°C (68°F)
Contact Resistance
• OFF Infinity
• ON 0 ohm
Shift Switch
Type SPDT - 2 position maintained contact
Rating 48V DC at 10 mA
Tow Switch
Rated Load 5A DC minimum
Voltage 48V
Type SPST, 2 position maintained contact

SPECIFICATIONS Service Specifications (YDRE)
Reverse Buzzer
Part Number JR1-H3383-01
Type Piezo Ceramic Buzzer
Frequency 2.4 - 3.6 kHz
Operating Current < 25 mA
Sound Pressure 83 dB/1 minute/48V
Minimum Operating Voltage 10V DC
System Fuse
Amperage 3A
Battery Charger
Model Number JW2-01
Part Number JW2-H2107-01
Input V AC 120Vac
Input A AC 12.0A AC
Frequency 60Hz
Output V DC 48V DC
Output A DC 17/13.0A DC
Safety Timer 20 Hours
Weight 10.8 lbs/4.9 kg/Including Plug

Cable Routing - YDRE SPECIFICATIONS
CABLE ROUTING - YDRE
11
8 3
7
6
5
F1
A2
9
F2
A1
10
Y-1511
Figure 2-3
1. Main Switch Wire 7. Motor Controller Unit

2. Stop Switch Wire 8. Main Harness
3. Throttle Position Sensor 9. Speed Sensor Wire
4. Brake Cable 10. Electric Motor
5. Negative Battery Cable 11. Forward/Reverse Switch
6. Positive Battery Cable

SPECIFICATIONS Cable Routing - YDRE
4 7
6
9 8
10
11
Y-1512
Figure 2-4
1. Positive Battery Cable 7. Solenoid Relay

2. Wires to Main Harness 8. Charging Receptacle
3. Positive Cable to Motor Controller 9. Negative Cable to Battery
4. Motor Controller 10. Positive Cable to Battery
5. Wires to Electric Motor 11. Optional Transmitting Unit
6. Electric Motor

PERIODIC
MAINTENANCE
Table of Contents
— Periodic Maintenance Program —
3
Inspection and Adjustment Schedule .................................................... 3-5
YDRA - Gas..................................................................................... 3-5
YDRE - Electric ............................................................................... 3-7
Daily Checks - Gas Cars ....................................................................... 3-9
Operational Inspection .................................................................... 3-9
Check the Engine Oil..................................................................... 3-10
Clean the Engine Cooling Inlet Duct ............................................. 3-10
Inspect the Fuel Lines ................................................................... 3-10
Check the Fuel Level..................................................................... 3-10
Check the Battery.......................................................................... 3-10
Check the Brakes .......................................................................... 3-11
Check the Steering ........................................................................ 3-11
Inspect Wheels and Tires.............................................................. 3-11
Inspect Tires ............................................................................ 3-11
Check Tire Pressure................................................................ 3-11
Inspect Wheels ........................................................................ 3-11
Check Reverse Buzzer Operation................................................. 3-12
Monthly Service - Gas Cars ................................................................ 3-12
Inspect the Fuel Filter and Hoses.................................................. 3-12
Drive Belt....................................................................................... 3-13
Inspect the Drive Belt .............................................................. 3-13
Replace the Drive Belt............................................................. 3-13
Adjust the Shift Cable.................................................................... 3-13
Check the Shift Cable Adjustment........................................... 3-13
Adjust the Shift Cable Adjustment ........................................... 3-14

PERIODIC MAINTENANCE
Six-Month Service - Gas Cars............................................................. 3-15
Clean the Pre-Filter/Air Filter......................................................... 3-15
Check the Engine Compression Pressure .................................... 3-16
Check and Adjust the Valve Clearance and Spark Plug ............... 3-17
Check the Valve Clearance and Spark Plug ........................... 3-17
Adjust the Valve Clearance ..................................................... 3-19
Yearly Service - Gas Cars................................................................... 3-20
Change the Engine Oil .................................................................. 3-20
Adjust the Throttle Cables ............................................................. 3-21
Introduction.............................................................................. 3-21
Adjustment Procedures ........................................................... 3-21
Starter Belt .................................................................................... 3-23
Inspect the Starter Belt ............................................................ 3-23
Adjust the Starter Belt ................................................................... 3-24
Check and Adjust the Speed Limiter ............................................. 3-24
Check the Speed Limiter ......................................................... 3-24
Adjust the Speed Limiter ......................................................... 3-25
Radial Inspection ..................................................................... 3-25
Bearing Inspection................................................................... 3-25
Wheel Alignment ........................................................................... 3-26
Adjust the Parking Brake............................................................... 3-29
Adjust Pedal Stop.......................................................................... 3-30
Two-Year Service - Gas Cars ............................................................. 3-30
Four-Year Service - Gas Cars............................................................. 3-31
Daily Checks - Electric Cars................................................................ 3-33
Operational Inspection .................................................................. 3-33
Inspect the Batteries...................................................................... 3-33
Inspect the Brakes......................................................................... 3-33
Inspect the Steering System ......................................................... 3-33
Inspect the Wheels and Tires........................................................ 3-33
Inspect the Tires ...................................................................... 3-34
Check the Tire Pressure.......................................................... 3-34
Inspect the Wheels .................................................................. 3-34
Check the Reverse Buzzer Operation........................................... 3-34
Monthly Service - Electric Cars ........................................................... 3-35
Check the Battery Electrolyte Level .............................................. 3-35

Inspect the Charge Receptacle ........................................................... 3-35
Inspect the Electrical Connectors .................................................. 3-35
Six-Month Service - Electric Cars........................................................ 3-36
Yearly Service - Electric Cars.............................................................. 3-37
Perform the Discharge Test .......................................................... 3-37
Apply Battery Terminal Protectant................................................. 3-37
Inspect the Controller Connector................................................... 3-37
Radial Inspection ..................................................................... 3-37
Bearing Inspection................................................................... 3-37
Wheel Alignment ...........................................................................
Inspect the Front Wheel Bearing...................................................
Check the Transaxle Oil Level ......................................................
3-38
3-39
3-39
3
Adjust the Parking Brake ............................................................... 3-41
Adjust the Pedal Stop.................................................................... 3-42
Four-Year Service - Electric Cars........................................................ 3-43

Periodic Maintenance Program

The YDRA/E Maintenance Program provides a schedule for service, which applies to golf cars that are
operated under optimum conditions. Cars that are operated in extreme conditions, or more than the limits
in the Periodic Inspection and Adjustment Schedule, will require shorter service intervals. To obtain the full
benefit of the preventive maintenance program, ensure each car receives the complete maintenance
recommended by Yamaha. The program includes a schedule of daily, monthly (40 rounds), six-month (250
rounds), yearly (500 rounds), two-year (1000 rounds) and four-year (2000 rounds) service checks. Each
service check should be performed with scheduled routine maintenance. For example, the six-month
service check should be added to the tasks associated with the daily and monthly service. This section
provides detailed instructions for the preventive maintenance program. For additional maintenance and
repair procedures refer to Batteries on page 4-1, Engine on page 5-1, Drive Train on page 6-1, Chassis on
page 7-1 or Electrical on page 8-1. The periodic inspection and adjustment charts on the following pages
identify the tasks associated with the service interval being accomplished.

Inspection and Adjustment Schedule PERIODIC MAINTENANCE
INSPECTION AND ADJUSTMENT SCHEDULE

WARNING
Always lock out car when you perform
maintenance, unless otherwise specified. See
Safety Lockout Procedure on page 1-7.
YDRA - Gas
Interval Service Comments
Daily Check engine oil. See Check the Engine Oil on page 3-10.
Before
Operation Check air cooling duct. See Clean the Engine Cooling Inlet Duct on
page 3-10.
Check fuel lines for leakage.
Check fuel level.
See Inspect the Fuel Lines on page 3-10.
See Check the Fuel Level on page 3-10.
3
Check for looseness and corrosion of battery See Check the Battery on page 3-10.
terminals and hold-downs.
Check brake pedal free play and adjust if See Check the Brakes on page 3-11.
necessary.
Check steering operation. See Check the Steering on page 3-11.
Check tire pressure, tread depth and tire surface See Inspect Wheels and Tires on page 3-11.
for damage.
Check body and chassis for damage. See Check the Body and Chassis for Damage
on page 3-12.
Check tightness of all bolts, nuts, screws and See Check the Tightness of Bolts, Nuts,
rivets. Screws and Rivets on page 3-12.
Check reverse buzzer operation. See Check Reverse Buzzer Operation on
page 3-12.
Monthly Check fuel filter for clogging. See Inspect the Fuel Filter and Hoses on
40 rounds page 3-12.
20 hours
100 miles Check drive belt for wear. See Inspect the Drive Belt on page 3-13.
160 kms Check operation of forward/reverse shifting. See Adjust the Shift Cable on page 3-13.
Check pedal operation. See Check the Pedal Group on page 3-14.
6 months Wash pre-filter, check air cleaner element. See Clean the Pre-Filter/Air Filter on
125 hours
600 miles Check tightness of cylinder head/adjust valve See Check and Adjust the Valve Clearance
1000 kms clearance and inspect/replace spark plug. and Spark Plug on page 3-17.
Check engine compression. See Check the Engine Compression Pressure
on page 3-16.
Check shock absorbers for oil leaks and damaged See Inspect the Shock Absorbers on
springs. page 3-20.

PERIODIC MAINTENANCE Inspection and Adjustment Schedule

Every year Change engine oil. See Change the Engine Oil on page 3-20.
500 rounds
250 hours Adjust throttle cables and choke cable; check See Adjust the Throttle Cables on page 3-21.
1200 miles carburetor throttle shaft for wear**.
2000 kms Check starter V-belt for damage and tension. See Starter Belt on page 3-23.
Check drive belt for slippage, wear or scratches. See Inspect the Drive Belt on page 3-13.
Check operation of speed limiter. See Check and Adjust the Speed Limiter on
page 3-24.
Apply battery terminal protectant. See Battery Cleaning on page 4-6.
Check wiring connections and insulation. See Inspect the Wire Harness and Electrical
Cables on page 3-25.
Check rear axle bearing play for roughness or free See Inspect the Rear Axle Bearing on
play. page 3-25.
Check steering knuckle bushing free play. See Inspect the Steering Knuckle on
page 3-26.
Check front wheels for proper alignment. See Wheel Alignment on page 3-26.
Check wheel nut tightness and front wheel bearing See Inspect the Front Wheel Bearing on
play. page 3-27.
Check transaxle oil level and inspect for leakage. See Check the Transaxle Oil Level on
page 3-28.
Check operation of parking brake and adjust if See Adjust the Parking Brake on page 3-29.
necessary.
Check the brake pedal free play. See Adjust Brake Pedal Free Play on
page 3-29.
Check operation and adjust pedal stop if See Adjust Pedal Stop on page 3-30.
necessary.
Every 2 years Check brushes for wear and commutator for See Inspect the Starter/Generator on
1000 rounds contamination. page 3-30.
500 hours
2500 miles
4000 kms
Every 4 Years Replace fuel filter and fuel hoses. See Inspect the Fuel Filter and Hoses on
1000 hours
5000 miles Change transaxle oil. See Change the Transaxle Oil on page 3-31.
8000 kms Inspect internal wet brake and replace discs if See Disassemble the Brake on page 6-17.
necessary.
** Related to emission control system

Inspection and Adjustment Schedule PERIODIC MAINTENANCE

YDRE - Electric
WARNING
Always lock out car when you perform
maintenance, unless otherwise specified. See
Safety Lockout Procedure on page 1-7.

Daily Charge battery. See Charging Procedure on page 4-10.
Before
Operation Check for looseness and corrosion of battery See Inspect the Batteries on page 3-33.
terminals and hold downs.
Check brake pedal free play and adjust if See Inspect the Brakes on page 3-33.
necessary.
Check steering operation.
Check tire pressure, tread depth and tire surface

See Inspect the Steering System on
page 3-33.
See Inspect the Wheels and Tires on
3
for damage. page 3-33.
Check body and chassis for damage. See Check the Body and Chassis for Damage
on page 3-34.
Check tightness of all bolts, nuts, screws and See Check the Tightness of Bolts, Nuts,
rivets. Screws and Rivets on page 3-34.
Check reverse buzzer operation. See Check the Reverse Buzzer Operation on
page 3-34.
Monthly Check electrolyte level. See Battery Watering on page 4-8.
40 rounds
20 hours Inspect battery charger connections. See Inspect the Charge Receptacle on
100 miles page 3-35.
160 kms Check for loose or broken connections. See Inspect the Electrical Connectors on
page 3-35.
Check pedal operation. See Check the Pedal Group on page 3-14.
6 months Check all wire insulation for cracks and/or See Inspect the Wire Harness and Electrical
250 rounds damage. Cables on page 3-36.
125 hours
600 miles Check shock absorbers for oil leaks or damaged See Inspect the Shock Absorbers on
1000 kms springs. page 3-36.

PERIODIC MAINTENANCE Inspection and Adjustment Schedule

Every year Perform a discharge test. See Discharge Load Test on page 4-23.
500 rounds
250 hours Apply terminal protectant. See Battery Cleaning on page 4-6.
1200 miles Check motor controller wire connectors. See Inspect the Controller Connector on
2000 kms page 3-37.
Check rear axle bearing play for roughness or free See Inspect the Rear Axle Bearing on
play. page 3-37.
Check steering knuckle bushing free play. See Inspect the Steering Knuckle on
page 3-38.
Check front wheels for proper alignment. See Wheel Alignment on page 3-38.
Check wheel nut tightness and front wheel bearing See Inspect the Front Wheel Bearing on
play. page 3-39.
Check transaxle oil level and inspect for leakage. See Check the Transaxle Oil Level on
page 3-39.
Check operation of parking brake and adjust if See Adjust the Parking Brake on page 3-41.
necessary.
Check brake pedal free play. See Adjust Brake Pedal Free Play on
page 3-41.
Check pedal stop operation and adjust if See Adjust the Pedal Stop on page 3-42.
necessary.
Every 4 years Change transaxle oil. See Change the Transaxle Oil on page 3-43.
2000 rounds
1000 hours Inspect internal wet brake and replace discs if See Disassemble the Brake on page 6-35.
5000 miles necessary.
8000 kms

Daily Checks - Gas Cars PERIODIC MAINTENANCE
DAILY CHECKS - GAS CARS

WARNING
Operational Inspection Explosion Hazard
Clean and inspect each car daily for any loose or Gasoline and its vapors are highly flammable
damaged parts. Tighten or replace any loose, and explosive. Always take the following
missing or damaged parts before placing the car precautions when working on the fuel system
into operation. The operational inspection must or gasoline:
be accomplished prior to operating the car, • Do not smoke when performing
ensuring the brakes, steering, reverse buzzer and maintenance on the fuel system and keep
forward/reverse switch operate correctly. away from sparks, flames or other sources
Additionally, be sure to inspect/service the of ignition.
following areas before use:
• Stop engine and allow it to cool several
minutes before performing maintenance or
refueling.
• Close the fuel shutoff valve before
performing any maintenance on the fuel
system.
3
• Work in a well-ventilated area.
• NEVER spill gasoline. If gasoline spills, wipe
it up immediately with shop towels. Always
dispose of shop towels properly.
• Tighten the fuel tank cap securely after
checking fuel level or refueling.
• If you swallow gasoline, inhale a lot of
gasoline vapor or get gasoline in your eyes,
get immediate medical attention.
• If any gasoline gets on your skin,
immediately wash with soap and water.
Change clothing if gasoline spills on it.
NOTE:
Avoid using gasoline blended with methyl
alcohol. Damage to the fuel system parts will
result.

PERIODIC MAINTENANCE Daily Checks - Gas Cars
Check the Engine Oil Specification:

1. Place the vehicle on a level surface and Recommended Engine Oil
engage the parking brake. YAMALUBE 4 cycle oil (10W-30) or
SAE 10W-30 classification API service type SF
2. Remove the seat. or SG or equivalent.
7. Install the seat.
Clean the Engine Cooling Inlet Duct

1. Check engine cooling inlet duct for blockage.
2. Remove foreign objects and wipe the duct
1
clean with a clean shop towel.
Inspect the Fuel Lines

SM-03-117
NOTE:
Figure 3-1 EP7 fuel line (FKM inner layer/ECO outer layer)
3. Clean the area around the dipstick to prevent or equivalent must be used when replacing
foreign matter from entering the engine. damaged or deteriorated fuel lines.
4. Remove the dipstick (Figure 3-1, (1)) and
wipe it clean. 1. Close the fuel shutoff valve.
5. Insert the dipstick fully and remove. 2. Inspect the fuel line routing to ensure that all
hardware and clamps are secure.
CAUTION 3. Inspect the fuel lines for damage,
Never add oil unless the level is at or below deterioration, poor connections or blockage
the minimum line. and replace as necessary.
Never overfill the engine crankcase. Early 4. Open the fuel shutoff valve and check for
engine failure may result due to the aeration leaks.
of the oil and the resulting poor lubricating
properties. Check the Fuel Level
Ensure there is sufficient fuel in the tank for the
next day's schedule. Add fuel if necessary.
Yamaha recommends using regular unleaded fuel
with a minimum of 87 octane.
MIN MAX
Y-130
Check the Battery
• Wipe battery top with a clean shop towel and
ensure vent cap is secure.
Figure 3-2
• Check for loose or corroded battery terminals
6. Observe the oil level on the dipstick and hold-downs and tighten to specification.
(Figure 3-2). The oil level should be between
the MIN and MAX marks. If the oil level is low, Specification:
add oil to within 6.4 mm (0.25 in.) of the MAX Battery Terminals ..................................... 9 N·m
mark. (10 m·kg; 80 lb-in.)
NOTE: Battery Hold-down Plates.................... 7- 9 N·m

(0.7 - 0.9 m·kg; 62 - 80 lb-in.)
The distance between MIN and MAX marks
represents approximately 0.5 L (0.5 US qt). • Clean battery corrosion per Battery Cleaning on
page 4-6.

Daily Checks - Gas Cars PERIODIC MAINTENANCE

Check the Brakes
CAUTION
The parking brake should not engage
automatically when the brake is applied. If it
does, the brakes require attention. Report the
car to the Maintenance Department
immediately.
Make sure the parking brake locks properly and

stays locked. Be certain the brake pedal moves SM-03-196
and returns freely. If the brakes fail to engage
within the first 38 mm (1.50 in.) of pedal Figure 3-3
movement, the cable must be adjusted before the
Inspect Tires
car goes out on the course. For cable inspection
and adjustment see Adjust the Parking Brake on
page 3-29.
• Inspect the tire surfaces for damage, cracks
or imbedded foreign objects.
3
Check the Steering • Replace any worn or damaged tires. See
Front Wheel and Tire Service on page 7-15.
WARNING Check Tire Pressure
• Never place a car in service that has
potential steering problems.
While the steering system rarely needs attention,

check it after each day’s use for possible damage
from operator abuse. Check for binding, sticking
or excessive free play in steering wheel
movement. Such problems can point to damage
in the steering and related systems. Never send a
car out until steering problems are corrected.
Refer to the alignment/adjustment procedures
detailed in Yearly Service - Gas Cars on Y-142
page 3-20.
Figure 3-4
Inspect Wheels and Tires Measure the air pressure in each tire and adjust
Before getting into the car, take a few moments to to specification.
inspect the tires. Check them for low air pressure, Specification:
cuts and uneven tread wear. A quick inspection
may save the much bigger problem of fixing a flat Tire Pressure ......................................... 110 kPa
out on the course. If the front tires appear to be (1.1 kgf/cm2; 16 psi)
wearing unevenly, schedule the car for an
alignment check before excessive wear occurs. Inspect Wheels
WARNING
Never attempt to repair damaged wheels.
• Inspect each wheel for damage or bends.

• Replace any damaged or bent wheels. See

PERIODIC MAINTENANCE Monthly Service - Gas Cars
Check the Body and Chassis for MONTHLY SERVICE - GAS

Damage CARS
Before each use, visually inspect the golf car Complete the daily service prior to completing
body and chassis for any damage and/or missing any of the following tasks.
parts. Do not operate the golf car if any damaged
or missing parts are noticed. Inspect the Fuel Filter and Hoses
Check the Tightness of Bolts, Nuts, 1. Remove the seat.
Screws and Rivets
Inspect all fasteners for tightness. Tighten or
replace any loose or missing fasteners before
operating the golf car. For specific tightening 1
specifications, see Torque Specifications on
page 2-4.
Check Reverse Buzzer Operation

Check the reverse buzzer for proper operation.
Turn the key switch to the ON position. Move the
forward-neutral-reverse lever to REVERSE. The
buzzer should sound.
Y-1139
Figure 3-5
2. Inspect the filter (Figure 3-5, (1)) for evidence
of dirt or water.
CAUTION
EP7 fuel line (FKM inner layer/ECO outer
layer) or equivalent must be used when
replacing damaged or deteriorated fuel lines.
3. Inspect the hoses for evidence of damage,

cracking or wear. Replace as necessary.
4. Put a pan or other gasoline retardant
container under the fuel filter.
5. If filter replacement is necessary, remove the
hose clamps from both ends of the filter.
6. Disconnect the hoses from the filter and
replace filter with a new one. Ensure the flow
arrow points toward the fuel pump.
7. Install the clamps securely.

Monthly Service - Gas Cars PERIODIC MAINTENANCE

Drive Belt 3. While holding the secondary sheave
assembly open, remove the belt from the
Inspect the Drive Belt secondary sheave assembly and then the
primary sheave assembly.
1. Park the vehicle on a level surface and
engage the parking brake. 4. Place the new belt on the primary sheave
assembly and begin routing it onto the top of
2. Remove the seat. the secondary sheave assembly.
5. Open the secondary sheave assembly by
rotating the movable face backward. Allow the
belt to drop into the sheave and route the belt
into place.
6. Install the rear access panel and secure with
plastic rivets.
Adjust the Shift Cable

Check the operation of the shift cables by moving
the shift lever from the FORWARD to the
3
Figure 3-6
REVERSE position.
3. Inspect the belt (Figure 3-6, (1)) for wear,
cracks, glazing, or evidence of oil or grease. The lever and cables should move freely and not
bind. Make sure the cables are not bent, twisted
4. Measure the belt width (Figure 3-6, (a)) and or frayed.
replace if less than specification.
Specification: Check the Shift Cable Adjustment
Drive Belt Wear Limit............27.8 mm (1.09 in.)
Replace the Drive Belt

engage the parking brake.
FWD
SM-03-192
Figure 3-8
Y-1143 Measure shift stroke (Figure 3-8, (a)). Adjust if

not within specification.
Figure 3-7
2. Open the secondary sheave assembly by Specification:
rotating the movable face backward Shift Stroke .............15 - 17 mm (0.59 - 0.67 in.)
(Figure 3-7). Pushing the belt down between
the sheaves will hold the sheaves open.

PERIODIC MAINTENANCE Monthly Service - Gas Cars
Adjust the Shift Cable Adjustment Check the Pedal Group

1 1. Turn the main switch to OFF and remove the
key.
2
Y-1465
Y-1259
Figure 3-9
Figure 3-11
1. Set the shifter lever to NEUTRAL. The holes
in the shift lever and the bracket should be 2. Remove the floor mat and service lid, being
aligned. Install an 8 mm bolt or pin into the careful not to scratch the body.
hole (Figure 3-9, (1)) to hold the shift lever in
the NEUTRAL position.
2. Loosen the adjusting nuts (Figure 3-9, (2)) for
the shift cables.
Y-1147
Figure 3-12
3. Check the pedal assembly for proper
operation.
4. Replace the service lid and floor mat.
Y-1464
Figure 3-10
3. Turn adjusting nuts so the shift stroke
(Figure 3-10, (1)) is to specification.
Specification:
Shift Stroke............. 15 - 17 mm (0.59 - 0.67 in.)
4. Tighten the adjusting nuts.
5. Remove pin from shifting lever.
6. Check the shift operation.

Six-Month Service - Gas Cars PERIODIC MAINTENANCE
SIX-MONTH SERVICE - GAS

CARS
Complete the daily and monthly service prior to
completing the following tasks.
3
Clean the Pre-Filter/Air Filter
CAUTION 4
Y-625
• Never wring a pre-filter element dry.
• Do not apply oil to the pre-filter element. Figure 3-14
Doing so would increase the resistance to
4. Remove the air filter element
air flow, resulting in poor engine
(Figure 3-14, (3)) and the foam pre-filter
performance.
element (Figure 3-14, (4)).
• Never wash the air filter or use compressed
air to clean the element. Damage to the
paper element will result.
CAUTION 3
Never operate the engine with the air filter
• Do not use filters made from any other
elements removed. This will allow unfiltered
material. Engine life will be reduced.
air to enter, causing rapid wear and possible
• Be careful not to drop anything into the air engine damage. Additionally, operation
inlet. without the elements will affect carburetor
tuning with subsequent poor performance
and possible engine overheating.
1. Remove the seat.
5. Remove surface dust from the paper element

1 by lightly tapping the element on one of its
2
hard edges. Never use compressed air to
1 blow through the element or attempt to wash
it to clean it. Replace the paper element if you
find any of the following:
1 • The element is torn, has been wet or is
oil-soaked.
• The element is very dirty.
Y-624a
Figure 3-13 4
5
2. Unlatch five air filter cover clips
(Figure 3-13, (1)).
3. Remove the air filter case cover
(Figure 3-13, (2)).
Y-627
Figure 3-15
6. Clean the pre-filter element (Figure 3-15, (4))
by washing with soap and water
(Figure 3-15, (5)). Allow the element to air
dry completely before installing.

PERIODIC MAINTENANCE Six-Month Service - Gas Cars
7. Use a vacuum cleaner to remove any debris 1. Check and adjust valve clearance. See Adjust
from the air filter case, then wipe with a clean the Valve Clearance on page 3-19.
shop towel. 2. Start the engine and allow it to warm to
normal operating temperature. Stop the
engine.
3. Remove the seat.
4. Remove the drive belt. See Replace the Drive
Belt on page 3-13.
1 5. Remove the spark plug.
6. Use a jumper wire to ground the spark plug
lead to prevent accidental electrical shock or
the igniting of fuel vapor from the cylinder.
Y-1138 1
Figure 3-16
CAUTION
• The “UP” mark on the pre-filter element
must face up. Also, ensure the profile SM-03-259
matches the housing.
Figure 3-17
◆ To prevent air leaks, make sure that the
sealing surface of the paper element is 7. Install the Engine Compression Tester
securely seated in the case during (Figure 3-17, (1)), using an adapter if
installation. necessary.
8. Ensure the choke is off. Hold the throttle wide
open and crank the engine until the reading
8. Install the foam pre-filter element, ensuring on the gauge stabilizes. Stop cranking engine
the notched side (Figure 3-16, (1)) of the and note reading on gauge.
pre-filter element is correctly aligned in the air
filter case. Specification:
9. Install the air filter element. Ensure it is Compression Pressure
seated correctly. (at sea level)
Minimum................................................. 687 kPa
10. Install and latch the air filter case cover. (6.87 kg/cm2; 97.7 psi)
Normal .................................................... 785 kPa
Check the Engine Compression (7.85 kg/cm2; 111.6 psi)
Pressure Maximum ................................................ 883 kPa
Special Tool: (8.83 kg/cm2; 125.6 psi)
Engine Compression • If the reading is below specification, apply a few
Tester ............................................P/N YU-33223 drops of oil into the cylinder and retest.
• If the reading increases substantially with
NOTE: oil, suspect worn or damaged piston
A fully charged battery is necessary to achieve rings.
an accurate test.


• If the reading remains approximately the
same, suspect a damaged head gasket,
burned or misadjusted valves or a broken
piston ring.
• If the reading is above maximum specification,
suspect carbon buildup or a malfunctioning
compression release.
WARNING
Use care not to crack the ceramic insulator. A SM-03-035
cracked insulator will allow external sparking, Figure 3-19

resulting in poor engine performance and
may possibly lead to fire or explosion. 3. Remove spark plug (Figure 3-19).
4. Visually inspect the spark plug and verify it is
the correct type and number.
9. Install the spark plug and tighten to
specification. Install spark plug lead.
Specification:
Specification:
Standard Spark Plug ...................NGK-BPR2ES
3
NGK-BPR4ES
Spark Plug Torque .................................. 20 N·m
(2.0 m·kg; 168 lb-in.)
Check and Adjust the Valve

Clearance and Spark Plug
Check the Valve Clearance and Spark
Plug
SM-03-197
NOTE: Figure 3-20

Allow engine to cool before adjusting the valve 5. Inspect the electrode (Figure 3-20, (1)) and
clearance. tip for wear or damage. Replace if worn.
6. Inspect the ceramic insulator
1. Remove the seat. (Figure 3-20, (2)) for cracks or damage. The
normal color is a medium to light tan. Replace
if darker than light tan.
7. Measure the gap (Figure 3-20, (a)) with a
wire feeler gauge.
Specification:
Spark Plug Gap...............................0.7 - 0.8 mm
(0.028 - 0.031 in.)
8. Adjust gap or replace the spark plug as
required.
Figure 3-18
2. Disconnect the cylinder head breather hose
(Figure 3-18, (1)) and remove spark plug
lead (Figure 3-18, (2)).

PERIODIC MAINTENANCE Six-Month Service - Gas Cars
12. Rotate the primary sheave assembly

counterclockwise one-half a turn from the top
dead center (TDC) and observe the rocker
arms.
4 (a) If the intake rocker arm (Figure 3-23, (6))
moved, rotate the primary sheave
assembly an additional half turn
counterclockwise to set the piston at top
dead center (TDC) on the compression
stroke.
SM-03-036 (b) If both rocker arms did not move, return
Figure 3-21 the primary sheave assembly to its initial
position.
9. Remove cylinder head cover
(Figure 3-21, (4)) and cylinder head cover
gasket with a 6 mm socket.
SM-03-039
Figure 3-24
SM-03-037 13. Check valve clearance using a feeler gauge. If
Figure 3-22 not within specification, adjust the clearance.
See Adjust the Valve Clearance on
10. Carefully insert a screwdriver page 3-19.
(Figure 3-22, (5)) through the spark plug hole
Specification:
until it touches the top of the piston. Rotate
the primary sheave assembly until the Valve Clearance (cold)
screwdriver reaches its highest position. Intake and Exhaust.....................0.08 - 0.12 mm
(0.00315 - 0.00472 in.)
14. Measure the valve clearance of the remaining
rocker arm and adjust as necessary.
SM-03-038
Figure 3-23
11. Paint alignment marks (Figure 3-23) on the
primary sheave assembly and crankcase.


Adjust the Valve Clearance Specification:
Valve Adjusting Locknut
Torque........................................................ 7 N·m
1 (0.7 m·kg; 62 lb-in.)
2
Cylinder Head Cover Screw
Torque...................................................... 11 N·m
(1.1 m·kg; 97 lb-in.)
NOTE:
Clean the spark plug sealing surface before
SM-03-040
installing spark plug.
Figure 3-25
1. Loosen the locknut (Figure 3-25, (1)) while
holding the adjustment screw with Valve
Adjuster Tool (Figure 3-25, (2)).
Special Tool:
WARNING
Use care not to crack the ceramic insulator. A
cracked insulator will allow external sparking,
3
resulting in poor engine performance and
Valve Adjuster Tool................. P/N YM-08035-A
may possibly lead to fire or explosion.
2. Insert a feeler gauge of specified thickness
between the valve adjusting screw end and
the valve end. 6. Install the spark plug and connect spark plug
lead.
Specification:
3
Spark Plug Torque.................................. 20 N·m
(2.0 m·kg; 168 lb-in.)
4
NOTE:
Ensure the breather hose is securely attached.
SM-03-041A
7. Connect the cylinder head breather hose and
oil delivery hose.
Figure 3-26
3. Turn the valve adjusting screw
(Figure 3-26, (3)) until the rocker arm
(Figure 3-26, (4)) creates a light drag on the
feeler gauge.
4. Hold the valve adjusting screw to prevent it
from moving and tighten the locknut to
specification.
NOTE:
Ensure all old gasket material is removed
before installing the cylinder head cover.
5. Install the cylinder head cover with a new

gasket. Tighten to specification.

PERIODIC MAINTENANCE Yearly Service - Gas Cars
Inspect the Shock Absorbers YEARLY SERVICE - GAS CARS

1. Raise and support the vehicle with jack Complete the daily, monthly and six-month
stands. See Recommended Jack Points on service prior to completing the following tasks.
page 1-7.
2. Remove all wheels. Change the Engine Oil
3. Visually inspect the shock absorbers for oil 1. Park the vehicle on a level surface.
leakage. If leakage is noted, replace the 2. Engage parking brake.
shock absorber. See Front Suspension
Components on page 7-46 or Rear 3. Start the engine and drive the car around and
Suspension Components on page 7-51. let it warm to normal operating temperature.
4. Visually inspect the coil spring for fatigue or 4. Stop the engine and put a drain pan under the
damage. If fatigue or damage is found, engine oil drain.
replace the shock absorber and spring 5. Remove the seat.
assembly. See Front Suspension 6. Clean the area around the oil filler and
Components on page 7-46 or Rear dipstick with a clean shop towel.
Suspension Components on page 7-51.
5. Verify the pivot bolts/nuts at the shock
absorber attaching points are tightened to 1
specification.
Specification:
Lower Front Shock Absorber Bolt
Torque ...............................................75 - 85 N·m
(7.6 - 8.6 m·kg; 55 - 62 lb-ft)
Upper Front Shock Absorber Bolt
Torque ...............................................40 - 50 N·m SM-03-119
(4.0 - 5.0 m·kg; 30 - 37 lb-ft)
Figure 3-27
Upper and Lower Rear Shock Absorber Bolts
7. Remove the engine oil filler cap
Torque ...............................................24 - 39 N·m
(Figure 3-27, (1)).
(2.4 - 3.8 m·kg; 17 - 28 lb-ft)
6. Install the wheels and tighten lug nuts to
specification.
Specification:
Wheel Lug Nut Torque............................ 80 N·m
(8.2 m·kg; 59 lb-ft)
7. Lower the car to the ground.
Figure 3-28
CAUTION
The engine oil will be hot. Use care not to
burn your hands when draining the engine oil.
8. Remove the engine oil servicing plug

(Figure 3-28, (2)) and gasket.
9. Allow the engine oil to drain completely from
the crankcase.

Yearly Service - Gas Cars PERIODIC MAINTENANCE

10. Wipe the oil servicing plug with a clean shop Adjustment Procedures
towel and install with a new gasket.
Perform the following procedures when making
11. Fill the crankcase with the specified amount throttle cable adjustments:
of the recommended engine oil. See Check
the Engine Oil on page 3-10.
CAUTION
12. Install the engine oil filler cap. Drive the car
and allow the engine to warm up for a few • When service is performed on the
minutes, then stop the engine. carburetor, throttle cables or governor
13. Check the engine for oil leaks. parts, the vehicle maximum speed should
be checked and the speed limiter setting
14. Allow the engine to cool for a few minutes and adjusted as necessary.
check the oil level again. Fill as required.
• There are two separate throttle cables.
15. Install the seat. Throttle cable “1” requires adjustment for
free play and throttle cable “2” for full
Adjust the Throttle Cables throttle operation.
Introduction
This technical service information clarifies the Throttle Valve
3
procedures for adjusting the YDRA throttle
cables. The YDR Service Manual will be updated 1
to reflect the clarified procedure.
The throttle system design on the YDRA utilizes
two cables. Throttle cable “1” actuates the 2
governor by depressing the accelerator pedal.
Throttle cable “2” controls the throttle valve on the
5
carburetor from the governor. There must be 3
some free play (1.0 - 2.0 mm (0.04 - 0.08 in)) in
throttle cable “1” to ensure the correct throttle
adjustment. The throttle is adjusted by checking
the stop gap on the throttle valve, and the free
play on throttle cable “1” in three steps:
4 Y-1600
• Positioning the throttle valve to full throttle.
• Verifying and adjusting throttle cable “2” to 1. To Carburetor
ensure the correct throttle valve lever 2. Throttle Cable “2”
position, as necessary. 3. Governor Lever
• Verifying and adjusting throttle cable “1,” as 4. Throttle Cable “1”
necessary. 5. Transaxle Assembly
Figure 3-29
1. Rotate the governor lever (Figure 3-29, (3))
counterclockwise by hand until it stops. This
will actuate the throttle valve on the carburetor
to the full open position.

Throttle Cable “2” (Governor to Carburetor)
1 2
7
5
1
2
6 Y-1602
3
1. Locknut
2. To Carburetor
Y-1601
3. Throttle Cable “2”
1. Throttle Valve Lever 4. Adjusting Nut
2. Gap 5. Governor Lever
3. Throttle Stop Boss 6. Throttle Cable “1”
Figure 3-30 7. Transaxle Assembly
Figure 3-31
2. Verify the throttle valve on the carburetor is in
the full open position. There should be a slight Adjust gap at carburetor as follows:
gap (Figure 3-30, (2)) between the throttle
• Loosen locknut (Figure 3-31, (1)).
valve lever (Figure 3-30, (1)) and the throttle
stop boss (Figure 3-30, (3)), with the • Rotate adjusting nut (Figure 3-31, (4)) until
governor lever rotated in a full gap at carburetor is within specification.
counterclockwise position. • Tighten the locknut.
Specification:
Throttle Cable “1” (Accelerator to Governor)
Throttle Valve Lever/Boss Gap ..... 0.1 - 1.0 mm
(0.004 - 0.04 in.)
NOTE:
3. If necessary, adjust throttle cable “2” to obtain The throttle valve should reach the full throttle
the correct clearance as detailed in Throttle position at the same time the accelerator pedal
Cable “2” (Governor to Carburetor) on reaches its limit. If the throttle valve is fully open
page 3-22. before the accelerator pedal reaches its limit,
4. Release governor lever. throttle cable “1” is too tight.
1. Fully depress the accelerator pedal and verify

the governor assembly rotates and stops in
sequence with the accelerator pedal reaching
its limit.
2. Release the accelerator pedal.


4. To Adjust:
1
• Loosen locknut (Figure 3-33, (1)).
2 • Rotate adjusting nut (Figure 3-33, (2)) until
free play is within specification, ensuring
throttle cable “1” is not tight. If throttle cable
“1” is tight, back off adjusting nut until there is
free play present in the cable.
3 • Tighten the locknut to specification.
5
Specification:
Throttle Cable to Pedal
Assembly Locknut.................................... 3 N·m
(0.3 m·kg; 27 lb-in.)
4 Y-1603
5. Test-drive the car to verify smooth

1. To Carburetor acceleration.
2.
3.
4.
Throttle Cable “2”
Governor Lever
Throttle Cable “1”
Starter Belt 3
5. Throttle Cable “1” Free Play Inspect the Starter Belt
Figure 3-32 1. Remove the seat.
3. Check free play (Figure 3-32, (5)) of throttle
cable “1” (between accelerator pedal and
governor) at the governor. Adjust as
necessary. 1
NOTE:
Ensure there is free play in throttle cable “1”
with accelerator pedal in the full up position.
SM-03-328
Figure 3-34
2. Inspect starter belt (Figure 3-34, (1)) for
2
1 wear, cracks, evidence of oil or grease, or
other damage. Replace starter belt if worn,
cracked, oil soaked or damaged. See
Replacing Starter/Generator Belt on
page 8-29.
Y-1604
1. Locknut
2. Adjusting Nut
Figure 3-33
Specification:
Throttle Cable “1” Free Play ......... 1.0 - 2.0 mm
(0.04 - 0.08 in.)

Adjust the Starter Belt Check and Adjust the Speed Limiter
NOTE:
1
The speed limiter is properly adjusted at the
factory. No adjustment is normally required.
3
The speed limiter can be adjusted to a
4 maximum speed of 16 - 24 km/h (10 - 15 mph).
SM-03-016
CAUTION
Figure 3-35 • When service is performed on the
carburetor, throttle cables or speed limiter
1. Loosen two 12 mm flange bolts parts, the vehicle maximum speed should
(Figure 3-35, (1)) that secure the be checked and the speed limiter setting
starter/generator to the mounting bracket. adjusted as necessary.
2. Loosen the lower tensioner locknut • Before performing repairs, mark the present
(Figure 3-35, (2)). limiter setting with a paint mark for future
3. Loosen adjuster bolt locknut reference. Return the adjustment to the
(Figure 3-35, (3)). original setting after repairs are completed,
4. Turn adjuster bolt (Figure 3-35, (4)). Adjust then test the vehicle speed.
belt tension:
• Turn adjuster bolt clockwise to increase
tension. Check the Speed Limiter
• Turn adjuster bolt counterclockwise to 1. Use a handheld GPS device to measure the
decrease tension. speed or compare the maximum speed with
another golf car driving parallel. (The golf car
5. Tighten two 12 mm flange bolts used for comparison should be representative
(Figure 3-35, (1)) to specification. of other cars in the same fleet.)
6. Tighten lower tensioner locknut 2. Check the speed limiter setting. If not within
(Figure 3-35, (2)) to specification. specification, adjust.
7. Tighten adjuster bolt locknut Specification:
(Figure 3-35, (3)) to specification.
Standard Speed Limiter
Specification: Setting ............................................. 3050 rpm at
Starter Attaching Bolt (12 mm) 19 km/h (12 mph)
Torque ...................................................... 59 N·m
(6.0 m·kg; 43.5 lb-ft)
Starter Lower Tensioner Locknut
Torque ...................................................... 21 N·m
(2.1 m·kg; 186 lb-in.)
Starter Adjuster Bolt Locknut
Torque ........................................................ 7 N·m
(0.7 m·kg; 62 lb-in.)
8. Check belt tension again and adjust if
necessary.


Adjust the Speed Limiter Inspect the Rear Axle Bearing
1. Remove the rear access cover. 1. Engage the parking brake and loosen the rear
wheel lug nuts.
WARNING 2. Block the front wheels and raise the rear of
Never, under any circumstances, exceed the the car with a jack. See Recommended Jack
maximum speed setting of 24 km/h (15 mph). Points on page 1-7.
3. Remove the rear wheels.
4. Release the parking brake.
5. Move the shift lever to the NEUTRAL position.
SM-03-189 2
3
A
Y-1198
B Figure 3-37
Radial Inspection
• Turn the rear axle slowly by hand
SM-03-190 (Figure 3-37, (1)) and feel for roughness or
grating. Replace the wheel bearing if roughness
1. Adjusting Nut or grating is detected. See Transaxle - YDRA
2. Adjusting Rod (Gas Car) on page 6-10 or Transaxle - YDRE
3. Speed Limiter Lever (Electric Car) on page 6-31.
4. Torsion Spring
Figure 3-36
Bearing Inspection
• Gently rock the rear axle up and down
2. Adjust distance (Figure 3-36, (a)) by turning
(Figure 3-37, (2)) to detect free play. Replace
the adjusting nut (Figure 3-36, (1)):
the bearing if free play is greater than 0.51 mm
(a) Counterclockwise (lengthening the rod) to (0.02 in). See Transaxle - YDRA (Gas Car) on
reduce maximum speed. page 6-10 or Transaxle - YDRE (Electric Car)
(b) Clockwise (shortening the rod) to increase on page 6-31.
maximum speed.
Inspect the Wire Harness and

Electrical Cables
Inspect the wire harness and all other wire
insulation for cracked, frayed or corroded
material. Pay particular attention to wires around
clamps and tie-wraps.
If inspection reveals a cracked, frayed or corroded
wire, the wire must be repaired or replaced.

Inspect the Steering Knuckle Wheel Alignment

1. Move the shift lever to the NEUTRAL position.
NOTE:
Move the car by pushing from the rear. Make
sure the front of the car is not lifted or pushed
down, which would cause an inaccurate
measurement.
2. Put the vehicle on a level surface and push

the empty car forward 6.1 m (20 ft) to stabilize
suspension. Allow the car to coast to a stop
with front wheels pointing straight ahead.
NOTE:
Do not push the car backward or apply the
Y-1184 brake to stop. Doing either will result in a
change in toe-in.
Figure 3-38
engage the parking brake.
2. Raise the front wheels with a suitable jack.
See Recommended Jack Points on page 1-7.
3. Gently rock the front wheel side to side
(Figure 3-38).
4. If more than 5 mm (0.20 in.) free play is noted,
replace the steering knuckle bushings. See
Front Suspension Components on page 7-46.
Y-1320
Figure 3-39
3. Put the Toe-in Measuring Gauge between the
inner sidewalls of the front tires approximately
60 mm (2.25 in.) behind the face of the front
tire (Figure 3-39). The height indicator chains
should just touch the floor evenly on each
side.
Special Tool:
Toe-in Measuring Gauge............. P/N YC-39526

NOTE:
0
TOE TOE When loosening or tightening the locknuts
OUT IN
(Figure 3-41, (1)), hold the tie-rod end
(Figure 3-41, (3)) with a wrench. The length of
the threads of both rod ends must be
approximately the same.
Y-104
Figure 3-40 7. Tighten the locknuts to specification.

4. Zero the scale on the gauge by sliding the Specification:
movable scale so the pointer is at zero Tie-Rod Locknut
(Figure 3-40). Torque...................................................... 40 N·m
5. With the gauge in place, roll the car forward (4.1 m·kg; 29.5 lb-ft)
one-half turn of the wheels. The height
8. Lower the vehicle to the ground.
indicator chains should just touch the floor.
6. Read the toe-in measurement on the gauge
scale and adjust the toe-in as follows:
9. Recheck the toe-in and repeat adjustment if
toe-in is found to be out of specification.
3
Inspect the Front Wheel Bearing
2 1
3
1. Park the vehicle on a level surface.
2. Engage parking brake.
3. Raise the front wheels. See Recommended
Jack Points on page 1-7.
4. Spin the wheel by hand.
SM-03-326
Figure 3-41
(a)
Engage the parking brake.
(b)
Raise the front of the vehicle.
(c)
Loosen locknuts (Figure 3-41, (1)).
(d)
Adjust the toe-in by turning both tie rods
equally (Figure 3-41, (2)) until toe-in is SM-03-014
within specification. Figure 3-42

Specification:
5. Touch the steering knuckle or kingpin bolt
Toe-in Measurement .......................... 0 - 10 mm while spinning the wheel (Figure 3-42, (1)).
(0.00 - 0.40 in.)
6. If excessive vibration is noted, replace
bearing and oil seal. See Front Suspension
Components on page 7-46.

Check the Transaxle Oil Level 6. If oil is at the correct level, install oil servicing
plug and tighten to specification. If oil needs
When checking the transaxle oil level, inspect the to be added, proceed to step 7.
exterior of the transaxle for any wetness or
evidence of an oil leak. Repair the leak before Specification:
putting the car into service. Oil Servicing Plug
Torque................................................... 16.3 N·m
(1.66 m·kg; 144 lb-in.)
NOTE:
It is not necessary to remove the bag tray insert
to check the oil level. The oil level servicing plug
can be accessed from underneath the rear
bumper. 1
2
1. Park car on a flat level surface.

2. Put an oil pan under the transaxle case.
1
Y-1193
Figure 3-44
7. Remove seven plastic rivets
(Figure 3-44, (1)), two bolts
(Figure 3-44, (2)) and the bag tray insert.
NOTE:
Failure to use the correct oil will cause noise
Y-1194A when braking.
Figure 3-43
8. Add SAE80 W90 API GL-5 Limited Slip High
NOTE: Performance Gear Oil into the oil servicing
hole until oil level is even with the bottom
Do not allow foreign material to enter the
edge of the oil servicing hole. Allow excess oil
transmission case.
to flow out of the hole until it stops.
9. Install the transaxle oil servicing plug and
3. Clean area around oil servicing plug tighten to specification.
(Figure 3-43, (1)). Specification:
4. Remove oil servicing plug with an 8 mm hex Transaxle Oil Servicing Plug
wrench. Torque................................................... 16.3 N·m
5. Oil level should be even with the bottom edge (1.66 m·kg; 144 lb-in.)
of the oil servicing hole or just beginning to
trickle out of hole. 10. Install the bag holder insert and secure with
two bolts and seven plastic rivets.


Adjust the Parking Brake Adjust Brake Pedal Free Play
Make sure the parking brake locks properly and 1. Remove the floor mat and the service lid.
stays locked. If brake does not lock properly,
adjustment is required.
NOTE:
a 16
17
18
Before performing parking brake adjustment, 10

11
12
13
14
15
adjust brake pedal free play.

9
8
7
Y-62b
Figure 3-46
2. Check the brake pedal free play by pressing
against the pedal with two fingers (using light
force) and measure the distance the pedal
3
travels (Figure 3-46, (a)) before resistance is
felt. Compare measurement to specification.
SM-03-193
Specification:
Figure 3-45 Brake Pedal Free Play ......................45 - 50 mm
(1.77 - 1.96 in.)
1. Inspect the parking brake ratchet
(Figure 3-45, (1)) and ratchet stopper
(Figure 3-45, (2)) for wear or damage. WARNING
2. Replace any worn or damaged parts. Do not over-tighten the brake cable.
3. Apply the brake and engage the stopper at Over-tightening will increase brake wear and
the second notch on the ratchet. affect overall performance of car.
4. Measure free play (release timing)
(Figure 3-45, (a)) and adjust if not within
specification:
A B
(a) Loosen the locknut (Figure 3-45, (4)).
(b) Adjust the release timing by turning the
adjusting bolt (Figure 3-45, (3)).
• To increase the release timing, turn the
adjusting bolt counterclockwise. Y-909A
• To decrease the release timing, turn the

Figure 3-47
adjusting bolt clockwise.
3. If pedal free play needs adjustment, loosen
Specification:
the jam nuts (Figure 3-47, (A and B)).
Parking Brake Free Play................ 0.0 - 0.3 mm
4. Adjust the free play by moving the brake
(0.0 - 0.011 in.)
cable. Tighten the jam nuts to specification.
Specification:
Brake Cable to Pedal Assembly
Jam Nuts ................................................. 13 N·m
(1.3 m·kg; 115 lb-in.)
5. Recheck brake pedal free play.

PERIODIC MAINTENANCE Two-Year Service - Gas Cars
Adjust Pedal Stop TWO-YEAR SERVICE - GAS

CARS
Complete the daily, monthly, six-month and yearly
service prior to performing the two-year service.
Inspect the Starter/Generator

1. Remove and disassemble the
starter/generator. See Starter/Generator
1 Components on page 8-14.
2 2. Visually inspect the brushes for wear and
damage.
3. Measure the length of the brushes. Replace if
not within specification.
Specification:
Starter Brush Length
(wear limit) ...............................................16 mm
Y-1521 (0.7 in.)
Figure 3-48
4. Remove the armature.
2. Remove the floor mat and service lid.
3. Loosen the locknut (Figure 3-48, (1)).
4. Place an inclinometer on the throttle pedal.
Measure the pedal angle. Compare the
measurement to the specification.
Specification:
Throttle Pedal Angle ...........................65° ± 1.5°
5. If the throttle pedal angle requires adjustment,
turn the throttle stop bolt (Figure 3-48, (2)) in Figure 3-49
or out to achieve the correct pedal angle.
5. Lightly clamp the armature in a vise
6. When the angle is to specification use a (Figure 3-49, (1)) with soft jaws
wrench to hold the throttle stop bolt (Figure 3-49, (2)). Clean the commutator
(Figure 3-48, (2)) in position and tighten the using #600 grit emery cloth
locknut (Figure 3-48, (1)) to specification. (Figure 3-49, (3)).
Specification:
Pedal Stop Bolt Locknut .................23 - 29 N·m
(2.3 - 2.9 m·kg; 204 - 257 lb-in.)
7. Install the service lid and the floor mat.

Four-Year Service - Gas Cars PERIODIC MAINTENANCE
FOUR-YEAR SERVICE - GAS

CARS
Complete the daily, monthly, six-month, yearly
and two-year service prior to completing the
following tasks.
Change the Transaxle Oil

Y-398
3. Put a drain pan under the transaxle case.
Figure 3-50 4. Clean dirt and debris from around the oil
6. Measure the diameter of the commutator servicing plugs.
using a micrometer or caliper (Figure 3-50).
Replace the armature if not within
specification.
Specification:
YDRA
1
3
Commutator Diameter
(wear limit)............................................... 39 mm
(1.54 in.)
Y-1196
Figure 3-51
5. Remove the oil servicing plug
(Figure 3-51, (1)).
6. Allow all oil to drain out.
7. When transaxle is completely drained, install
the oil servicing plug and tighten to
specification.
Transaxle Oil Servicing Plug
Torque................................................... 16.3 N·m
(1.66 m·kg; 144 lb-in.)

PERIODIC MAINTENANCE Four-Year Service - Gas Cars
NOTE:
1 when braking.
2

Performance Gear Oil into the oil servicing
to flow out of the hole until it stops.
12. Install the oil servicing plug and tighten to
Y-1193
specification.
Figure 3-52
Specification:
8. Remove seven plastic rivets Transaxle Oil Servicing Plug
(Figure 3-52, (1)), two bolts Torque................................................... 16.3 N·m
(Figure 3-52, (2)) and the bag tray insert. (1.66 m·kg; 144 lb-in.)
13. Install the bag holder insert and secure with
1 two bolts and seven plastic rivets.
Inspect the Brake Discs

The wet brake discs should be inspected for
wear. See Disassemble the Brake on page 6-35.
Y-1194A
Figure 3-53
CAUTION
transmission case.
9. Clean area around oil servicing plug

(Figure 3-53, (1)).
10. Remove oil servicing plug with an 8 mm hex
wrench.

Daily Checks - Electric Cars PERIODIC MAINTENANCE
DAILY CHECKS - ELECTRIC Inspect the Brakes

CARS
CAUTION
Operational Inspection The parking brake should not engage
Clean and inspect each car daily for any loose or automatically when the brake is applied. If it
damaged parts. Tighten or replace any loose, does, the brakes require attention. Report the
missing or damaged parts before placing the car car to the Maintenance Department
into operation. The operational inspection must immediately.
be accomplished prior to operating the car,
ensuring the brakes, steering, reverse buzzer and Make sure the parking brake locks properly and
forward/reverse switch operate correctly. stays locked. Be certain the brake pedal moves
Additionally, be sure to inspect/service the and returns freely. If the brakes fail to engage
following areas before use: within the first 38 mm (1.50 in.) of pedal
movement, the cable must be adjusted before the
Inspect the Batteries
WARNING
car goes out on the course. For cable inspection
and adjustment see Adjust the Parking Brake on
page 3-29.
3
Electrolyte is a solution of acid and water. Inspect the Steering System
Avoid skin contact.
WARNING
WARNING Never place a car in service that has potential
steering problems.
Always dispose of used shop towels properly.
While the steering system rarely needs attention,
• Wipe battery tops with a clean shop towel and check it after each day’s use for possible damage
ensure all vent caps are secure. from operator abuse. Check for binding, sticking
or excess free play in steering wheel movement.
• Check for loose or corroded battery terminals
Such problems can point to damage in the
and hold-downs and tighten to specification.
steering and related systems. Never send a car
Specification: out until steering problems are corrected. Refer to
Battery Terminals...................................... 9 N·m the alignment/adjustment procedures detailed in
(10 m·kg; 80 lb-in.) the yearly service section in this chapter.
Battery Hold-down Plates ....................7-9 N·m Inspect the Wheels and Tires
(0.7 - 0.9 m·kg; 62 - 80 lb-in.) Before getting into the car, take a few moments to
• Clean battery corrosion per Battery Cleaning on inspect the tires. Check them for low air pressure,
page 4-6. cuts and uneven tread wear. A quick inspection
may save the much bigger problem of fixing a flat
out on the course. If the front tires appear to be
wearing unevenly, schedule the car for an
alignment check before excessive wear occurs.

PERIODIC MAINTENANCE Daily Checks - Electric Cars
Check the Body and Chassis for

Damage
Before each use, visually inspect the golf car
body and chassis for any damage and/or missing
parts. Do not operate the golf car if any damage
or missing parts are noticed.
Check the Tightness of Bolts, Nuts,

Screws and Rivets
Inspect all fasteners for tightness. Tighten or
SM-03-196 replace any loose or missing fasteners before
operating the golf car. See Torque Specifications
Figure 3-54 on page 2-4 for specific tightening specifications.
Inspect the Tires Check the Reverse Buzzer

• Inspect the tire surfaces for damage, cracks Operation
or embedded foreign objects.
Check the reverse buzzer for proper operation.
• Replace any worn or damaged tires. See Turn the key switch to the ON position. Move the
Front Wheel and Tire Service on page 7-15. forward-neutral-reverse lever to the REVERSE
position. The buzzer should sound.
Check the Tire Pressure
Y-142
Figure 3-55
Measure the air pressure in each tire and adjust
to specification.
Specification:
Tire Pressure..........................................138 kPa
(1.1 kgf/cm2; 20 psi)
Inspect the Wheels
WARNING
• Inspect each wheel for damage or bends.

• Replace any damaged or bent wheels. See

Monthly Service - Electric Cars PERIODIC MAINTENANCE
MONTHLY SERVICE - Check the Pedal Group

ELECTRIC CARS 1. Turn the main switch to OFF and remove the
key.
Complete the daily service prior to completing
any of the following tasks.
Check the Battery Electrolyte Level

Check the electrolyte level in each battery. See
Battery Watering on page 4-8.
INSPECT THE CHARGE

RECEPTACLE
WARNING
• Secure vehicle and discharge the controller Y-1259
3
capacitor. See Safety Lockout Procedure on Figure 3-56
page 1-7.
2. Remove the floor mat and service lid, being
• Always disconnect the negative (-) cable
careful not to scratch the body.
from the battery first and install it last.
• Use insulated wrenches to avoid short
circuits to the batteries.
• Ensure the vehicle is in TOW position.
1. Inspect the charge receptacle contacts for

damage or corrosion, and make sure
receptacle is securely mounted.
2. Replace the receptacle if any damaged,
corroded or loose contacts are found.
WARNING
Damaged receptacle contacts can cause
excessive resistance (heat) and lead to fire. Y-1147
Figure 3-57
3. Check the pedal assembly for proper
Inspect the Electrical Connectors operation.
Check all wire connections per the electrical 4. Replace the service lid and floor mat.
wiring diagram illustrated in Electrical on
page 8-1 for damaged, loose or broken
connections. Inspect wire insulation for cracked
or frayed material. Pay particular attention to
wires passing through holes in frame and over
rough edges. If inspection reveals a broken or cut
wire, the wire must be repaired or replaced.

PERIODIC MAINTENANCE Six-Month Service - Electric Cars
SIX-MONTH SERVICE - 5. Verify the pivot bolts/nuts at the shock

absorber attaching points are tightened to
ELECTRIC CARS specification.
Complete the daily and monthly service prior to Specification:
completing the following tasks. Lower Shock Absorber Bolt
Torque............................................... 75 - 85 N·m
Inspect the Wire Harness and (7.6 - 8.6 m·kg; 55- 62 lb-ft)
Electrical Cables
Upper Shock Absorber Bolt
Inspect the wire harness and all other wire Torque............................................... 40 - 50 N·m
insulation for cracked, frayed or corroded (4.0 - 5.0 m·kg; 30 - 37 lb-ft)
material. Pay particular attention to wires around
clamps and tie-wraps. Upper and Lower Rear Shock Absorber Bolts
Torque............................................... 24 - 39 N·m
• If inspection reveals a cracked, frayed or (2.4 - 3.8 m·kg; 17 - 28 lb-ft)
corroded wire, the wire must be repaired or
replaced. 6. Install the wheels and tighten lug nuts to
specification.
Inspect the Shock Absorbers Specification:
1. Raise and support the vehicle with jack Wheel Lug Nut Torque ........................... 80 N·m
stands. See Recommended Jack Points on (8.2 m·kg; 59 lb-ft)
page 1-7.
7. Lower the car to the ground.
2. Remove all wheels.
3. Visually inspect the shock absorbers for oil
leakage. If leakage is noted, replace the
shock absorber. See Front Suspension
Components on page 7-46 or Rear
4. Visually inspect the coil spring for fatigue or
damage. If fatigue or damage is found,
replace the shock absorber and spring
assembly. See Front Suspension
Components on page 7-46 or Rear

Yearly Service - Electric Cars PERIODIC MAINTENANCE
YEARLY SERVICE - ELECTRIC

CAUTION
CARS Use care when connecting the wire harness
Complete the daily, monthly and six-month connector. The connector pins are easily
service prior to completing the following tasks. damaged which can cause system anomalies.
Perform the Discharge Test

A discharge test on the battery should be Inspect the Rear Axle Bearing
performed yearly. See Discharge Load Test on 1. Engage the parking brake and loosen the rear
page 4-23. wheel lug nuts.
Apply Battery Terminal Protectant 2. Block the front wheels and raise the rear of
the car with a jack. See Recommended Jack
Battery terminals should be cleaned and battery Points on page 1-7.
terminal protectant should be applied. See
Battery Cleaning on page 4-6.
Inspect the Controller Connector

4. Release the parking brake.
5. Place the tow switch in the TOW position. 3
CAUTION
Secure vehicle and discharge the controller 1
capacitor. See Safety Lockout Procedure on
page 1-7.
Y-1198
Figure 3-59
Radial Inspection
• Turn the rear axle slowly by hand
(Figure 3-59, (1)) and feel for roughness or
Y-1536
grating. Replace the wheel bearing if roughness
Figure 3-58 or grating is detected. See Transaxle - YDRA
1. Inspect the motor control unit connector (Gas Car) on page 6-10 or Transaxle - YDRE
(Figure 3-58) for deformation, bent or missing (Electric Car) on page 6-31.
pins, or corrosion.
Bearing Inspection
2. If electrical connector is deformed, cracked or
chipped to the extent that an electrical • Gently rock the rear axle up and down
connection cannot be made, pins are bent or (Figure 3-59, (2)) to detect free play. Replace
missing or connector is heavily corroded, the bearing if free play is greater than 0.51 mm
replace the wire harness. (0.02 in). See Transaxle - YDRA (Gas Car) on
3. Lubricate with light dielectric grease, if page 6-10 or Transaxle - YDRE (Electric Car)
necessary. on page 6-31.

PERIODIC MAINTENANCE Yearly Service - Electric Cars
Inspect the Steering Knuckle
Y-1320
Figure 3-61
3. Place the Toe-in Measuring Gauge between
the inner sidewalls of the front tires
approximately 60 mm (2-1/4 in.) behind the
face of the front tire (Figure 3-61). The height
indicator chains should just touch the floor
Y-1184 evenly on each side.
Figure 3-60
Special Tool:
Toe-in Measuring Gauge............. P/N YC-39526
engage parking brake.
2. Raise the front wheels with a suitable jack. 0
See Recommended Jack Points on page 1-7. TOE TOE
OUT IN
3. Gently rock the front wheel side to side
(Figure 3-60).
4. If more than 5 mm (0.20 in.) of free play is
noted, replace the steering knuckle bushings. Y-104
See Front Suspension Components on
page 7-46. Figure 3-62
4. Zero the scale on the gauge by sliding the
Wheel Alignment movable scale so the pointer is at zero
1. Move the tow switch to the TOW position. (Figure 3-62).
5. With gauge in place, roll the car forward
NOTE: one-half turn of the wheels. The height
indicator chains should just touch the floor.
Move the car by pushing from the rear. Make
sure the front of the car is not lifted or pushed
down, which will cause an inaccurate
measurement.
2. Place the vehicle on a level surface and push

the empty car forward 6.1 m (20 ft) to stabilize
suspension. Allow the car to coast to a stop
with front wheels pointing straight ahead.
NOTE:
Do not push the car backward or apply the
brake to stop the car. Doing either will result in a
change in toe-in.


6. Read the toe-in measurement on the gauge Inspect the Front Wheel Bearing
scale and adjust the toe-in as follows:
1 2. Engage parking brake.
2 3
3. Raise the front wheels. See Recommended
Jack Points on page 1-7.
4. Spin the wheel by hand.
SM-03-326
Figure 3-63
(a)
Engage the parking brake.
(b)
Raise the front of the vehicle. 3
(c)
Loosen locknuts (Figure 3-63, (1)). SM-03-014
(d)
Adjust the toe-in by turning both tie rods Figure 3-64
equally (Figure 3-63, (2)) until toe-in is 5. Touch the steering knuckle or flange bolt
within specification. while spinning the wheel (Figure 3-64, (1)).
Specification: 6. If excessive vibration is noted, replace
Toe-in Measurement ....................... 0.0 - 10 mm bearing and oil seal. See Front Suspension
(0.0 - 0.40 in.) Components on page 7-46.
Check the Transaxle Oil Level

NOTE:
When checking the transaxle oil level, inspect the
When loosening or tightening the locknuts exterior of the transaxle for any wetness or
(Figure 3-63, (1)), hold the tie-rod end evidence of an oil leak. Repair the leak before
(Figure 3-63, (3)) with a wrench. The length of putting the car into service.
the threads of both rod ends must be
approximately the same.
NOTE:
It is not necessary to remove the bag tray insert
7. Tighten the locknuts to specification.
to check the oil level. The oil level servicing plug
Specification: can be accessed from underneath the rear
Tie-Rod Locknut bumper.
Torque ...................................................... 40 N·m
(4.1 m·kg; 29.5 lb-ft)
8. Lower the vehicle to the ground. 2. Put an oil pan under the transaxle case.
9. Check the toe-in again and repeat adjustment
if toe-in is found not to be within specification.

2 1
Y-1193
Y-1194A
Figure 3-66
Figure 3-65
NOTE: (Figure 3-66, (2)) and the bag tray insert.
YDRA is shown; YDRE is similar.
NOTE:
NOTE: when braking.

transmission case. 8. Add SAE80 W90 API GL-5 Limited Slip High
3. Clean area around servicing plug edge of the oil servicing hole. Allow excess oil
(Figure 3-65, (1)). to flow out until it stops.
4. Remove the oil servicing plug with an 8 mm 9. Install the transaxle oil servicing plug and
hex wrench. tighten to specification.
5. Oil level should be even with the bottom edge Specification:
of the oil servicing hole or just beginning to
trickle out of hole.
Torque................................................... 16.3 N·m
6. If oil is at the correct level install oil servicing (1.66 m·kg; 144 lb-in.)
plug and tighten to specification. If oil needs
to be added proceed to step 7. 10. Install the bag holder insert and secure with
Specification: two bolts and seven plastic rivets.
Torque ................................................... 16.3 N·m
(1.66 m·kg; 144 lb-in.)


Adjust the Parking Brake Adjust Brake Pedal Free Play
Make sure the parking brake locks properly and 1. Remove the floor mat and the service lid.
stays locked. If brake does not lock properly
adjustment is required.
NOTE:
a 16
17
18
15
Before performing parking brake adjustment, 9

10
11
12
13
14
adjust brake pedal free play.

8
7
Y-62b
Figure 3-68
2. Check the brake pedal free play by pressing
against the pedal with two fingers (using light
force) and measure the distance the pedal
3
travels (Figure 3-68, (a)) before resistance is
felt. Compare measurement to specification.
SM-03-193 Specification:
Brake Pedal Free Play ......................45 - 50 mm
Figure 3-67 (1.77 - 1.96 in.)
1. Inspect the parking brake ratchet
(Figure 3-67, (1)) and ratchet stopper WARNING
(Figure 3-67, (2)) for wear or damage.
Do not over-tighten the brake cable.
2. Replace any worn or damaged parts. Over-tightening will increase brake wear and
3. Apply the brake and engage the stopper at affect overall performance of car.
the second notch on the ratchet.
4. Measure free play (release timing)
(Figure 3-67, (a)) and adjust if not within
specification: A B
(a) Loosen the locknut (Figure 3-67, (4)).
(b) Adjust the release timing by turning the
adjusting bolt (Figure 3-67, (3)).
• To increase the release timing, turn the Y-909A
adjusting bolt counterclockwise.
Figure 3-69
• To decrease the release timing, turn the
adjusting bolt clockwise. 3. If pedal free play needs adjustment, loosen
the jam nuts (Figure 3-69, (A and B)).
Specification:
4. Adjust the free play by moving the brake
Parking Brake Free Play................ 0.0 - 0.3 mm cable. Tighten the jam nuts to specification.
(0.0 - 0.011 in.)
Specification:
Brake Cable to Pedal Assembly
Jam Nuts ................................................. 13 N·m
(1.3 m·kg; 115 lb-in.)
5. Recheck brake pedal free play.

Adjust the Pedal Stop
2
1
Y-1513
Figure 3-70
2. Remove the floor mat and service lid.
3. Loosen the locknut (Figure 3-70, (1)).
4. Place an inclinometer on the throttle pedal.
Measure the pedal angle. Compare the
measurement to the specification.
Specification:
Throttle Pedal Angle ...........................65° ± 1.5°
5. If the throttle pedal angle requires adjustment,
turn the throttle stop bolt (Figure 3-70, (2)) in
or out to achieve the correct pedal angle.
6. When the angle is to specification use a
wrench to hold the throttle stop bolt
(Figure 3-70, (2)) in position and tighten the
locknut (Figure 3-70, (1)) to specification.
Specification:
Pedal Stop Bolt Locknut .................23 - 29 N·m
(2.3 - 2.9 m·kg; 204 - 257 lb-in.)
7. Install the service lid and the floor mat.

Four-Year Service - Electric Cars PERIODIC MAINTENANCE
FOUR-YEAR SERVICE -
ELECTRIC CARS
Complete the daily, monthly, six-month and yearly 1
2
service prior to completing the following tasks.
Change the Transaxle Oil

3. Put a drain pan under the transaxle case.
4. Clean dirt and debris from around the oil Y-1193
servicing plugs.
Figure 3-72
YDRE 8. Remove seven plastic rivets
(Figure 3-72, (2)) and the bag tray insert. 3
1
1
Y-1197
Figure 3-71
5. Remove the oil servicing plug
(Figure 3-71, (1)). Y-1194A
6. Allow all oil to drain out. Figure 3-73

7. When transaxle is completely drained, install
oil servicing plug and tighten to specification. NOTE:
Oil Servicing Plug YDRA is shown; YDRE is similar.
Torque ................................................... 16.3 N·m
(1.66 m·kg; 144 lb-in.)
CAUTION
transmission case.
9. Clean area around oil servicing plug

(Figure 3-73, (1)).

PERIODIC MAINTENANCE Four-Year Service - Electric Cars
10. Remove oil servicing plug with an 8 mm hex

wrench.
NOTE:
when braking.

to flow out until it stops.
12. Install the oil servicing plug and tighten to
specification.
Specification:
Oil Servicing Plug
Torque ................................................... 16.3 N·m
(1.66 m·kg; 144 lb-in.)
13. Install the bag holder insert and secure with
two bolts and seven plastic rivets.
Inspect the Brake Discs

The wet brake discs should be inspected for
wear. See Disassemble the Brake on page 6-35.

BATTERIES
Table of Contents
— General Information —
Introduction............................................................................................ 4-3
Recommended Equipment.............................................................. 4-3
General Care................................................................................... 4-3
Battery Type ....................................................................................
Battery Cycle Life ............................................................................
4-3
4-4
4
— Service Procedures —
Preventive Maintenance........................................................................ 4-5
Battery Cleaning.............................................................................. 4-6
Battery Inspection............................................................................ 4-6
Electrolyte Levels ............................................................................ 4-7
Battery Watering.............................................................................. 4-8
Watering Procedures................................................................. 4-8
Battery Charging ................................................................................... 4-9
Charging Guidelines...................................................................... 4-10
Charging Procedure ...................................................................... 4-10
Battery Charger ................................................................................... 4-11
Charger Safety .............................................................................. 4-11
Features and Benefits ................................................................... 4-11
Installation ..................................................................................... 4-12
Grounding...................................................................................... 4-12
Charging (for Western Hemisphere Markets)................................ 4-12
Five-Step Charging Cycle ............................................................. 4-14
Step 1 - Pre-Test ..................................................................... 4-14
Step 2 - Constant Current Charge........................................... 4-14
Step 3 - Constant Voltage Charge........................................... 4-14
Step 4 - Topping Off ................................................................ 4-14
Step 5 - Storage ...................................................................... 4-14
LED Error Codes (for battery condition) .................................. 4-15
Hardware System Faults ......................................................... 4-16

BATTERIES
Charging (for All Markets Outside of the Western Hemisphere) ... 4-16
LED Error Codes (for battery condition) .................................. 4-19
Hardware System Faults ......................................................... 4-20
Battery Storage ............................................................................. 4-21
Testing and Troubleshooting Batteries ............................................... 4-21
Specific Gravity Test ..................................................................... 4-22
Open-Circuit Voltage Test ............................................................. 4-23
Discharge Load Test ..................................................................... 4-23
Scheduling Discharge Load Test ............................................ 4-24
Battery Discharge Chart .......................................................... 4-25
Battery Discharge Worksheet........................................................ 4-26
Remove and Replace the Battery ....................................................... 4-27

Introduction BATTERIES
General Information
New batteries are not capable of the full operating
WARNING capacity until they have been cycled in; therefore,
battery use should be limited to 18 holes during
Always lock out car when you perform any
the first 10 charging cycles of at least six hours.
tests or repairs, unless otherwise specified.
Limit use to 27 holes for two charging cycles and
See Safety Lockout Procedure on page 1-7.
36 holes thereafter. Give new batteries an extra
charge once a week. The amperage hours of the
current a battery can deliver without
over-discharge varies directly with the
INTRODUCTION temperature of the electrolyte. This is also true of
charge acceptance.
This section provides care and maintenance
information exclusively for the YDR Electric Golf Follow these guidelines to prevent excessive
Car batteries. The key factor to achieving discharge early in battery life:
optimum performance and long battery life is a • When the temperature is 18.3°C (65°F) or
solid care and maintenance program. While below, expect less operation range and limit
reading, please keep in mind that all battery operation accordingly.
systems are unique. Battery type, charger
technology, equipment loads, cable size, climate • Charge the batteries immediately after use
and other factors can all vary. Strict adherence to while the electrolyte temperature is high from
the care and maintenance information will ensure
long life from your batteries.
use.
• During the first four months of use, give new
batteries an extra six hours of boost charge
4
There are many tools that may help in properly once a week, ideally, during the warmest part
caring for and maintaining batteries. Below is a of the day. Excessive discharge can cause
list of basic items that Yamaha recommends for polarity reversal of individual cells. This
general battery care and maintenance: results in their complete failure shortly
thereafter.
Recommended Equipment
• Wrench NOTE:
• Distilled Water Avoid sending out cars which have not been
• Voltmeter charged; verify the state of charge on cars
• Hydrometer going out that day. The 48-volt battery charger
is equipped with LED status lights that indicate
• Post Cleaner the state of charge. A green LED indicates a
• Baking Soda completed charging cycle.
• Battery Terminal Protector
• Goggles and Gloves
Battery Type
• Spray Bottle with Baking Soda/Water
Solution Lead-acid batteries are generally classified by
application and construction. Golf cars utilize
General Care deep-cycle flooded batteries (wet). Flooded
batteries (wet) are constructed with a solution of
When idle, wet lead-acid batteries self-discharge sulfuric acid and water that can spill out if the
at a rate that varies directly with temperature and battery is tipped over. Always ensure the batteries
conditions of service. New batteries should not be are properly secured to avoid injury to yourself or
allowed to sit, unused, for longer than six weeks others.
without recharging. Before operating on a golf
course, new batteries should be charged for at
least six hours.

BATTERIES Introduction
Battery Cycle Life

CAUTION
Battery cycle life varies inversely with the depth of
discharge. Therefore, regular charging is key in If you are using an energy management
maintaining longer battery life. To ensure this, system, be sure the timer is set properly to
make sure you rotate your fleet and do not send allow the batteries to receive a full charge.
out a car a second time until all vehicles have Otherwise, the batteries will be
been around once for charging. For good cycle over-discharged resulting in shorter cycle life.
life, specific gravity of the fully charged cells
should remain within a 10-point spread (20 points A hydrometer check at the end of the charge
total) between cells. See Specific Gravity Test on cycle is a good way to confirm the batteries are
page 4-22 to determine your specific gravity fully charged.
levels. Also, never allow a battery to sit idle in a
discharged state. This will cause sulfation that
destroys the ability of the battery to provide its
rated output. (Slow charging may reverse
sulfation to some degree.)

Preventive Maintenance BATTERIES
Service Procedures
PREVENTIVE MAINTENANCE • Antidote (EXTERNAL)

◆ SKIN – flush with water.
◆ EYES – flush with water for 15 minutes
WARNING
and get immediate medical attention.
• Battery electrolyte is dangerous; it contains • Antidote (INTERNAL)
sulfuric acid and is therefore poisonous and
highly caustic. ◆ Drink large quantities of water or milk;
follow with milk of magnesia, beaten egg
• Always follow these precautionary or vegetable oil. Get immediate medical
measures: attention.
◆ Avoid bodily contact with electrolyte as it • Batteries generate explosive hydrogen gas.
can cause severe burns or permanent eye Always follow these precautionary
injury. measures:
◆ Always wear protective clothing, gloves
and goggles when handling batteries and ◆ Charge batteries in a well-ventilated area.
electrolyte, and when charging your ◆ Keep batteries away from fire, sparks or
battery. open flames (e.g., welding equipment, lit
cigarettes, etc.).
batteries.
4

BATTERIES Preventive Maintenance
Battery Cleaning
Batteries need to be cleaned approximately once
a month. They will require more frequent cleaning
if they are being used in hot weather or are
over-filled or over-charged.
Lack of cleaning can cause the following
problems:
• Reduced reliability and performance.
• Increased corrosion.
Y-695
• Shortened battery life.
Figure 4-1
• Increased maintenance costs.
3. Clean the battery terminals using Yamaha
Battery Terminal Cleaner & Protector
WARNING
P/N ACC-BATTC-LN-PR.
• Remove all metal jewelry before working on 4. Rinse with water and dry with a clean shop
the electrical system or batteries. Failure to towel.
do so may result in personal injury from a
short circuit. 5. Check battery clamps and tighten to
specification. Coat the battery leads and
• Wear eye protection when working on the terminals with Yamaha Battery Terminal
electrical system or batteries. Failure to do Protector P/N ACC-BATTP-RO-TE to prevent
so could result in personal injury. corrosion.
• Only use insulated tools for battery cable Battery Clamps ......................................... 9 N·m
nuts to prevent accidental short circuits. (0.9 m·kg; 80 lb-in.)
Failure to do so could result in explosion or
fire and personal injury. 6. Keep the area around batteries clean and dry.
Replace or clean all parts with any visible
signs of corrosion.
NOTE: Battery Inspection

Batteries tend to attract dust, dirt and grime. Batteries should be carefully inspected on a
Keeping them clean will help spot trouble signs regular basis in order to detect and correct
if they appear and avoid problems. potential problems before they can do harm. It is
recommended that this routine is started when
the batteries are first received.
1. Check that all vent caps are securely in place.
2. Clean the battery tops, sides, hold-downs and Inspection Guidelines:
surrounding area with a shop towel or brush
and a solution of baking soda and water (use
CAUTION
a 100/1 mixture of water and baking soda).
When cleaning, do not allow any cleaning • Secure vehicle and discharge the controller
solution or other foreign matter to get inside capacitor. See Safety Lockout Procedure on
the battery. page 1-7 and See Discharge the Motor
Control Unit Capacitor on page 1-7.
• Always disconnect the negative (-) cable
from the batteries first and install it last.
• Use insulated wrenches to avoid short
circuits to the batteries.
1. Examine the exterior of the battery container

checking for cracks or leaks.

Preventive Maintenance BATTERIES

2. The top of the battery, posts and connections
should be clean and free of dirt, fluids and
corrosion. If batteries are dirty, see Battery
Cleaning on page 4-6 for the proper cleaning
procedure.
3. Any fluids on or around the battery may be an
indication that electrolyte is spilling, leaching
or leaking. Leaking batteries must be repaired
or replaced.
4. Repair or replace any damaged batteries.
Figure 4-3
9. Check the battery hold-down plates
(Figure 4-3) to ensure the batteries are
properly secured. Replace any damaged or
corroded parts or hardware. Tighten all
hardware to specification.
Battery Hold-down Plates ................... 7 - 9 N·m
(0.7 - 0.9 m·kg; 62 - 80 lb-in.)
Electrolyte Levels
Y-672b
Figure 4-2
5. Inspect all battery cables and wire leads for
Flooded (wet) batteries require watering. More
importantly, watering must be done at the right
time and in the right amount or the battery’s
4
performance and longevity suffers.
corrosion.
6. Ensure the battery cables are connected as Checking and maintaining the electrolyte levels in
shown (Figure 4-2). your batteries can save thousands of dollars by
preventing early battery failure due to cell dilution
7. Look closely for loose or damaged parts.
and imbalance. Although adding water to battery
Battery cables should be intact; broken or
cells is time-consuming, it is a necessity!
frayed cables can be extremely hazardous.
Electrolyte levels drop during discharge and rise
Replace any cable that looks suspicious.
during charging; therefore, it is mandatory that
8. Tighten all battery clamps to specification. electrolyte levels be checked and adjusted after
Make certain there is good contact with the the batteries are fully charged. Adding water
terminals. correctly helps maintain the specific gravity level
Battery Clamps ......................................... 9 N·m balance among the battery cells. When batteries
(0.9 m·kg; 80 lb-in.) are new, they will require water approximately
every four weeks. As they get older, they will need
water more frequently. Near the end of their lives,
WARNING batteries may require water once or twice a week.
Do not over-tighten terminals. Doing so can
result in post-breakage, post-meltdown, fire
or explosion.

BATTERIES Preventive Maintenance
Battery Watering Watering Procedures

Water should always be added after fully charging
the battery. Prior to charging, there should be Fill Well
enough water to cover the plates. If the battery
has been discharged (partially or fully), the water Electrolyte 1/8” Below
Bottom of Fill Well Electrolyte
level should also be above the plates. Keeping
the water at the correct level after a full charge
will prevent having to worry about the water level
at a different state of charge.
Max. Level - 1/8”

charged battery
Max. Level -
discharged
battery
Figure 4-4
Yamaha Golf-Car Company (YGC) recommends
using a battery-watering gun (Figure 4-4) that Y-1537
automatically fills the batteries to the correct level. Figure 4-5

The battery-watering gun is available at:
www.yamahagolfcar.com. 1. Open the vent caps and look inside the fill
wells.
Important things to remember: 2. Check electrolyte level. The minimum level
• Do not allow the battery plates to become before charging is at the top of the plates.
exposed to air. This will damage (sulfate) the 3. If necessary, add just enough water to cover
battery plates. the plates at this time.
• Do not fill the water level to the cap. This will 4. Put batteries on a complete charge before
cause the battery to overflow acid, adding any additional water. See Charging
consequently losing capacity and causing a Procedure on page 4-10.
corrosive mess. 5. Once charging is completed, open the vent
• Use distilled or deionized water only. Do not caps and look inside the fill wells. Add water
use water with a high mineral content. until the electrolyte level is 3.17 mm (1/8 in.)
below the bottom of the fill well.
WARNING 6. A piece of rubber can be used safely as a
dipstick to help determine this level.
Electrolyte is a solution of acid and water.
Avoid skin contact. 7. After filling the battery, reinstall the vent caps.
CAUTION
Never add acid to a battery. Damage to battery
may result.

Battery Charging BATTERIES

Follow these guidelines when watering your BATTERY CHARGING
batteries:
• Add only distilled or deionized water when
the cells get low. Never use common tap CAUTION
water, “reclaimed” water or electrolyte in your To ensure maximum battery performance:
batteries. Complete deionizing systems are • Batteries must be fully charged before using
available through your Yamaha Golf-Car for the first time. This initial charge will
Service dealer. prolong the life of the batteries. Periodic
• Never fill a battery before charging unless the charging is also necessary during extended
plates are dry. storage.
• Check the specific gravity of the battery with • Maintain proper electrolyte levels.
a hydrometer before adding water unless
plates are dry. • Never overfill the batteries or allow the
electrolyte level to drop below the top of the
• Only fill the battery to the minimum fill level. plates.
Add only enough water to cover the tops of
the plates. As the battery charges, the • Never overcharge the batteries.
electrolyte level will rise. Failure to observe these points will result in
• Never overfill batteries to reduce the number shortened battery life.
of times the batteries must be watered.
Overfilling the batteries will result in the
Charging the batteries properly requires
battery gassing through the vent caps. This
causes self-discharge of the battery and
corrosion problems.
• In hot weather, batteries will need to be
administering the right amount of current at the
right voltage. The 48-volt Battery Charger
regulates these values and ensures adequate
4
charge during extended storage. Before charging
watered more often. the batteries, read and understand the owner’s
• Note any large differences in the amount of manual provided with the charger.
water needed from cell to cell. Since all
battery cells should gas about the same
amount, large differences may indicate a
WARNING
defective cell. • Batteries generate explosive hydrogen gas.
Always follow these precautionary
measures:
◆ Charge batteries in a well-ventilated area.
◆ Keep batteries away from fire, sparks or
open flames (e.g., welding equipment, lit
cigarettes, etc.).
batteries.
• Always wear protective clothing, gloves and
goggles when handling batteries and
electrolyte, and when charging your battery.

BATTERIES Battery Charging
Charging Guidelines Charging Procedure

• If feasible, connect the golf car to the same
charger every night. CAUTION
• Recharge batteries as soon after usage as Water should only be added prior to charging
possible. when the electrolyte level IS NOT covering the
• A 20-minute charge between rounds helps battery plates.
extend battery life.
• Organize and store cars to ensure equal 1. Check the water level of each battery cell to
rotation of usage. ensure it covers the plates. Add water only if
necessary.
2. Tighten all vent caps before charging.
WARNING
Damaged receptacle contacts can cause
excessive resistance (heat) and lead to fire.
3. Check the charge receptacle and battery

charger contacts for damage or corrosion.
Clean, repair or replace any damaged or
corroded parts.
4. Plug the battery charger connector into the
charge receptacle.
5. Check the state of charge before and after the
charging cycle to ensure adequate charge.
See Battery Charger on page 4-11 for
determining state of charge.
6. Disconnect and stow the charger connector.
7. Check the water level in each battery to
ensure the watering level is within limits.

Battery Charger BATTERIES
BATTERY CHARGER
Charger Safety
Read the following label located on the top of the charger before operating or using the charger and
promptly replace the label if it becomes damaged.
Features and Benefits • Step 1: Pre-test: Tests several

conditions before charging
YGC has developed a state-of-the-art begins. If a problem is
battery/charger combination. The battery charger
is designed to recharge deep-cycle, lead-acid
batteries and delivers maximum performance
detected, charging is
terminated.
4
through the use of “Smart Charger” technology. • Step 2: Constant Current Step: Battery
The charger runs diagnostic testing on the is charged with full rated
vehicle’s electrical system to ensure optimized output current, restoring up to
charging and battery performance. Additionally, 80% of charge.
built-in charge protection delays charging a • Step 3: Constant Voltage Step:
battery in a fully charged state and initiates a new Regulated voltage “equalizes”
charge cycle after a completed charge cycle in individual battery cells
the event of a power interruption. These features, resulting in full charge
coupled with the multi-step charge cycle and the delivered to the battery.
other features and benefits listed below, have
enabled YGC to offer an industry-leading battery • Step 4: Topping Off Step: Battery pack
warranty. is brought slowly to full charge
without excess gassing.
• Switching Mode Design: High efficiency
• Step 5: Storage: Every 14th day and if
operation with smooth DC output.
voltage becomes less than
• 5- or 10-LED Display: Displays state of 48-volt, charger restarts cycle
charge and charge error conditions. to refresh batteries in storage.
• Charge Protection: Protects from improper • Automatic Battery Equalization
connection, overload and excessive (Boosting): Automatically boosts the battery
temperatures. Programmed safety features pack when individual cell voltages are not
include charge time monitoring and balanced and restores pack capacity.
over-temperature protection.
• Charge Algorithm: I-E-I - constant
current/constant voltage/constant current
charge profile.
• Pre-Test: Performs several diagnostic tests
before charging begins.
• Multi-Charge Steps: Ensures a consistent
and repeatable charge.

BATTERIES Battery Charger
Installation Grounding
The AC line connected to the charger must be The battery charger must be grounded to reduce
capable of supplying 15 amperes to the charger. the risk of electric shock. The charger is equipped
with an AC cord set having an equipment-
grounding conductor. The AC cord set must be
WARNING connected to an appropriate receptacle that is
To reduce the risk of fire, use this charger properly installed and grounded in accordance
only on circuits provided with a maximum of with the National Electrical Code and all local
15-amp branch circuit protection (circuit codes and ordinances.
breaker or fuse), in accordance with the
national electrical code, ANSI/NFPA 70 and all
WARNING
local codes and ordinances.
Improper connection of the equipment-
grounding conductor can result in a risk of
The use of an extension cord with the charger electric shock.
should be avoided. The use of an improper
extension cord could result in a risk of fire or
electric shock. The conductor with insulation having an outer
surface that is green, with or without yellow
Provide adequate ventilation for the batteries and stripes, is the equipment-grounding conductor.
charger. The convection and fan-cooled design Do not repair the charger’s AC cord; just replace
requires an unobstructed flow of cooling air for it. If replacement of the charger’s AC cord set is
proper operation. Keep all charger ventilation necessary, do not connect the equipment-
openings at least 5 cm (2 in.) away from walls and grounding connector to a live terminal.
other objects. Keep clothing, plastic, canvas, etc.,
away from charger at all times. Charging (for Western Hemisphere
Markets)
WARNING
Chargers can ignite flammable materials and WARNING
vapors. Do not use near fuels, grain dust,
solvents or other flammables. To reduce the risk of electric shock, connect
only to a properly grounded, single-phase
(3-wire) outlet. Also, refer to grounding
instructions.
WARNING
To reduce the risk of an electric shock, keep
the charger dry. Do not expose it to rain. For WARNING
storage, keep the charger indoors.
Risk of electric shock! Do not touch any
uninsulated parts of the charger output plug,
battery charging receptacle or battery
NOTE: terminals.
This charger is not designed for on-board use.
CAUTION
NOTE: Charge only 48-volt battery systems. Damage
to the charger and batteries may result if this
This charger is not designed for use with an charger is used on the wrong battery type.
electric generator.


The operating instructions printed on the charger
WARNING (as depicted below) are for daily reference. The
charger is factory preset to use with Trojan 48-volt
• Visually and manually inspect to verify that
golf car batteries.
the DC output cord, plug and battery
charging receptacle are in good working
condition before each and every use, and do CAUTION
not use the charger if:
Always move the tow switch to the TOW
◆The DC charging receptacle does not grip position before charging the batteries.
the DC cord set plug tightly, is loose or Damage to the electrical system may result if
does not make a good electrical the tow switch is not in the TOW position.
connection.
◆ The DC cord set plug or charging
receptacle feels hotter than normal.
OPERATING INSTRUCTIONS
receptacle contacts are bent, corroded, or 1. MOVE TOW SWITCH TO THE TOW POSITION.
are dark or bluish in appearance.
◆ The DC cord set plug, cords, receptacle or
2. PLUG AC CORD INTO A GROUNDED
RECEPTACLE.
equipment charging wiring are cut, worn,
broken or have any exposed conductors. 3. PLUG DC CORD INTO A VEHICLE RECEPTACLE.
◆ The DC cord plug, cords, charger or
receptacles are damaged or distressed in 4. WHEN CHARGING IS COMPLETED,
any way. DISCONNECT DC CORD FROM VEHICLE.
• Using the charger with any of the above
symptoms could result in fire, property
damage or personal injury.
Connect charger’s AC cord set to AC power.
Then, connect the DC cord set plug to the vehicle
4
charging receptacle by grasping the plug handle
and pushing the plug straight into the receptacle.
The charger will start automatically.
WARNING
Do not disconnect the DC cord set plug from
the charging receptacle when the charger is
on. If the charger must be stopped, first
disconnect the AC power supply cord from its
AC outlet and then disconnect the charger DC
cord set plug from the charging receptacle.
WARNING
When removing AC or DC cord set plugs from
receptacles, pull from the plugs’ body and not
from their respective cords. Be sure area
around battery is well-ventilated while battery
is being charged.

Upon connection to AC power source, all five The duration of this step is dependent on the
LEDs blink for a second, then Power LED turns condition of your battery – approximately 10
on. Upon connection to Battery Pack, all five seconds under average circumstances. If your
LEDs blink once, then power and charging battery pack was allowed to severely discharge to
indicators blink for 10 seconds. less than 42 volts, then this step can last several
hours while the charger tries to revive the battery
pack.
POWER ON 1
Step 2 - Constant Current Charge
ERROR1 2
The yellow LED (charging) illuminates
ERROR2 3 continuously, indicating that the charger is
CHARGING 4 charging the battery at the full rated output.
90%
CHARGED 5 Step 3 - Constant Voltage Charge
The charger now regulates voltage instead of
Y-1560
current. While the charger maintains a constant
voltage, the charge current gradually decreases.
Figure 4-6 During this phase, the yellow LED (charging)
Under normal charge circumstances, the LEDs illuminates and the green LED (charged) blinks.
operate as follows:
Step 4 - Topping Off
Power On (Red): (Figure 4-6, (1)) Illuminates The yellow and green LEDs light when the
continuously when AC power is present. See charger has determined that the battery pack has
Troubleshooting on page 4-15. reached 90% capacity.
Error 1 (Red): (Figure 4-6, (2)) Normally not This step ends when the charge is replenished to
illuminated. See Troubleshooting on page 4-15 if 100% capacity. Charging is completed when only
blinking. the green LED (charged) remains illuminated.
Error 2 (Red): (Figure 4-6, (3)) Normally not If the charger detects that the battery needs to be
illuminated. See Troubleshooting on page 4-15 if boosted at the end of this stage, then the charger
blinking. keeps operating for an extra four hours. This
Charging (Yellow): (Figure 4-6, (4)) Charge additional function is called “boosting” and only
Status Indicator – it blinks or illuminates during the Power LED blinks.
the 5-Step Charge Process. See Five-Step Upon charge completion, the charger’s DC cord
Charging Cycle on page 4-14. set can now be disconnected from the charging
Charged (Green): (Figure 4-6, (5)) Illuminates receptacle by grasping the plug body or handle
continuously after the fourth step of the charge and pulling the plug straight out of the receptacle.
process. See Five-Step Charging Cycle on
page 4-14.
Step 5 - Storage
Only after the completion of step 4, and after 14
Five-Step Charging Cycle days have elapsed and if the battery voltage falls
below 48V DC, the charger will restart a new
During operation, the charge algorithm controls charge cycle routine (steps 1-4 above) and
both voltage and current for precise charging.
restore battery to full capacity.
The LEDs will illuminate during the five-step
charging cycle to indicate the state of charge as If the charger is left connected to AC Power and
described below: then the DC cord set plug is reconnected to
another battery pack, the charger will restart a
Step 1 - Pre-Test new charge cycle from the beginning (steps 1-4
The yellow LED (charging) blinks on and off above).
during this step. This step applies tests to the If, during any part of the five-step charge process,
battery pack. Further charging is prohibited if AC power should be disconnected and
unsuitable conditions are found such as reversed reconnected, the charger will restart a new
battery polarity or over/under voltage. Refer to charge cycle.
Troubleshooting on page 9-1 for understanding
faults.

If the charger finds an abnormal charge condition
while charging, it will attempt to shut down and WARNING
indicate the condition by blinking one or all of its
Have a qualified service technician inspect if
red LEDs. Refer to Troubleshooting below for a
problems persist.
description of the Charge Error Condition if you
encounter a blinking red LED.
• Battery Voltage High: Charger’s DC cord
Troubleshooting set may be connected to a battery pack with
voltage higher than the output rating of the
WARNING charger.
Remedy: Confirm battery is 48-volt system or
Incorrect reassembly may result in a risk of
electric shock or fire. The following specified battery.
procedures are intended only to determine if a • Battery Polarity Reversed: Battery or wire
malfunction may exist in the charger. connections may be incorrect.
Remedy: Confirm that the polarity for wiring
is correct from charger receptacle in the
WARNING vehicle to all battery terminals.
To reduce the risk of electric shock, always • Output Overload and Overheat: Charger
disconnect the charger's AC cord set from AC may shut down if the current output exceeds
power and its DC cord set plug from batteries rated capacity or the charger temperature is
before attempting any maintenance or
cleaning.
too high.
Remedy: Confirm that no external load is
connected to battery and lower the ambient
4
temperature of the charging location.
WARNING
• Excessive Charging Time: Charging time
Do not operate the charger if it is
has reached the safety timer. Possible
malfunctioning. Personal injury or property
causes include: a battery load that is draining
damage could result.
energy from the battery while charging; aged
or unbalanced batteries; high temperature
If any of the three red LEDs blink, the charge environment.
cycle has terminated prematurely. An abnormal Remedy: Confirm that no external load is
charging condition was detected and charging connected to battery, check battery condition
was stopped due to a Charge Error Condition. and lower the ambient temperature of the
Refer to the following Charge Error Table for a charging location.
description of the possible failure or condition. • Excessive Discharged: This error is
LED Error Codes (for battery condition) generated by a condition found during the
Pre-Test Step. This error occurs if a severely
Condition Power On Error 1 Error 2 discharged battery pack did not recharge to
Battery Voltage High OFF OFF BLINK 42 volts within 5 hours.
Battery Polarity Reversed OFF BLINK OFF Remedy: Confirm that no external load is
Output Overload and OFF BLINK BLINK connected to battery; check battery condition
Overheat and battery wiring.
Excessive Charging Time BLINK OFF BLINK
Excessive Discharge BLINK BLINK BLINK

Hardware System Faults
WARNING
Have a qualified service technician inspect if
problems persist.
Problem Description Cause Remedy

1. Charger does not start. No AC power to charger. Ensure correct voltage at AC outlet.
No LEDs illuminate or blink Check AC cord connections.
when AC cord is connected. Replace AC cord if damaged.
2. Charger does not start Incorrect wiring or disconnection Ensure polarity for wiring is correct
charging when DC cord set is from DC cord, receptacle and from DC cord, receptacle and batteries.
plugged into the receptacle batteries.
and the red power LED is on. Battery voltage less than 24 Check battery pack voltage.
volts.
3. Charger runs longer than 20 Charger may be in “boosting” Confirm green LED illuminates after
hours. stage. power LED is blinking. This indicates
“boosting.”
Charging (for All Markets Outside of

WARNING
the Western Hemisphere)
• Visually and manually inspect to verify that
the DC output cord, plug and battery
WARNING charging receptacle are in good working
To reduce the risk of electric shock, connect condition before each and every use, and do
only to a properly grounded, single-phase not use the charger if:
(3-wire) outlet. Also, refer to grounding ◆ The DC charging receptacle does not grip
instructions. the DC cord set plug tightly, is loose or
does not make a good electrical
connection.
WARNING
receptacle feels hotter than normal.
Risk of electric shock! Do not touch any ◆ The DC cord set plug or charging
uninsulated parts of the charger output plug, receptacle contacts are bent, corroded, or
battery charging receptacle or battery are dark or bluish in appearance.
terminals. ◆ The DC cord set plug, cords, receptacle or
equipment charging wiring are cut, worn,
broken or have any exposed conductors.
◆ The DC cord plug, cords, charger or
WARNING receptacles are damaged or distressed in
Surfaces may be hot. To avoid risk of burns, any way.
do not touch. • Using the charger with any of the above
symptoms could result in a fire, property
damage or personal injury.
CAUTION
Charge only 48-volt battery systems
manufactured by Trojan Battery Company.
Damage to the charger and batteries may
result if this charger is used on the wrong
battery type.


The operating instructions printed on the charger
WARNING (as depicted below) are for daily reference. The
charger is factory preset to use with Trojan 48-volt
Do not disconnect the DC cord set plug from
golf car batteries.
the charging receptacle when the charger is
on. If the charger must be stopped, first
disconnect the AC power supply cord from its OPERATING INSTRUCTIONS
AC outlet and then disconnect the charger DC 1. PLUG AC CORD INTO A GROUNDED
cord set plug from the charging receptacle. RECEPTACLE.
2. PLUG DC CORD INTO GOLF CAR RECEPTACLE.
WARNING 3. CHARGE CYCLE WILL BEGIN AFTER A FEW

SECONDS AND AMMETER WILL TURN ON.
Whenever removing AC or DC cord set plugs
from receptacles, pull from the plugs’ body 4. CHARGER SHUTS OFF AUTOMATICALLY WHEN
BATTERIES ARE CHARGED.
and not from their respective cords.
Connect charger’s AC cord set to AC power.
Then, connect the DC cord set plug to the vehicle
charging receptacle by grasping the plug handle
and pushing the plug straight into the receptacle.
The charger will start automatically.
Upon connection to AC power source, the lower
four LEDs come on as a Power-On Self-Test, then
the AC power LED turns on. Upon connection to
battery pack, output indicators turn on to indicate
4
charging is active.

Under normal charge circumstances, the LEDs operate as follows:
Ammeter On: Displays

(Amber) approximate scale
of current output
during Step 2.
Blinking: High internal
charger
temperature.
Current output
reduced.
80% Charge On: 80% charged, Step
(Amber) 2 complete. Begin
Step 3.
Blinking: With no battery
connected,
indicates algorithm
# selected by
number of flashes
at startup.
100% Charge On: Charging
(Green) complete.
Charger in
Storage Mode.
Blinking: Step 3 complete.
Begin Step 4.
AC On On: AC power good.
(Amber) Blinking: Charger may be
overheated.
Move charger to
cooler location.
Fault Blinking: Charger error.
(Red) Refer to
Troubleshooting
on next page.
Y-1679
To reset charger after 100% charge (Green LED), disconnect the DC plug from battery for more
than 30 seconds. Then, reconnect DC plug.


Troubleshooting
WARNING
LED Error Codes (for battery condition) To reduce the risk of electric shock, always
disconnect the charger's AC cord set plug
WARNING from AC power and its DC cord set plug from
batteries before attempting any maintenance
Incorrect reassembly may result in a risk of or cleaning.
electric shock or fire. The following
procedures are intended only to determine if a
malfunction may exist in the charger.
WARNING
Do not operate the charger if it is
malfunctioning. Personal injury or property
damage could result.
If a fault occurs, count the number of red flashes between pauses and refer to the table below:
Red Flashes Cause Remedy

Battery High Voltage Check battery size and
condition and reset charger
(interrupt DC connection for 15
seconds).
4
Battery Low Voltage Check battery size and
condition and reset charger
(interrupt DC connection for 15
seconds).
Charge Timeout caused by Check connections
battery pack not reaching
required voltage.
Charger output was reduced Operate charger at a lower
due to high temperatures. ambient temperature.
Check Battery: Battery could Check for shorted or damaged
not be trickle charged up to cells.
minimum voltage.
Over-Temperature: Charger Ensure sufficient cooling air
shut down due to high internal flow and reset charger
temperature. (interrupt DC connection for 15
seconds).
Charger Internal Fault Reset charger (interrupt AC

power for 15 seconds). Return
to qualified service depot if
fault persists.
WARNING
Have qualified service technician inspect if
problems persist.

Hardware System Faults
Problem Description Cause Remedy
1. Charger does not start. No AC power to charger. Ensure correct voltage at AC outlet.
No LEDs illuminate or blink Check AC cord connections.
when AC cord is connected. Replace AC cord if damaged.
2. Charger does not start Incorrect wiring or disconnection Ensure polarity for wiring is correct
charging when DC cord set is from DC cord, receptacle and from DC cord, receptacle and batteries.
plugged into the receptacle batteries.
and the amber AC On LED is Battery voltage less than 20 Check battery pack voltage.
illuminated. volts.
3. Charger runs longer than 20 Charger may be in “boosting” Confirm green 100% LED is blinking.
hours. stage. This indicates “boosting.”
WARNING
Have qualified service technician inspect if
problems persist.

Testing and Troubleshooting Batteries BATTERIES

Battery Storage TESTING AND
Periods of inactivity can be extremely harmful to TROUBLESHOOTING
lead-acid batteries. When placing a battery into
storage, follow the recommendations below to BATTERIES
ensure that the battery remains healthy and Visual inspection alone is not sufficient to
ready for use. determine the overall health of the battery. Both
open-circuit voltage and specific gravity readings
NOTE: can give a good indication of the battery’s charge
level, age and health. Routine voltage and gravity
Storing, charging or operating batteries on checks will not only show the state of charge but
concrete is an acceptable practice. also help spot signs of improper care, such as
undercharging and over-watering and possibly
even locate a bad or weak battery. The following
Important things to avoid: steps outline how to properly perform routine
• Freezing: Avoid locations where freezing voltage and specific gravity testing on batteries.
temperatures are expected. Keeping a Utilize the charts and instructions on the following
battery at a high state of charge will also page when performing specific gravity,
prevent freezing. Freezing results in open-circuit voltage and discharge testing.
irreparable damage to a battery’s plates and
container. NOTE:
• Heat: Avoid direct exposure to heat sources,
such as radiators or space heaters.
Temperatures above 26.7°C (80°F)
accelerate the battery’s self-discharge
Battery pack voltage may be checked with the
Genius Diagnostic System. Please see the
Motor Control Unit Troubleshooting section for
4
instructions on utilizing the Genius Diagnostic
characteristics.
System.
Storage procedures:
1. Completely charge the battery before storing.
2. Store the battery in a cool, dry location
protected from the elements.
3. During storage, monitor the specific gravity
(flooded) or voltage. Batteries in storage
should be given a boost charge when they
show a 70% charge or less.
4. Completely charge the battery before
reactivating.
5. For optimum performance, allow the charger
to remain plugged in during storage period.
Refer to Charger Safety on page 4-11 for this
procedure.

BATTERIES Testing and Troubleshooting Batteries
Specific Gravity Test State of Charge as related to

1. Do not add water at this time. specific gravity and operating circuit
2. Fill and drain the hydrometer two to four times voltage
before pulling out a sample. Percentage Specific Open-Circuit
3. There should be enough sample electrolyte in of Charge Gravity Voltage
the hydrometer to completely support the Corrected to 48V
float. 26.7°C (80°F)
4. Take a reading, record it and return the 100 1.277 50.93
electrolyte back to the cell. 90 1.258 50.47
5. To check another cell, repeat steps 2-4 above.
80 1.238 49.99
6. Check all cells in the battery.
70 1.217 49.49
7. Replace the vent caps and wipe off any
electrolyte that might have been spilled. 60 1.195 48.96
8. Adjust the readings to 26.7°C (80°F) as 50 1.172 48.41
indicated in Table 1 below: 40 1.148 47.83
.
Satisfactory 30 1.124 47.26

Temperature Uncorrected 20 1.098 46.63
Hydrometer Reading 10 1.073 46.03
°F °C
120 48.9 1.244 Table 2
110 43.3 1.248 The readings should be at or above the factory
100 37.8 1.252 specification of 1.277 ± 0.007. If any specific
gravity readings register low, follow the steps
90 32.2 1.256 below:
80 26.7 1.260 (a) Check and record voltage level(s).
70 21.1 1.264 (b) Put battery(ies) on a complete charge.
60 15.6 1.268 (c) Take specific gravity readings again.
50 10 1.272 (d) If any specific gravity readings still register
40 4.4 1.276 low then follow the steps below:
30 -1.1 1.280 • Check the voltage level(s).
• Recharge the batteries.
Table 1 • Measure the specific gravity.
9. Compare the readings.
10. Check the state of charge using Table 1.


11. If any specific gravity reading still registers The purpose of the discharge load test is to
lower than the factory specification of 1.277 ± determine how many minutes it will take to bring
0.007, then one or more of the following the total voltage of a fully charged 48-volt battery
conditions may exist: pack to 42 volts. This test represents the
(a) The battery is old and approaching the end maximum work or runtime capability of a 48-volt
of its life. battery pack at 26.7°C (80°F) to fall to 42 volts.
Sixty minutes should deliver 36 holes of golf for
(b) The battery was left in a state of discharge most courses. A shorter time period will indicate
too long. that one or more of the batteries needs service or
(c) Electrolyte was lost due to spillage or replacement.
overflow.
When you are load testing, you will need a load
(d) A weak or bad cell is developing. tester and a high-quality digital voltmeter capable
(e) Battery was watered excessively before of reading at least 55 volts DC. YGC
testing. recommends using the Lester 17770 Battery
Batteries identified with any one of the conditions Discharge Unit (Figure 4-1).
listed in items 11a through 11e should be taken to
a specialist for further evaluation or retired from NOTE:
service. The Lester Battery Discharge Unit is available
through Lester at www.lesterelectrical.com.
Open-Circuit Voltage Test
For accurate voltage readings, batteries must
remain idle (no charging, no discharging) for at
least six hours, preferably 24 hours. 4
1. Disconnect all loads from the batteries.
2. Measure the voltage using a DC voltmeter.
3. Check the state of charge with Table 2.
4. Charge the battery if it registers 0% to 70%
charged.
5. After charging, if battery registers below the
Table 2 values, the following conditions may
exist:
(a) The battery was left in a state of discharge
too long.
(b) The battery has a bad cell. Y-1106
Batteries in these conditions should be taken to a Figure 4-1

specialist for further evaluation or retired from Use the voltmeter to monitor the overall voltage
service. decrease of the pack and the decreasing voltage
of each individual battery during testing.
Discharge Load Test Individual batteries that decrease at a faster rate
are the weaker batteries in the pack. Note the
WARNING weaker batteries as they will require additional
measurement after the discharge tester shuts off.
Batteries generate explosive hydrogen gas. Once the weaker batteries are identified, they
Always follow these precautionary measures: need to be replaced with batteries of comparable
◆ Charge batteries in a well-ventilated area. age and strength of the remaining pack.
◆ Keep batteries away from fire, sparks or Remember that 60 minutes is the industry
open flames (e.g., welding equipment, lit standard considered adequate for 36 holes of
cigarettes, etc.). play at 26.7°C (80°F) and that ambient
◆ Do not smoke when charging or handling temperature has an effect on discharge times.
batteries. When temperatures are low, discharge times
decrease. The Battery Discharge Chart on
page 4-25 (Figure 4-2) may be used for
predicting the effects on discharge times.
The Lester 36/48-Volt Battery Discharge Unit has Scheduling Discharge Load Test
the following features:
Test each car once during the first year of
• Specifically Designed for Golf Batteries operation and twice each succeeding year. If your
course exceeds the national average of 250
• Simple to Operate rounds each year, then your discharge test
• Tests 36V and 48V Battery Systems schedule must be increased accordingly. Consult
your Yamaha service representative for help with
• Microprocessor Controlled Logic schedule adjustments.
• Automatic Test Cycle, Disconnects when If you start out discharge testing an older fleet
Complete with questionable batteries, then at least 10%
• No AC Power Required (i.e., 10 cars out of 100) should be tested. These
results will give you a feel for your replacement
• Available with Translated Graphics and Manual battery needs. Widespread failures or lack of
36-hole performance in the second year is not
• Bright LED Display normal. It is normal to have a few battery failures
Lester Battery Discharge units provide accurate on cars in their third or fourth year of service.
Golf Cart battery testing for both 36V and 48V
Before testing, complete the following tasks:
systems. The automatic test regime discharges
batteries at the appropriate BCI rate and displays 1. Fully charge the batteries (a full charge
the run time in minutes at the end of the test. The cycle).
test can be restarted momentarily to allow for
2. Inspect all cables and connections.
measuring individual cell voltages.
3. Check the water level in each cell and add
The Lester Battery Discharge unit requires no AC water as necessary.
power to operate and requires little training for
4. Start the charger and let it finish charging
operation. A multifunction display and
again.
microprocessor control logic board ensure the
accurate measurement and display of the 5. Let the batteries cool for five minutes.
information you need. It can be programmed to The following instructions are specifically for the
shut off with time or voltage. Discharge data can Lester 17770 Battery Discharge Unit. You will
be viewed on the display or with a terminal or also need a thermometer and a voltmeter. The
computer. worksheet on page 4-26 may be used to record
your measurements.
Large 500 amp alligator clips, heavy duty DC
cables, and a durable 18G powder coated steel 1. Attach the Lester 17770 Battery Discharge
case ensure years of trouble free use. Repair Unit to the battery pack, remembering to
parts are also available, should the unit ever observe polarity.
become damaged.
Private branding and translation into other NOTE:
languages is available, with a minimum order. Heavily coated battery terminals may not
provide good electrical connections. Clean if
necessary.
2. Record surface voltage from the discharge

unit readout panel.
3. Record the ambient temperature using the
thermometer.
4. Turn the discharge unit ON and wait at least
three minutes. If you have a bad connection
or reverse polarity, the discharge unit will
automatically shut off in three minutes.
Correct any problems.


5. Let the discharge unit run until it shuts off and 7. Turn off the discharge unit. Wait until the fan
immediately record the surface voltage from stops and then disconnect the battery leads.
the discharge unit readout panel. Restart the Be sure to do the loaded individual battery
discharge unit and let it run until the voltage measurements with the battery pack fully
reaches 42 volts. discharged to 42 volts. Failure to do this part of
6. While the discharge unit is still connected and the test immediately after the discharge unit
operating, measure and record each shutoff will allow the batteries to recover.
individual battery voltage. Look over the Recovered batteries will give false readings.
voltage measurements you just recorded. A
difference of 0.5 volts from the highest to If more than a few minutes elapse before you do
lowest measurement indicates a weak the individual battery measurements, turn the
battery. discharge unit back on. Allow the discharge unit
to run until the total battery pack voltage is again
approaching 42 volts. This will prevent a false
WARNING “good” voltage measurement from a recovered
If the fan is running and you disconnect the battery.
unit, a spark will be produced and could result
in explosion and fire.
Battery Discharge Chart

Discharge Minutes Adjusted for Temperature
°F 80 75 70 65 60
Temperature
55 50 45 40 35 30
4
°C 27 24 21 18 15.5 13 10 7 4.5 2 -1
105
100 103 107
95 98 101 105
90 93 96 100 103 107
85 88 91 94 97 101 105
80 83 85 88 92 95 99 103
75 77 80 83 86 89 93 97 101 105
Discharge Minutes
70 72 75 77 80 83 87 90 94 98 103
65 67 69 72 75 77 80 84 87 91 96
60 62 64 66 69 71 74 77 81 84 88
55 57 59 61 63 65 68 71 74 77 81
50 52 53 55 57 60 61 64 67 70 74
45 46 48 50 52 54 56 58 60 63 66
40 41 43 44 46 48 50 52 54 56 59
35 36 37 39 40 42 43 45 47 49 51
30 31 32 33 34 36 37 39 40 42 44
25 26 27 28 29 30 31 32 34 35 37
20 21 21 22 23 24 25 26 27 28 29
15 15 16 17 17 18 19 19 20 21 22
10 10 11 11 11 12 12 13 13 14 15
Adjusted Discharge Minutes = Discharge Minutes

1-(((80-temp)/100)*.64)
Figure 4-2

Battery Discharge Worksheet

I. Customer Information:
Customer: Date of Test:
Location: Tested by:
Dealer: Temperature:
II. General Car Information

Date Codes:
Car # Vehicle Serial No. Vehicle Charger Rounds Amp-Hours Hours 1 2 3 4
Type Type
III. Battery Condition

Examples: loose, tight, corroded, damaged, clean, wet, excellent, good, poor, low
Accessories
Car # Posts Wiring Fluid Levels Case Mounting Cleanliness Types 12V or 48V
General Comments:
IV. On-Charge Test

1. Fully charge batteries. Disconnect and reconnect DC plug to restart charger.
2. Wait 15 minutes. Record set and individual voltages.
3. If set voltage is > 56.0V, then proceed to step 5.
4. If not, check charger for proper output and recharge batteries.
5. Replace any battery that is BOTH below 14V and more than 1V from any other battery in the set.
Proceed to discharge test.
On-Charge Voltages
Car # Set Voltage 1 2 3 4
V. Discharge Test
End of Discharge Battery Voltages
Car # Discharge Minutes Minutes (temperature corrected) 1 2 3 4

Remove and Replace the Battery BATTERIES
REMOVE AND REPLACE THE

CAUTION
BATTERY Do not over-tighten the battery hold-down
nuts. Excessive force will damage the battery
WARNING casing.
• Secure the vehicle and discharge the
controller capacitor. See Safety Lockout 8. Install the battery hold-down plates and
Procedure on page 1-7. secure with the hold-down rods and 12 mm
• Always remove the negative (-) battery nuts. The battery hold-downs should be
cables first and ensure they are stowed in a tightened to specification.
manner to prevent arching. Specification:
Battery Hold-down Plates ................... 7 - 9 N·m
1. Put tow switch in TOW position. (0.7 - 0.9 m·kg; 62 - 80 lb-in.)
2. Loosen the battery terminal nuts with an 9. Connect the battery cables and wire leads
insulated 14 mm wrench then remove the with the 14 mm nuts as shown (Figure 4-3).
battery cables and wire leads. Tighten to specification.
3. Loosen the battery hold-down nuts with an Specification:
insulated 12 mm wrench, then remove the Battery Clamps ......................................... 9 N·m
hold-down plates. (0.9 m·kg; 80 lb-in.)
CAUTION
Battery removal requires the ability to lift at
4
least 40.8 kg (90 lb) and the use of two (2)
battery-lifting straps.
4. Attach a battery-lifting strap to each battery

and remove, remembering to use proper
lifting techniques.
5. Clean and dry the battery tray and
surrounding area. See Battery Cleaning on Y-672b
page 4-6.
Figure 4-3
6. Inspect and replace any worn or corroded
battery hold-down rods.
CAUTION
• When installing batteries:
◆ Carefully position the cables and
hold-downs making sure the cables do
not lay across the battery vent caps.
◆ Install the negative (-) battery cable last.
7. Using two battery-lifting straps, install each

battery (Figure 4-3).

BATTERIES Remove and Replace the Battery

ENGINE
Table of Contents
— Tests and Adjustments —
Engine Tests and Adjustments.............................................................. 5-3
Check the Engine Compression Pressure ...................................... 5-3
Testing the Fuel Pump .................................................................... 5-3
Spark Output Test ........................................................................... 5-4
Test and Adjust Transistor Control Ignition (TCI) ............................ 5-4
Adjust......................................................................................... 5-4
Test............................................................................................ 5-4
Adjust the Choke Cable................................................................... 5-5
— Engine Repair —
Preparation for Engine Repair............................................................... 5-6
5
Carburetor ............................................................................................. 5-6
Air Filter Housing............................................................................. 5-6
Remove the Air Filter Housing................................................... 5-6
Install the Air Filter Housing....................................................... 5-7
Remove the Carburetor................................................................... 5-7
Repair the Carburetor...................................................................... 5-8
Disassemble the Carburetor...................................................... 5-8
Clean and Inspect the Carburetor ............................................. 5-9
Assemble the Carburetor......................................................... 5-10
Install the Carburetor..................................................................... 5-11
Muffler ................................................................................................. 5-11
Remove the Engine............................................................................. 5-12
Disassemble the Engine...................................................................... 5-14
Cylinder Head and Rocker Arm Components ............................... 5-14
Remove the Cylinder Head ........................................................... 5-15
Disassemble the Cylinder Head .................................................... 5-16
Remove the Flywheel Magneto..................................................... 5-18
Remove the Camshaft Components ............................................. 5-20
Remove Piston and Crankshaft..................................................... 5-22

ENGINE
Inspect the Engine Components ......................................................... 5-23
Inspect the Cylinder Head ............................................................. 5-23
Check the Cylinder Head .............................................................. 5-24
Inspect the Camshaft .................................................................... 5-29
Check the Valve Lifter ................................................................... 5-30
Check the Balancer Shaft.............................................................. 5-30
Check the Bearings ....................................................................... 5-30
Check the Cylinder and Piston ...................................................... 5-31
Check the Piston Rings ................................................................. 5-32
Check the Piston Pin ..................................................................... 5-33
Check the Crankshaft.................................................................... 5-33
Assemble the Engine .......................................................................... 5-34
Assemble the Piston...................................................................... 5-34
Install Piston and Crankshaft......................................................... 5-35
Install the Camshaft Components ................................................. 5-36
Install the Flywheel Magneto......................................................... 5-37
Assemble the Cylinder Head......................................................... 5-37
Install the Cylinder Head ............................................................... 5-38
Install the Engine................................................................................. 5-39

Engine Tests and Adjustments ENGINE
Tests and Adjustments
WARNING 4

1
ENGINE TESTS AND SM-03-321
ADJUSTMENTS Figure 5-2

3. Connect pressure hose from Mityvac®
Check the Engine Compression Vacuum and Pressure Tester to fuel pump
Pressure inlet fitting (Figure 5-2, (1)) to check the
diaphragm.
See Check the Engine Compression Pressure on
page 3-16.
NOTE:
Testing the Fuel Pump During the following steps, do not exceed the
specified pressure or damage to the fuel pump
may result.
NOTE:
This test requires that the fuel pump be “wet”
(have fuel in it). A completely dry pump will not 4. Block fuel outlet fitting (Figure 5-2, (4)) and
function due to leakage between the check pressurize to 48.2 ± 6.9 kPa (7.0 ± 1.0 psi).
valves and valve seats in the pump. 5. Check that the pressure is being maintained.
Replace the fuel pump if pressure loss is
observed.
5
3
SM-03-322
2 Figure 5-3
1
6. Connect pressure hose from Mityvac® to
pump inlet fitting (Figure 5-3, (2)) to check
Y-1251
the inlet check valve.
Figure 5-1
7. Apply negative pressure to 300 mb
1. Label the fuel inlet (Figure 5-1, (1)), fuel (120.45 in.Aq; 8.86 in.Hg) ± 10%.
pump pulse hose (Figure 5-1, (2)) and fuel 8. Check for sudden pressure loss and replace
outlet hose (Figure 5-1, (3)) at the fuel pump the fuel pump if sudden pressure change is
to allow for connection in their proper location observed.
after test.
2. Disconnect the hoses from the fuel pump.

ENGINE Engine Tests and Adjustments
Spark Output Test Specification:

Special Tool: TCI Air Gap......................................0.3 - 0.5 mm
(0.012 - 0.020 in.)
Spark Tester ................................ P/N YM-34487
3. If not within specification, loosen the two
screws and adjust the TCI air gap to
specification.
4. Tighten screws to specification.
Specification:
TCI Screw Torque ................................... 11 N·m
(0.1 m·kg; 97 lb-in.)
Test
1 1. Disconnect the primary wire from the TCI unit.
2 Y-1202
2. Twist the spark plug cap counterclockwise to
Figure 5-4 remove it from spark plug lead.
1. Remove spark plug cap (Figure 5-4, (1)) from
spark plug and connect to spark tester x1
(Figure 5-4, (2)).
2. Set spark gap tester to a gap (Figure 5-4, (a))
of less than 6.0 mm (0.240 in.).
– +
3. Connect spark gap tester to spark plug cap
and spark plug.
4. Turn the main switch to ON and depress the
throttle pedal to crank the engine. Spark Y-811
should consistently jump the gap with a sharp

blue spark. Figure 5-5
5. Increase the gap until the spark becomes 3. Set meter to Ωx1.
intermittent. 4. Connect the red meter lead to the primary
6. Stop cranking the engine and measure the terminal. Connect the meter black lead to the
gap. If less than specification, a defective laminations (Figure 5-5) to measure primary
spark plug cap, improper TCI air gap or resistance. Note the meter reading.
defective TCI unit are indicated.
Specification:
x 1k
Spark Gap
Minimum ................................6.0 mm (0.240 in.)
Test and Adjust Transistor Control

– +
Ignition (TCI)
Special Tool:
Digital Multimeter........................ P/N YU-A1927 Y-812
Adjust Figure 5-6

1. Remove the flywheel cover to expose the 5. Move the black meter lead to the spark plug
flywheel and TCI unit. See Remove the lead to measure secondary resistance. Note
Flywheel Magneto on page 5-18. the meter reading.
2. Use a feeler gauge to measure the air gap 6. If readings are not within specifications,
between the TCI and the flywheel magneto. replace the TCI unit.

Engine Tests and Adjustments ENGINE

Specification:
TCI Primary Resistance.............. 0.9 - 1.5 ohms
@ 20°C (68°F)
TCI Secondary
Resistance ............................10.5 - 12.9 k-ohms
@ 20°C (68°F)
Adjust the Choke Cable

1. Remove the air filter housing. See Air Filter
Housing on page 5-6. 1
2. Push choke knob in completely.
Y-1514
Figure 5-8
5. Pull choke knob out to the full choke position
and ensure the choke plate is fully closed
(Figure 5-8, (1)).
2
1 6. Install air filter housing. See Air Filter Housing
on page 5-6.
Y-1252A
Figure 5-7
3. Loosen clamp screw (Figure 5-7, (1)).
5
4. Lightly pull cable housing until slack is
removed from the cable (Figure 5-7, (2)) but
the choke plate remains fully open.
While holding cable housing in this position,

tighten clamp screw.

ENGINE Preparation for Engine Repair
Engine Repair
NOTE: CAUTION
Use only Yamaha genuine replacement parts. Make sure all traces of cleaner are removed
Any failure that is caused by the use of before engine is reassembled. Engine oil can
non-Yamaha parts will not be covered under be adversely affected by even small amounts
warranty. of cleaner.
NOTE:
It is not necessary to remove the engine in CARBURETOR
order to remove the following components:
Air Filter Housing
• Cylinder Head Assembly
• Carburetor Remove the Air Filter Housing
• Starter/Generator 1. Park the vehicle on a level surface.
• Primary Sheave Assembly 2. Engage parking brake.
PREPARATION FOR ENGINE

REPAIR
1. Remove all dirt, mud, dust and foreign
material before removal and disassembly.
2. Use proper tools and cleaning equipment.
See General Information on page 1-1.
3. Disconnect the negative (-) battery cable.
Figure 5-9
NOTE: 3. Disconnect the cylinder head breather hose
When disassembling the engine, keep mated (Figure 5-9, (1)).
parts together. This includes gears and
cylinders, pistons and rings, and other parts
that have been “mated” through normal wear.
Mated parts must be reused as an assembly or
replaced.
4. During the engine disassembly, clean all parts

and place them in trays in the order of
disassembly. This will speed up reassembly
time and help ensure that all parts are
correctly reinstalled in the engine. Figure 5-10
4. Remove the air filter case cover
(Figure 5-10, (1)) and air filters. See Clean
the Pre-Filter/Air Filter on page 3-15.

Carburetor ENGINE
2. Install the air filters and air filter case cover.
See Clean the Pre-Filter/Air Filter on
page 3-15.
CAUTION
1 Ensure the breather hose and oil delivery
hose are securely attached or engine damage
may result.
3. Connect the cylinder head breather hose.

Y-1332
Remove the Carburetor
Figure 5-11
5. Remove two hex head bolts (10 mm hex) CAUTION
(Figure 5-11, (1)).
When service is performed on the carburetor,
throttle cables or speed limiter parts, the
vehicle maximum speed should be checked
and the speed limiter setting adjusted as
necessary.
1. Remove the seat.

2. Remove the air filter housing. See Air Filter
Housing on page 5-6.
1
2
6 4
5
Y-1145
Figure 5-12
6. Remove two nuts (12 mm hex) 1
3
(Figure 5-12, (1)).
7. Remove and clean the air filter case. 5
Install the Air Filter Housing
NOTE:
Ensure the fuel pump pulse hose is routed Y-1252
across the top of the cylinder block to prevent Figure 5-13

accidental pinching by the air cleaner housing.
3. Remove retainer clips (Figure 5-13, (1)) and
pins (Figure 5-13, (2)).
1. Install the air filter case and tighten to 4. Remove choke cable retainer
specification. (Figure 5-13, (3)) and throttle cable e-ring
Specification: (Figure 5-13, (4)).
Air Filter Case Bolt Torque....................... 7 N·m 5. Disconnect the choke and throttle cables.
(0.7 m·kg; 62 lb-in.) 6. Remove the fuel hose (Figure 5-13, (5)).
Carburetor Mounting Nut Torque ............ 7 N·m 7. Remove the carburetor from the engine.
(0.7 m·kg; 62 lb-in.) 8. Remove and discard gaskets.

ENGINE Carburetor
Repair the Carburetor 1. Remove carburetor from engine. See Remove

the Carburetor on page 5-7.
Disassemble the Carburetor 2. Remove drain bolt (Figure 5-14, (12)) and
gasket and drain the fuel from the float bowl.
10 3 3. Remove float bowl (Figure 5-14, (7)) and
bowl gasket (Figure 5-14, (15)).
1
13
2
1
9 5 Y-1186
4
Figure 5-15
11
4. Remove the main jet (Figure 5-15, (1)).
6
NOTE:
The float pin is staked at one end. Use a small
15
punch on the end opposite the staking. Use
care not to break stanchions.
7
5. Carefully drive out the float pin

14 (Figure 5-15, (2)).
12
8
1
2
Y-1442
Figure 5-14
1. Choke Cable Clamp
2. Pilot Adjustment Screw
3. Throttle Stop Screw
4. Main Jet
5. Main Nozzle Y-1187
6. Float
7. Float Bowl Figure 5-16
8. Float Chamber Bolt 6. Remove the float (Figure 5-16, (1)) and float
9. Float Inlet Needle inlet needle (Figure 5-16, (2)). Remove inlet
10. Pilot Jet needle from float.
11. Pipe, Main Bleed
12. Drain Bolt
13. Tamper-Proof Cap (DO NOT remove)
14. Gasket
15. Float Bowl Gasket

Carburetor ENGINE
Clean and Inspect the Carburetor
1
WARNING
• Always wear safety glasses when using
compressed air.
• Reduce air pressure to 207 kPa (30 psi)
when drying components with compressed
air.
• Carburetor cleaners are extremely
Y-1188
flammable. Keep sparks and flame away
from work area.
Figure 5-17
• Always follow the carburetor cleaner
7. Remove the main nozzle (Figure 5-17, (1)). manufacturer’s warnings and instructions.
• Never use gasoline as a cleaning agent.
NOTE:
The low-speed nozzle will be visible after the
main nozzle is removed. The low-speed nozzle
is not removable and must be cleaned in place. CAUTION
• Never use a caustic carburetor cleaning
solution to clean the carburetor and its
components.
• Never use a wire or drill to clean small
passages.
• Always blow fuel system components dry
1 using compressed air.
• Never use a paper or a cloth rag to dry the
fuel system components. Doing so can
cause small particles to become lodged in
5
passages, resulting in poor carburetor
operation.
1. Clean all components with petroleum-based

Y-1253 carburetor cleaning solvent and blow dry with
Figure 5-18 compressed air.
8. Remove the pilot jet (Figure 5-18, (1)). 2. Inspect the carburetor body and float
chamber for cracks or other damage.
3. Inspect the float for damage or evidence of
NOTE:
cracks.
Never remove the pilot screw or limiter cap. 4. Inspect the tip of the float inlet needle for
These have been adjusted and installed during wear.
manufacture and must not be removed to
maintain EPA compliance. 5. Inspect the inlet valve seat for damage or
wear.

ENGINE Carburetor
3 C
4 Y-1189 Y-373A
Figure 5-19 Figure 5-20

6. Inspect the throttle stop screw 6. Check the float level (Figure 5-20, (C)).
(Figure 5-19, (1)) for wear or damage. (a) Hold carburetor upside down and incline to
7. Inspect the pilot jet (Figure 5-19, (2)), main approximately 60 - 70° to prevent the float
jet (Figure 5-19, (3)) and main nozzle from compressing the inlet needle.
(Figure 5-19, (4)) for evidence of (b) Measure the distance from the inside of
contamination. Clean as necessary. the gasket sealing surface of the
carburetor body to the float.
NOTE: • If the float is not within specification, inspect
The throttle and choke shafts and the the inlet needle and seat for wear or damage.
carburetor body must be replaced as an • If the inlet valve seat is worn, replace the
assembly if wear or damage is evident. carburetor body.
• If both are good, replace the float.
8. Inspect the throttle plate shaft and choke
Specification:
plate shaft for looseness or wear. Check that
they operate smoothly. Float Setting.......................... 14.5 mm (0.57 in.)
9. Inspect the carburetor throat for evidence of 7. Install the float chamber using new gaskets.
wear or damage from contact with the throttle Tighten bolt to specification.
or choke plates. Specification:
Assemble the Carburetor Float Chamber Bolt
Torque........................................................ 9 N·m
1. Install the pilot jet. (0.9 m·kg; 80 lb-in.)
2. If removed, install the throttle stop screw and
spring. Turn an additional 1/4 turn after screw 8. Install the carburetor. See Install the
contacts throttle lever. Carburetor on page 5-11.
3. Install the main nozzle.
4. Attach the inlet needle to the float. Install the
float and needle assembly and insert the float
pin from the side opposite the original staking.
5. Install the main jet.

Muffler ENGINE
Install the Carburetor
NOTE:
6 4 Ensure the breather hose is securely attached
2 or engine damage may result.

13. Check the maximum speed setting. See
1 Check and Adjust the Speed Limiter on
3 page 3-24.
5
MUFFLER
.
Y-1252
1
Figure 5-21
1. Install new carburetor mounting gaskets on
both sides of the isolator (Figure 5-21, (6)). 2
2. Install carburetor on mounting studs.

3. Connect fuel hose (Figure 5-21, (5)).
4. Install throttle cable in anchor bracket and
secure with e-ring (Figure 5-21, (4)).
5. Install choke cable and secure with clamp
(Figure 5-21, (3)).
6. Connect choke and throttle cables to the
carburetor with pins (Figure 5-21, (2)) and
retainer clips (Figure 5-21, (1)). Figure 5-22
Y-1522 5
7. Adjust the choke cable. See Adjust the Choke 1. Remove the seat.
Cable on page 5-5.
2. Remove the rivets (Figure 5-22, (1)) and
8. Check and adjust the throttle cable. See remove the air duct (Figure 5-22, (2)).
Check and Adjust the Speed Limiter on
page 3-24.
9. Install the air filter housing and new gasket.
See Air Filter Housing on page 5-6.
NOTE:
Always install new air filter elements when
servicing the carburetor or engine.
10. Install new air filter elements.

11. Install air filter case cover. Ensure the tabs
are securely inserted in the housing. See
Clean the Pre-Filter/Air Filter on page 3-15.

ENGINE Remove the Engine
2 REMOVE THE ENGINE

1
Y-1530
Figure 5-24
1. Remove the seat.
5 2. Disconnect the wire connector for the TCI
(Figure 5-24, (1)).
6 Y-1427
Figure 5-23
3. Remove lower nut (Figure 5-23, (6)).
4. Remove two nuts (Figure 5-23, (2)) and
remove the muffler (Figure 5-23, (1)).
5. Remove and discard the gasket
(Figure 5-23, (3)). 1
6. Installation is done in the reverse of removal.
Tighten fasteners to specification.
Specification:
Muffler Flange Mounting Nuts
Torque ...................................................... 19 N·m Y-1526
(1.9 m·kg; 13 lb-ft) Figure 5-25

Muffler Mounting Bracket 3. Disconnect the fuel pump vacuum line
Nut and Bolts (Figure 5-25, (1)) from the fuel pump.
Torque ...................................................... 16 N·m 4. Remove drive belt and primary sheave
(1.6 m·kg; 11 lb-ft) assembly. See Primary Sheave Assembly on
page 6-5.
5. Remove carburetor. See Remove the
Carburetor on page 5-7.
6. Remove muffler. See Muffler on page 5-11.

Remove the Engine ENGINE
Y-1529
Figure 5-26
2
7. Disconnect the wire (Figure 5-26, (1)) from
1 Y-1428
the oil pressure sender.
8. Remove starter/generator. See Figure 5-27
Starter/Generator Components on page 8-14.
9. Remove four engine mounting nuts
(Figure 5-27, (1)) and washers
(Figure 5-27, (2)).
10. Use a hoist and remove engine assembly.
5

ENGINE Disassemble the Engine
DISASSEMBLE THE ENGINE

Cylinder Head and Rocker Arm Components
3
5
6
11 12
9 10
4
7 9
14
8
10
8
13
1. Spark Plug Cap 8. Rocker Arm (two used)

2. Air Shroud 9. Locknut (two used)
3. Cylinder Head Breather Hose 10. Valve Adjusting Screw (two used)
4. Spark Plug 11. Cylinder Head Assembly
5. Cylinder Head Cover 12. Cylinder Head Gasket
6. Cylinder Head Cover Gasket 13. Dowel Pin (two used)
7. Rocker Arm Shaft 14. Push Rod (two used)
Figure 5-28

Disassemble the Engine ENGINE

Remove the Cylinder Head 9. Push the rocker shaft out of the cylinder head
and remove it and both rocker arms.
1. Disconnect the spark plug cap
(Figure 5-28, (1)). 10. Remove the push rods. Mark the push rods
so they can be installed in their original
2. Remove the spark plug. positions.
3. Remove the valve cover (Figure 5-28, (5))
and gasket (Figure 5-28, (6)). 1 3
4. Remove the air shroud (Figure 5-28, (2)).
5. Mark the rocker arms so they can be installed
in their original positions.
1
4 2
Figure 5-31
NOTE:
Loosen the cylinder head bolts in the proper
sequence as shown.
Figure 5-29
11. Loosen four cylinder head bolts in the
6. Carefully insert a screwdriver into the spark sequence shown (Figure 5-31).
plug hole until it touches the piston top. 12. Remove cylinder head and head gasket.
13. Remove two dowel pins (Figure 5-28, (13)).
5
1
Figure 5-30
7. Rotate the flywheel magneto clockwise to

bring the piston to the top dead center (TDC)
of its compression stroke (when the
screwdriver (Figure 5-29, (1)) inserted into
the spark plug hole reaches the highest
position). At this point, both rocker arms
should be loose. If they are not, rotate the
flywheel one full revolution (360°).
8. Make alignment marks (Figure 5-30, (1)) on
the flywheel magneto and crankcase when
the piston is at top dead center (TDC) of the
compression stroke so that the piston can be
positioned to TDC during cylinder head
installation.

Disassemble the Cylinder Head
1 2 3 6
5
1 2 3
Figure 5-32
1. Valve Keeper (two used) 4. Intake Valve

2. Valve Spring Retainer (two used) 5. Exhaust Valve
3. Valve Spring (two used) 6. Valve Stem Seal (Intake Side)

Figure 5-33
1. Use a valve spring compressor tool
(Figure 5-33, (2)) to compress the spring.
Special Tool:
Valve Spring Compressor ......... P/N YM-01253,
90890-04019
2. Remove the valve keepers (Figure 5-33, (1)).
3. Carefully release the tension on the valve
spring and remove compressor.
4. Remove the valve spring and retainer.
5. Remove the valve.
6. Repeat steps 1-5 with the remaining valve.
7. Remove the valve stem seal from the intake
valve guide.

Remove the Flywheel Magneto
Figure 5-34
1. Flywheel Cover 4. Flywheel Magneto

2. Air Intake Cover 5. Woodruff Key
3. TCI Unit


1. Remove the flywheel cover (Figure 5-34, (1)). 5. Remove the flywheel magneto nut and
washer.
1 1
2
Figure 5-35
Figure 5-37
2. Rotate flywheel magneto to align the flywheel
cutaways (Figure 5-35, (2)) with the TCI unit 6. Remove the flywheel magneto
bolt holes. (Figure 5-37, (1)) using a two- or three-jaw
3. Remove the TCI unit (Figure 5-35, (1)). puller (Figure 5-37, (2)).
Figure 5-36
4. Use the primary sheave assembly holder or
5
sheave holder (Figure 5-36, (1)) to hold the
flywheel magneto.
Special Tool:
Holder ....................................... P/N YS-01880-A
Sheave Holder .........................P/N 90890-01701

Remove the Camshaft Components
3
7
7
5
2
Figure 5-38
1. Crankcase Cover 6. Camshaft

2. Crankcase Cover Gasket 7. Valve Lifter (two used)
3. Dowel Pin (two used) 8. Balancer Shaft
4. Wire Retainer 9. Baffle Plate
5. Oil Level Switch

1
6
4 3
2 5
Figure 5-39
1. Loosen the crankcase cover bolts in the
sequence shown (Figure 5-39). Remove the
crankcase cover and gasket.
2. Remove two dowel pins (Figure 5-38, (3)).
3. Remove wire retainer (Figure 5-38, (4)) and
oil level switch (Figure 5-38, (5)).
4. Place the engine on a bench with the piston
facing down to allow the valve lifters to fall
away from the camshaft.
5. Remove the camshaft (Figure 5-38, (6)).
6. Remove the valve lifters (Figure 5-38, (7)).
7. Remove the balancer shaft (Figure 5-38, (8)).
8. Remove the baffle plate (Figure 5-38, (9)).
9. Wash all components in parts cleaning
solvent and allow to dry.
5

Remove Piston and Crankshaft
2
4
7
Figure 5-40
1. Connecting Rod Cap 5. Piston Pin

2. Crankshaft 6. Piston
3. Connecting Rod 7. Piston Ring Set
4. Piston Pin Retaining Ring (two used)

Inspect the Engine Components ENGINE

1. Remove any carbon ridge at the top of the (b) Turn the handle to remove the pin
cylinder bore. (Figure 5-42, (2)) from the piston
2. Remove two connecting rod bolts and the (Figure 5-42, (3)).
connecting rod cap (Figure 5-40, (1)). Special Tool:
3. Push the piston and connecting rod assembly Piston Pin Puller Set .............. P/N 90890-01304
(Figure 5-40, (3, 4, 5, 6, 7)) out of the cylinder 9. Spread the end gaps while lifting the piston
bore being careful not to damage the ring over the top of the piston crown to
crankshaft journal. remove the piston rings.
4. Remove the crankshaft.
5. Carefully press out the main bearings and
crankshaft seals. INSPECT THE ENGINE
COMPONENTS
3 2 1
Inspect the Cylinder Head
Check the Push Rods
Figure 5-41
6. Remove the piston pin retaining rings
(Figure 5-41, (1)) from each side of the
piston.
7. Deburr the retaining ring grooves to ease
piston pin removal.
8. Push the piston pin (Figure 5-41, (2)) from
Figure 5-43
1. Place the push rod across two V-blocks.
5
the piston (Figure 5-41, (3)).
2. Set up a dial indicator as shown (Figure 5-43)
and set to zero.
NOTE:
3. Slowly rotate the push rod and note the total
Never use a hammer to drive the piston pin out. indicator reading (TIR). If not within
If the pin cannot be removed by hand, use a specification, replace the push rod.
Piston Pin Puller Set.
Specification:
Push Rod Runout ................... 0.5 mm (0.02 in.)
Figure 5-42
(a) Install the Piston Pin Puller Set
(Figure 5-42, (4)).

ENGINE Inspect the Engine Components
Check the Cylinder Head Cylinder Head Resurfacing
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
5. Resurface the head with 400 - 600 grit wet

emery cloth using a figure-eight sanding
pattern.
Check the Rocker Arms
Figure 5-44
1. Use a non-metallic rounded scraper to
remove carbon deposits from the combustion
chamber.
1
NOTE:
Never use a sharp instrument to remove carbon 2
or gasket material.
Figure 5-46
2. Remove all gasket material. 1. Check rocker arm lobe contact surface
3. Inspect the cylinder head for scratches or (Figure 5-46, (1)) for wear or discoloration.
damage. 2. Check valve adjusters (Figure 5-46, (2)) for
blue discoloration, pitting, scratches or
uneven wear. Replace if damaged and check
lubrication.
Figure 5-45
4. Use a straight edge and feeler gauge to
measure cylinder head warpage in the
directions shown. If not within specification, Figure 5-47
resurface the head as follows: 3. Check the surface of the rocker arm shaft for
Specification: blue discoloration, pitting, scratches or excess
wear. Replace if not within specification and
Cylinder Head check lubrication.
Warpage.............................Less than 0.030 mm
(0.0012 in.) 4. Measure the diameter (Figure 5-47, (1)) of
the rocker arm pivot hole. Replace if not
within specification.
Specification:
Rocker Arm Pivot Hole
Diameter ..............................12.000 - 12.018 mm
(0.4724 - 0.4731 in.)


Specification:
1 Rocker Arm Shaft Inside
Diameter ..............................12.000 - 12.027 mm
(0.4724 - 0.4735 in.)
Rocker Arm To Shaft - Rocker Arm
Shaft Support Clearance ........0.009 -0.037 mm
(0.0004 - 0.0015 in.)
<Limit>: 0.08 mm (0.0031 in.)
Figure 5-48 Check the Valves and Guides
5. Measure the outside diameter 1. Remove carbon deposits from the valve face,
(Figure 5-48, (1)) of the rocker arm shaft. valve stem and valve seat using a wire wheel
Replace if not within specification. or chemical carbon remover.
Specification:
Rocker Arm Shaft
Outside Diameter ............... 11.981 - 11.991 mm
(0.4717 - 0.4721 in.)
6. Calculate the clearance by subtracting the 1
rocker arm shaft outside diameter from the
rocker arm hole diameter. Replace if not
Specification:
Rocker Arm Shaft Figure 5-50
Clearance................................ 0.009 - 0.037 mm
(0.0004 - 0.0015 in.) 2. Measure valve guide inside diameter
(Figure 5-50, (1)).
<Limit>: 0.08 mm (0.0031 in.)
1
5
Figure 5-51
Figure 5-49
7. Check rocker arm shaft support hole for wear, 3. Measure valve stem diameter
pitting, scratches or blue discoloration. If (Figure 5-51, (1)).
damaged, replace the cylinder head. 4. Subtract valve stem diameter from valve
8. Measure rocker arm shaft support inside guide diameter to get stem-to-guide
diameter. If not within specification, replace clearance. If not within specification, replace
the cylinder head. the valve guide, valve or both.

Specification: 9. Slowly rotate the valve and note the total

Stem-to-Guide Clearance indicator reading (TIR) to measure the valve
stem runout. Replace valve if not within
Intake ...................................... 0.037 - 0.064 mm specification.
(0.0015 - 0.0025 in.)
<Limit>: 0.08 mm (0.0031 in.) Specification:
Valve Stem Runout.................................0.1 mm
Exhaust................................... 0.045 - 0.072 mm (0.0004 in.)
(0.0018 - 0.0028 in.)
<Limit>: 0.10 mm (0.0039 in.)
NOTE:
5. Check the valve face for pitting and wear.
Grind the valve face or replace valve as • When installing a new valve, always replace
the valve guide.
necessary.
• If the valve is removed or replaced, always
6. Check the valve stem end for mushroom replace the valve stem seal.
shape or diameter larger than the body of the
stem. Replace valve as necessary.
10. Inspect valve seat for pitting or wear. Unless
1 the seat is severely damaged, it can usually
be renewed using a valve seat cutter.
45°
Figure 5-52
7. Measure the valve head margin thickness Figure 5-54
(Figure 5-52, (1)). Replace the valve if less
than specification. 11. Measure the valve seat width
(Figure 5-54, (1)). Renew the valve seat
Specification: using a valve seat cutter if not within
Valve Margin Thickness specification.
Intake ............ 1.0 - 1.4 mm (0.0394 - 0.0551 in.) Specification:
Exhaust........ 0.5 - 0.8 mm (0.0197 - 0.0315 in.) Valve Seat Width
Intake .............0.7 - 0.9 mm (0.0276 - 0.0354 in.)
<Limit>: 1.6 mm (0.0630 in.)
Exhaust .........0.7 - 0.9 mm (0.0276 - 0.0354 in.)
<Limit>: 1.6 mm (0.0630 in.)
Figure 5-53
8. Place the valve in V-blocks and set up a dial
indicator (Figure 5-53). Adjust the indicator to
zero.

CAUTION
Do not allow the compound to enter the gap
between the valve stem and the guide or
1 excessive valve guide wear will occur.
Figure 5-55
12. Apply a light coating of mechanic’s bluing dye
(Dykem) to the valve face (Figure 5-55, (1)).
13. Install the valve into the cylinder head.
14. Press the valve onto the valve seat to make a
clear pattern.
15. Inspect the contact pattern of the valve and Figure 5-57
valve seat. The seat should make contact
approximately in the middle of the valve face 2. Apply molybdenum disulfide oil to the valve
and show consistent contact all the way stem (Figure 5-57).
around. 3. Install the valve into the cylinder head.
16. If the valve seat is too wide, too narrow or the
seat is not centered, the valve seat and/or
valve must be refaced.
17. Once seat width and contact are correct, lap
the valves to the seats.
NOTE: 5
After refacing the valve seat or replacing the
valve or valve guide, the valve seat and valve
face should be lapped.
Figure 5-58
Lapping Valves NOTE:

For best lapping results, occasionally lift the
valve off the seat while rotating the valve back
and forth between your hands.
4. Use a valve lapping tool to turn the valve until

the valve face and valve seat are evenly
polished, then clean off all of the compound.
5. Apply a fine lapping compound to the valve
face and repeat the above steps.
Figure 5-56
1. Apply a coarse lapping compound to the valve NOTE:
face. After every lapping operation be sure to clean
off all of the compound from the valve face and
valve seat.

6. Apply mechanic’s bluing dye (Dykem) to the Specification:

valve face. Installed Valve Spring
7. Install the valve into the cylinder head. Height ....................................................29.0 mm
8. Press the valve onto the valve seat to make a (1.14 in.)
clear pattern. Compressed Valve
9. Measure the valve seat width again. If the Spring Force
valve seat width is not within specification, at Installed Height ....................... 91.2 - 104.9 N
reface and lap the valve seat. (9.30 - 10.70 kg; 20.59 - 20.59 lb)
Checking Valve Springs
1
Figure 5-61
1
3. Measure valve spring tilt (Figure 5-61, (1)).
Figure 5-59 Replace the spring if not within specification.
1. Measure valve spring free length Specification:
(Figure 5-59, (1)). Replace the spring if not
Valve Spring Tilt
Limit........................... 2.5° or 1.6 mm (0.063 in.)
Specification:
Valve Spring Replacing Valve Guides
Free Length ...........................36.2 mm (1.43 in.)
<Limit>: 34.4 mm (1.35 in.) NOTE:
To ease guide removal and installation and to
maintain correct fit, heat the cylinder head to
100°C (212°F) in an oven.
2
Figure 5-60
2. Measure spring compressed force
(Figure 5-60, (1)) at installed length
(Figure 5-60, (2)). Replace the spring if not
1. Remove the valve guide using a valve guide
driver or valve guide remover
(Figure 5-62, (1)).


Inspect the Camshaft
1 1. Check the camshaft lobes for pitting,
scratches or blue discoloration.
Figure 5-63
2. Install the new valve guide using a valve
guide driver or valve guide remover
(Figure 5-63, (1)) and valve guide installer
(Figure 5-63, (2)).
Figure 5-65
2. Measure the height (Figure 5-65, (a)) and
width (Figure 5-65, (b)) of each camshaft
Figure 5-64
3. After installing the valve guide, ream the valve
guide using a valve guide reamer
lobe. Replace the camshaft if not within
specification. 5
Specification:
(Figure 5-64, (1)) to obtain proper
stem-to-guide clearance. Camshaft Lobe Dimension <Wear Limit>
Special Tool: Camshaft Intake Lobe
Valve Guide Driver Height ............................ 32.395 mm (1.2754 in.)
(6 mm) ...................................... P/N YM-04064-A Width ............................. 25.929 mm (1.0208 in.)
Valve Guide Remover Camshaft Exhaust Lobe
(6 mm) ......................................P/N 90890-04064 Height ............................ 32.395 mm (1.2754 in.)
Valve Guide Installer Width ............................. 25.929 mm (1.0208 in.)
(6 mm) ..................................... P/N YM-04065-A,
90890-04065 3. Check the surface of camshaft gear teeth for
excess wear or damage.
Valve Guide Reamer (6 mm) ..... P/N YM-04066,
90890-04066

Check the Valve Lifter

2
Figure 5-66
4. Inspect the decompression system for
damage. Figure 5-68
5. Check that the decompressor lever pin Check the valve lifters for wear or damage.
(Figure 5-66, (1)) projects from the camshaft.
Check the Balancer Shaft
6. Check that the decompressor fly weight
(Figure 5-66, (2)) moves smoothly.
Figure 5-69
Check the balancer shaft gear teeth for blue
Figure 5-67 discoloration, pitting or wear.
7. Measure the camshaft bearing journal
diameter (Figure 5-67, (1)). Replace the Check the Bearings
camshaft if not within specification.
8. Measure the diameter of the camshaft
bearing bore in both the crankcase and
crankcase cover. Replace the appropriate
component if not within specification.
9. Subtract the measured camshaft bearing
journal dimension from the measured
camshaft bearing bore dimension to calculate
the clearance. If not within specification,
replace the camshaft, crankcase and
crankcase cover. Figure 5-70
Specification:
Camshaft Bearing Journal WARNING
Diameter ............................. 15.965 - 15.990 mm Never allow bearing to spin if using
(0.6285 - 0.6295 in.) compressed air to dry after cleaning. The
Camshaft Bearing Bore bearing could explode causing death or
Diameter ............................. 16.000 - 16.018 mm serious injury.
(0.6299 - 0.6306 in.)
Camshaft Journal-to-Camshaft 1. Wash bearings in parts cleaning solvent and
Bearing Clearance ................. 0.010 - 0.053 mm allow to dry.
(0.0004 - 0.0021 in.)


2. Visually inspect the balls and races for Specification:
evidence of wear or damage. Cylinder Bore..........................85.00 - 85.02 mm
3. Rotate bearings by hand and check for (3.3465 - 3.3472 in.)
roughness. <Limit:> 85.05 mm (3.3484 in.)
4. Replace any bearing that is damaged or does
Taper <Limit:> .................. 0.15 mm (0.0059 in.)
not rotate smoothly.
Out-of-Round .................... 0.15 mm (0.0059 in.)
5. Apply a light coat of clean engine oil to the
bearings and rotate to distribute the oil. If not within specification, rebore or replace the
cylinder and replace the piston and piston rings
Check the Cylinder and Piston as a set.
1. Inspect the piston skirt for evidence of
scratches or scoring. Replace the piston and P
rings as a set if damaged.
1
2. Inspect the cylinder wall for scratches or
scoring.
D1
D2
D3
D4 Figure 5-72
4. Measure piston skirt diameter
D5 (Figure 5-72, (P)) using a micrometer.
D6 Measure 10 mm (0.39 in.) from the bottom
edge of the piston (Figure 5-72, (1)) and
Figure 5-71 perpendicular to the piston pin.
NOTE:
Specification:
Piston Diameter
5
Standard ..............................84.960 - 84.980 mm
Measure cylinder bore parallel to and at right (3.3449 - 3.3457 in.)
angles to the crankshaft axis. Then, use the
average of the measurements for measured
bore. NOTE:
If not within specification, replace the piston
3. Measure the cylinder bore diameter at three and piston rings as a set.
places using a cylinder bore gauge. Make two
measurements perpendicular to each other at
each place (Figure 5-71). 5. Subtract the piston diameter from the
measured cylinder bore to calculate the
Definitions: piston-to-cylinder clearance. If not within
• Cylinder bore = the average of all specification, rebore or replace the cylinder
and replace the piston and piston rings as a
measurements
set.
• Taper = the maximum of D1 or D2 minus the Specification:
maximum of D5 or D6
Piston-to-Cylinder
• Out-of-round = the maximum of D1, D3 or D5 Clearance ................................0.020 - 0.060 mm
minus the minimum of D2, D4 or D6 (0.0008 - 0.0024 in.)
<Limit>: 0.15 mm (0.0059 in.)

Check the Piston Rings
NOTE:
Piston rings are color-coded to indicate 1
position:
Blue paint = top ring
Yellow paint = second ring
Figure 5-74
3. Insert each piston ring into the cylinder (one
at a time) and push it approximately 20 mm
(0.8 in.) (Figure 5-74, (1)) into the cylinder.
Use the piston to push the ring so that the ring
will be at a right angle to the cylinder bore.
4. Measure the piston ring end gap using a
feeler gauge. Replace the piston ring if not
Figure 5-73
NOTE:
1. Remove carbon deposits from the piston ring
grooves and piston rings. The oil ring expander end gap cannot be
measured. If an oil ring rail end gap is
NOTE: excessive, replace the entire oil ring set.
It is not necessary to install the piston rings to

check side clearance. Place the ring into the Specification:
groove backward instead. Piston Ring End Gap
Top Ring (blue) ...........................0.20 - 0.35 mm
2. Place the appropriate piston ring into the (0.008 - 0.014 in.)
groove and measure the clearance using a <Limit>: 0.60 mm (0.024 in.)
feeler gauge. If not within specification,
replace the piston and rings as a set. Second Ring (yellow) .................0.25 - 0.40 mm
(0.010 - 0.016 in.)
Specification: <Limit>: 0.75 mm (0.0295 in.)
Piston Ring Side Clearance
Oil Ring........................................0.20 - 0.70 mm
Top Ring (blue)........................... 0.04 - 0.08 mm
(0.008 - 0.028 in.)
(0.0016 - 0.0031 in.)
<Limit>: 0.13 mm (0.0051 in.)
Second Ring (yellow) ................ 0.03 - 0.07 mm
(0.0012 - 0.0028 in.)
<Limit>: 0.13 mm (0.0051 in.)


Check the Piston Pin Check the Crankshaft
1. Inspect the piston pin for blue discoloration or
wear. If damaged, check the lubrication
system.
2
1
Figure 5-77
1. Visually inspect the crankshaft journal
surfaces for wear or damage.
1
2. Inspect the camshaft drive gear
Figure 5-75 (Figure 5-77, (1)) and balancer drive gear
2. Measure the piston pin outside diameter (Figure 5-77, (2)) for damage or excess wear.
(Figure 5-75, (1)).
Specification:
Piston Pin Outside
Diameter ............................. 19.995 - 20.000 mm
(0.7872 - 0.7874 in.)
<Limit>: 19.975 mm (0.7864 in.)
5
Figure 5-78
3. Use V-blocks and a dial indicator to measure
crankshaft runout. If not within specification,
replace crankshaft.
1
4. Measure crank pin diameter. Replace the
crankshaft and connecting rod if not within
specification.
Figure 5-76 Specification:
Maximum Crankshaft
3. Measure the piston pin bore diameter
Runout................................. 0.05 mm (0.002 in.)
(Figure 5-76, (1)).
Crankpin Diameter .............35.969 - 35.984 mm
Specification:
(1.4161 - 1.4167 in.)
Piston Pin Bore Diameter.. 20.004 - 20.015 mm
(0.7876 - 0.7880 in.)
<Limit>: 20.045 mm (0.7892 in.)
4. Subtract the pin diameter from the piston pin
bore diameter to calculate the clearance. If
not within specification, replace the piston
and pin as a set.
Piston Pin-to-Piston
Clearance................................ 0.004 - 0.020 mm
(0.0002 - 0.0008 in.)
<Limit>: 0.070 mm (0.0028 in.)

ENGINE Assemble the Engine
5. Measure the crankshaft pin to connecting rod

big end clearance as follows:
Measure the Connecting Rod Bearing
Clearance
Figure 5-81
7. Measure the compressed width of the
Plastigauge® (Figure 5-81, (1)). If the
Figure 5-79 connecting rod big end clearance is not within
specification, replace the crankshaft or
1. Clean oil from the crankshaft pin and the connecting rod and then measure the
inside of the connecting rod halves. clearance again.
2. Place a piece of Plastigauge® Specification:
(Figure 5-79, (1)) on the crankshaft pin.
Connecting Rod Big
End Clearance ........................0.016 - 0.046 mm
1 (0.0006 - 0.0018 in.)
2
ASSEMBLE THE ENGINE
Assemble the Piston
Figure 5-80
3. Lubricate the connecting rod cap bolts
threads with molybdenum oil.
4. Assemble the connecting rod
(Figure 5-80, (1)) and connecting rod cap
(Figure 5-80, (2)).
Figure 5-82
NOTE:
Do not allow the connecting rod and crankshaft NOTE:
to rotate until the clearance measurement has • Piston rings are color-coded to indicate
been completed. position:
Blue paint = top ring
Yellow paint = second ring
5. Tighten the connecting rod cap bolts to the
• The paint marks should face toward the
specified torque in two stages. piston crown.
Specification:
• Lubricate the piston and piston rings liberally
Connecting Rod Cap Bolt with clean engine oil during assembly.
Torque ...................................................... 20 N·m
(2.0 m·kg; 177 lb-in.)
1. Use a piston ring expander to install the
6. Remove the connecting rod and connecting piston rings. Install them beginning with the oil
rod cap. ring expander, oil ring rails, the second ring
and the top ring.

Assemble the Engine ENGINE

Install Piston and Crankshaft
4 5
1. Install new crankshaft seals.
2. Lubricate the crankshaft main journals and
bearing bores, crankshaft pin, connecting rod
big end, connecting rod cap inner surface and
connecting rod cap bolt threads with
molybdenum disulfide oil.
3. Install the crankshaft.
1 3 2
4. Lubricate the piston, piston rings and cylinder
Figure 5-83 bore with clean engine oil.
1. Top Ring Gap 5. Stagger the end gaps as shown in
(Figure 5-83).
2. Upper Oil Ring Rail Gap
3. Oil Ring Expander Gap
1
4. Lower Oil Ring Rail Gap
5. Second Ring Gap
2. Stagger the end gaps as shown
(Figure 5-83).
4
1
3
3
2
4
5 Figure 5-85
2 6. Install a piston ring compressor on the piston.
Figure 5-84
NOTE:
• Make sure that the arrow mark
5
(Figure 5-85, (3)) on the piston head faces
toward the push rod cavity.
NOTE: • Make sure that the “YAMAHA” mark
Make sure that the arrow mark (Figure 5-85, (4)) on the connecting rod faces
(Figure 5-84, (4)) on the piston head and the toward the crankcase cover.
“YAMAHA” mark (Figure 5-84, (5)) on the
connecting rod are positioned as shown when 7. Carefully install the piston and connecting rod
assembling the piston to the connecting rod. assembly into the cylinder bore being careful
not to allow the connecting rod to damage the
3. Apply a light coat of clean engine oil to the the crank pin journal.
piston pin and the piston pin bores in the
piston and connecting rod.
4. Assemble the connecting rod into the piston
(Figure 5-84, (1)) and push the piston pin
(Figure 5-84, (2)) into place.
5. Install the piston pin retaining rings
(Figure 5-84, (3)). Ensure retaining rings are
properly seated.

8. Align the hole (Figure 5-87, (3)) in the

camshaft gear with the punch mark
(Figure 5-87, (4)) on the crankshaft drive
gear.
9. Align the punch mark (Figure 5-87, (5)) in the
1
crankshaft gear with the hole
(Figure 5-87, (6)) in the balancer gear.
2
8
3
5 6
Figure 5-86
8. Install the connecting rod cap making sure 2
that the arrow mark (Figure 5-86, (1)) on the
connecting rod is aligned with the arrow mark 1
(Figure 5-86, (2)) on the rod cap. 4
7
9. Tighten the connecting rod cap bolts to the
specified torque in two stages. Figure 5-88
Specification: 10. Install the crankcase cover dowel pins.
Connecting Rod Cap Bolt 11. Install the crankcase cover with a new gasket.
Torque ...................................................... 20 N·m
(2.0 m·kg; 177 lb-in.)
NOTE:
Install the Camshaft Components Bolts 3 and 5 are M10. All remaining bolts are
M8.
1. Install a new crankshaft seal in the crankcase
cover.
2. Apply a light coat of clean engine oil to the 12. Tighten the bolts to specification in the
camshaft bearing journals and lobes, the sequence shown (Figure 5-88).
balancer shaft bearing journals, the Specification:
crankcase and crankcase cover bearing
Crankcase Cover Bolt
bores (including the crankcase bearing bore),
Torque (M8) ............................................. 26 N·m
and the valve lifters.
(2.6 m·kg; 19 lb-ft)
3. Install the baffle plate.
4. Place the engine on a bench with the piston Crankcase Cover Bolt
facing down. Torque (M10) ........................................... 43 N·m
(4.3 m·kg; 31 lb-ft)
4 5 13. Rotate the crankshaft and check for binding.
2 3 6
1
Figure 5-87
5. Install the balancer shaft (Figure 5-87, (1)).
6. Install the valve lifters.
7. Install the camshaft (Figure 5-87, (2)).

Assemble the Engine ENGINE

Install the Flywheel Magneto Specification:
1. Remove any oil or grease from the tapered TCI Bolt Torque....................................... 10 N·m
portion of the crankshaft and flywheel (1.0 m·kg; 86 lb-in.)
magneto with a non-oily solvent. 7. Check to ensure the TCI air gap is within
2. Install the woodruff key. specification. If not, loosen the bolts and
3. Install the flywheel magneto. repeat the procedure.
4. Install the washer and nut. Specification:
TCI Air Gap......................................0.3 - 0.5 mm
(0.012 - 0.020 in.)
1
Assemble the Cylinder Head
1. Install the valve stem seal on the intake valve
guide.
2. Apply a small amount of grease to the keeper
grooves on the valve stem to help retain the
valve keepers during assembly.
3. Apply a light coat of clean engine oil to the
Figure 5-89 valve stem and valve guide.
5. Use the primary sheave assembly holder or
sheave holder (Figure 5-89, (1)) to hold the
flywheel magneto. Tighten the flywheel
magneto nut to specification. 2
Specification:
Flywheel Magneto Nut
Torque .................................................... 120 N·m
(12.0 m·kg; 85 lb-ft)
1 5
Figure 5-91
4. Install the valve and place the valve spring
and retainer over the end.
2
5. Compress the valve spring using a valve
spring compressor tool (Figure 5-91, (2)).
1
NOTE:
Figure 5-90 Install the chamfered side of the valve keeper

facing down.
CAUTION
Pull the TCI unit away from the flywheel while 6. Install two valve keepers (Figure 5-91, (1)).
tightening the two TCI unit bolts. Damage to 7. Carefully release the tension on the valve
the TCI will result if it contacts the rotating spring compressor until the retainer is
flywheel. securely in contact with the keepers.
8. Remove the valve spring compressor tool.
6. Align the notches (Figure 5-90, (2)) with the 9. Repeat with remaining valve.
TCI unit bolts. Install the TCI unit Special Tool:
(Figure 5-90, (1)) and tighten bolts to
specification. Valve Spring Compressor
Tool ..............................................P/N YM-01253,
90890-04019

1 3
1 1
4 2
Figure 5-94
4. Install cylinder head bolts.
CAUTION
2
Tighten the cylinder head bolts in the proper
tightening sequence as shown, and tighten
Figure 5-92 them in two stages or cylinder head warpage
10. Pour clean solvent (Figure 5-92, (1)) into the may occur.
intake and exhaust ports to check that the
valve seals properly. There should be no
leakage at the valve seats (Figure 5-92, (2)). 5. Tighten the cylinder head bolts in two stages
to specification and in the sequence shown
11. Dump the solvent after confirming there is no (Figure 5-94).
leakage.
Specification:
Install the Cylinder Head Cylinder Head Bolt
Torque...................................................... 44 N·m
1. Install the dowel pins. (4.4 m·kg; 32 lb-ft)
3
2
Figure 5-93 1
NOTE:
Figure 5-95
The beaded side of the new cylinder head
gasket should face up (Figure 5-93, (3)).
NOTE:
2. Install cylinder head gasket (Figure 5-93, (1)) When the alignment marks are aligned, the
with the sealing bead up (Figure 5-93, (3)). piston is at top dead center (TDC).
3. Install cylinder head (Figure 5-93, (2)).
6. Ensure the mark on the flywheel
(Figure 5-95, (1)) is aligned with the mark on
the crankcase that was made during
disassembly.
7. Dip both ends of the push rods in clean
engine oil.
8. Install the push rods in their original locations.

Install the Engine ENGINE

9. Check that both push rods appear to be about INSTALL THE ENGINE
the same length. If they appear to be different
lengths, rotate the flywheel one full revolution
(360°).
1
3
Y-1237
Figure 5-96
10. Loosen the adjuster jam nut
(Figure 5-96, (1)) and turn the adjuster screw
(Figure 5-96, (2)) one to two turns
counterclockwise.
11. Dip the rocker arms and rocker arm shaft in
clean engine oil. 2
12. Install one rocker arm in its original location 1 Y-1428

and push the shaft through until it is held in
Figure 5-97
place. Install the second rocker arm and push
the shaft into final position. 1. Use a hoist to lower engine into place.
13. Adjust valve clearance. See Check and Adjust 2. Install four engine mounting bolts
the Valve Clearance and Spark Plug on
page 3-17.
14. Wipe any excess oil from the valve cover
(Figure 5-97, (3)). Install the washers
(Figure 5-97, (2)) and nuts (Figure 5-97, (3)).
Tighten to specification.
5
gasket surface. Install the valve cover and Engine Mounting Bolt and Nut
new gasket. Tighten securely. Torque...................................................... 32 N·m
15. Install the flywheel cover. (3.2 m·kg; 23 lb-ft)
16. Install the air shroud.
17. Install the spark plug and connect the spark
plug lead.
18. Fill the engine with clean engine oil.

ENGINE Install the Engine
Y-1530
Figure 5-100
Y-1529 9. Connect the wire connector for the TCI
Figure 5-98 (Figure 5-100, (1)).
3. Connect the wire (Figure 5-98, (1)) to the oil
pressure sender.
4. Install the starter/generator. See
Starter/Generator Components on page 8-14.
5. Install the primary sheave assembly and drive
belt. See Primary Sheave Assembly on
page 6-5.
6. Install the muffler using a new gasket. See
Muffler on page 5-11.
7. Install the carburetor. See Install the
Y-1526
Figure 5-99
8. Connect the fuel pump vacuum line
(Figure 5-99, (1)) to the fuel pump.

DRIVE TRAIN
Table of Contents
— Drive Train Repair —
Forward and Reverse Shifting Assembly - Gas Cars............................ 6-3
Shift Cables - Gas Cars......................................................................... 6-4
Remove the Shift Cables................................................................. 6-4
Install the Shift Cables..................................................................... 6-4
Replace the Drive Belt........................................................................... 6-5
Primary Sheave Assembly .................................................................... 6-5
Remove the Primary Sheave Assembly.......................................... 6-5
Disassemble and Inspect the Primary Sheave Assembly ............... 6-6
Assemble the Primary Sheave Assembly ....................................... 6-8
Install the Primary Sheave Assembly............................................ 6-10
Secondary Sheave Assembly ............................................................. 6-10
Remove the Secondary Sheave Assembly ................................... 6-10
Install the Secondary Sheave Assembly ....................................... 6-10
Transaxle - YDRA (Gas Car)...............................................................
Remove the Transaxle - YDRA .....................................................
6-10
6-10
6
Install the Transaxle - YDRA ......................................................... 6-13
Disassemble the Transaxle - YDRA.............................................. 6-14
Remove the Main Case and Gears ......................................... 6-16
Disassemble the Brake............................................................ 6-17
Disassemble the Side Gear..................................................... 6-18
Remove the Brake Lever and Spring ...................................... 6-19
Remove Axle Assembly........................................................... 6-19
Disassemble the Carrier Assembly ......................................... 6-20
Assemble the Side Gear.......................................................... 6-21
Assemble the Axle................................................................... 6-22
Assemble the Transaxle .......................................................... 6-22

DRIVE TRAIN
Transaxle - YDRE (Electric Car) ......................................................... 6-31
Remove the Transaxle - YDRE ..................................................... 6-31
Install the Transaxle - YDRE ......................................................... 6-32
Disassemble the Transaxle - YDRE.............................................. 6-33
Disassemble the Main Case and Gears .................................. 6-34
Disassemble the Brake ........................................................... 6-35
Disassemble the Side Gear..................................................... 6-36
Remove the Brake Lever and Spring ...................................... 6-37
Remove the Axle Assembly .................................................... 6-37
Disassemble the Carrier Assembly ......................................... 6-38
Assemble the Side Gear ......................................................... 6-39
Assemble the Axle................................................................... 6-40
Assemble the Transaxle .......................................................... 6-40

Forward and Reverse Shifting Assembly - Gas Cars DRIVE TRAIN
Drive Train Repair
WARNING
FORWARD AND REVERSE SHIFTING ASSEMBLY - GAS CARS
2
1
14
17
7 13
19 15 18
5
12
6 11
10 6
4
16 8
9
Y-1461
Figure 6-1
1. Washer 9. Spring Clip 15. Washer (two used)

2. Flange Bolt 10. Washer 16. Shift Cable Bracket
3. Shift Cables 11. Washer 17. Flange Bolt (three used)
4. Shift Lever 12. Retaining Ring 18. Reverse Switch
5. Clevis Pin (two used) 13. Pan Head Screw 19. Clamp
6. Washer (two used) (two used)
7. Cotter Pin (two used) 14. Spring Washer
8. Shift Knob (two used)

DRIVE TRAIN Shift Cables - Gas Cars
SHIFT CABLES - GAS CARS Install the Shift Cables
Remove the Shift Cables 2

1. Shift the transaxle to NEUTRAL position.
2. Remove the seat and the rear access panel.
1 Y-1462
Figure 6-4
1
NOTE:
When installing the shift cable equalizer bracket
to the transaxle, align missing spline tooth on
the shaft with the missing spline tooth on the
shift cable equalizer bracket.
1
Y-1468A
Figure 6-2 1. Install the shift cable equalizer bracket onto

3. Loosen the adjustment nuts (Figure 6-2, (1)) the shifting shaft on transaxle.
for the forward and reverse shift cables. 2. Install the flange bolt and washer
4. Remove the cotter pins, washers and clevis (Figure 6-4, (2)) and tighten to specification.
pins (Figure 6-2, (2)) from the shift lever. Specification:
Shift Cable Equalizer Bracket Bolt
2
Torque............................................. 3.5 - 5.5 N·m
(0.36 - 0.56 m·kg; 31 - 49 lb-in.)
3. Route the new shift cables along the frame.
1 Y-1462
Figure 6-3
5. Remove the wire tie (Figure 6-3, (1))
securing cables to the frame.
6. Remove the flange bolt (Figure 6-3, (2))
holding the shift cable equalizer bracket to the
shifting shaft.
7. Remove the cables from the shaft and slide
cables out of the bracket on top of the
transaxle.
8. Remove the cables from the golf car.

Replace the Drive Belt DRIVE TRAIN

9. Adjust the shift cables. See Adjust the Shift
Cable on page 3-13.
10. Install the seat and the rear access panel.
1 REPLACE THE DRIVE BELT

See Replace the Drive Belt on page 3-13 in the
Periodic Maintenance section for drive belt
replacement.
2
PRIMARY SHEAVE ASSEMBLY
Remove the Primary Sheave
Assembly
Y-1463
1. Remove the seat and the rear access panel.
Figure 6-5 2. Remove the starter/generator belt.
4. The FORWARD position of the shift cable 3. Remove the drive belt. See Replace the Drive
equalizer bracket is the cable closest to the Belt on page 3-13.
engine and is attached at the top of the shift
lever (Figure 6-5, (1)).
5. The REVERSE position of the shift cable
equalizer bracket is the cable closest to the
rear of the car and is attached at the bottom
of the shift lever (Figure 6-5, (2)).
1
6
Y-1445
Figure 6-7
4. Put a floor jack under the left side of the frame
and raise until the jack just supports the car.
1
Y-1468A
Figure 6-6
6. Install cables to the shift lever with clevis pins,
washers and cotter pins (Figure 6-6, (2)).
7. Slide cables into slots on shift lever bracket
and loosely tighten adjustment nuts
(Figure 6-6, (1)).
8. Secure the cables to the frame using a wire
tie (Figure 6-4, (1)).

DRIVE TRAIN Primary Sheave Assembly
Y-1446
Figure 6-8
5. Disconnect the rear connecting rod on the left Y-1349
side (Figure 6-8, (1)). Figure 6-10

6. Remove the left rear shock upper mounting
9. Thread the primary sheave assembly puller
bolt (Figure 6-8, (2)).
YG-1890-B (Figure 6-10, (1)) into the sheave
assembly. Hold the sheave assembly with a
strap wrench and tighten the puller to remove
sheave assembly.
1 Special Tool:
Primary Sheave Assembly Puller.... YG-1890-B
Disassemble and Inspect the

1. Clear an area on a workbench with a vise to
disassemble sheave assembly.
1
Y-1348
2
Figure 6-9
7. Using the hydraulic jack, raise the left side of
the car until primary sheave assembly
retaining bolt has clearance from the frame.
8. Remove primary sheave assembly retaining
bolt (Figure 6-9, (1)). 1 1
Y-1350
Figure 6-11
2. Remove the cover bolts (Figure 6-10, (1))
and remove cover (Figure 6-10, (2)).

Primary Sheave Assembly DRIVE TRAIN
3 1
1
Y-1352
Figure 6-12 Y-1354
3. Mount the holding tool YS-38518-A Figure 6-14

(Figure 6-12, (1)) into a vise.
7. Remove washer (Figure 6-14, (1)) and
Special Tool: weights (Figure 6-14, (2)).
Primary Sheave Assembly 8. Inspect the fixed sheave shaft
Holder .............................................. YS-38518-A (Figure 6-14, (3)) for grooves or scratches.
4. Install sheave assembly on top of holding tool. Remove any buildup from the shaft.
9. If there are deep scratches or gouges on
1 shaft, the sheave assembly must be replaced.
2
1
6
Y-1355
Y-1353
Figure 6-15
Figure 6-13
10. Inspect the wear surfaces of the weights
5. Install sheave assembly spider removal tool (Figure 6-15, (1 and 2)). Replace all six
YG-42131-B (Figure 6-13, (1)) so the pins weights if there are any flat spots or gouges
from the tool fit in the grooves of the spider found on any of the weights.
(Figure 6-13, (2)).
Special Tool:
Sheave Assembly Spider Tool .......YG-42131-B
6. Using a breaker bar, turn counterclockwise to
remove the spider tool.

DRIVE TRAIN Primary Sheave Assembly
Assemble the Primary Sheave

1 Assembly
2
1. Install sheave assembly fixed sheave onto
sheave assembly holding tool for assembly of
sheave assembly.
3 1
Y-1356
Figure 6-16
2
11. Inspect the movable sheave weight wear
surfaces (Figure 6-16, (1)) for flat spots or
gouges.
12. Inspect the bushing (Figure 6-16, (2)).
Y-1354
Figure 6-18
1 2. Install the movable sheave onto the fixed
2 sheave shaft.
3. Install the washer (Figure 6-18, (1)) onto the
shaft.
4. Install the weights (Figure 6-18, (2)) into the
grooves in the movable sheave.
Y-1357
Figure 6-17
13. Inspect the weight wear area 2
(Figure 6-17, (1)) of the spider for flat spots
or gouges.
14. Inspect the slides (Figure 6-17, (2)). The
slides should fit tightly on the spider and not
be loose.
Y-1459
Figure 6-19

Primary Sheave Assembly DRIVE TRAIN
NOTE:
The primary sheave assembly is balanced as
an assembly. When assembling the sheave
assembly index marks must be lined up with
each other.
5. Line up the index mark on the spider

(Figure 6-19, (1)) with the index mark on the
movable sheave (Figure 6-19, (2)).
6. Install the spider onto the movable sheave,
sliding the slides onto the towers of the 2 1
movable sheave. Make sure to align the index
marks on the spider and the movable sheave. Y-1348
Figure 6-21
1
9. When installing the cover the “X” on the cover
(Figure 6-21, (1)) and the “X” on the spider
(Figure 6-21, (2)) must line up with each
other.
1 1
Y-1353
Figure 6-20
7. Install the spider tool YG-42131-B
(Figure 6-20, (1)) into the grooves of the
6
spider (Figure 6-20, (2)).
Y-1350
8. Tighten the spider to specification.
Figure 6-22
Specification:
10. Install sheave assembly cover
Primary Sheave Assembly Spider (Figure 6-22, (2)) and cover bolts
Torque ...........................................237 - 305 N·m (Figure 6-22, (1)). Tighten bolts to
(24.2 - 31.1 m·kg; 175 - 225 lb-ft) specification.
Specification:
Sheave Assembly Cover Bolt
Torque............................................... 15 - 19 N·m
(15.2 - 19.4 m·kg; 132 - 168 lb-in.)

DRIVE TRAIN Secondary Sheave Assembly
Install the Primary Sheave Install the Secondary Sheave

Assembly Assembly
Installation is done in the reverse of removal with Installation is done in the reverse of removal with
the following notes: the following notes:
• Tighten all fasteners to the specified torque. • Clean the splined input shaft of the transaxle
Specification: and apply a light film of anti seize compound
to the shaft before installing the sheave
Primary Sheave Assembly Bolt assembly.
Torque .............................................70 - 100 N·m
(7.1 - 10.2 m·kg; 52 - 74 lb-ft) • Tighten all fasteners to the specified torque.
Specification:
Upper Rear Shock Absorber Bolt
Torque ...............................................24 - 39 N·m Secondary Sheave Assembly Bolt
(2.4 - 3.8 m·kg; 17 - 28 lb-ft) Torque............................................... 33 - 52 N·m
(3.4 - 5.3 m·kg; 24 - 38 lb-ft)
Suspension Connecting Rod Nut
Torque ...................................................... 90 N·m
(9.2 m·kg; 66 lb-ft) TRANSAXLE - YDRA
(GAS CAR)
SECONDARY SHEAVE Remove the Transaxle - YDRA
ASSEMBLY 1. Park the vehicle on a flat surface.
Remove the Secondary Sheave 2. Block the front wheels.
Assembly 3. Remove the seat.
1. Remove the seat.
2. Remove the drive belt. See Replace the Drive Belt on page 3-13.
Belt on page 3-13.
6. Remove secondary sheave assembly. See
Secondary Sheave Assembly on page 6-10.
1
1
Y-1395
Figure 6-23 Y-1453
3. Remove the sheave assembly retaining bolt Figure 6-24

(Figure 6-23, (1)). 7. Remove retaining nut (Figure 6-24, (1)).
4. Slide the sheave assembly off the splined Remove choke cable from the body.
input shaft of the transaxle.

Transaxle - YDRA (Gas Car) DRIVE TRAIN
1
2 1
Y-1193
Figure 6-25
(Figure 6-25, (1)) and two bolts
(Figure 6-25, (2)). Remove the bag tray
insert.
9. Remove rear access panel.
10. Raise the rear of the vehicle and lower onto
jack stands under the rear frame.
11. Place a hydraulic jack under the transaxle to
support it.
12. Remove the rear wheels. 2
3
Y-1467A
Figure 6-26
13. Remove flange bolt and washer
(Figure 6-26, (1)) from the shifting shaft.
Slide shift lever off the shaft.
14. Slide transaxle vent tube (Figure 6-26, (3))
out of bracket (Figure 6-26, (2)) on transaxle.
15. Remove two bolts holding bracket
(Figure 6-26, (2)) to transaxle.
16. Move bracket, shift lever and cables toward
6
the front of car away from transaxle.

DRIVE TRAIN Transaxle - YDRA (Gas Car)
2
3 1
1 2
Y-1315
Figure 6-27 Y-1317
17. Disconnect throttle cables Figure 6-29

(Figure 6-27, (1 and 2)) from the speed 19. Remove the cotter pin from pin
limiter. (Figure 6-29, (1)). Remove pin and washers
from brake arm.
CAUTION 20. Remove three bolts (Figure 6-29, (2)). Move
Watch the solenoid wires when lowering the bracket (Figure 6-29, (3)) and cable away
transaxle. If the wires get too tight, remove from transaxle.
bolts (Figure 6-27, (3)) and allow solenoid to
rest on top of transaxle.
2
1 1
Y-1318
Figure 6-30
Y-1316
21. Remove the rear suspension connecting rod
Figure 6-28 bolts (Figure 6-30, (1)). Remove connecting
18. Remove throttle cable bracket rod.
(Figure 6-28, (1)) with the cable attached 22. Remove the rear shock lower mounting bolts
from the transaxle. (Figure 6-30, (2)).
CAUTION
Watch the solenoid wires when lowering the
transaxle. If the wires get too tight, remove
bolts (Figure 6-27, (3)) and allow solenoid to
rest on top of transaxle.


23. Using the hydraulic jack, slowly lower the Install the Transaxle - YDRA
transaxle and rear suspension assembly to
the floor. Installation is done in the reverse of removal with
the following notes:
• Tighten all fasteners to the specified torque.
• Adjust the shift cables. See Adjust the Shift
Cable on page 3-13.
1
• Adjust the brake cable.
• Adjust throttle cables. See Check and Adjust
the Speed Limiter on page 3-24.
Specification:
Shift Cable Equalizer Bracket Bolt
Torque............................................. 3.5 - 5.5 N·m
(0.4 - 0.6 m·kg; 31 - 49 lb-in.)
Transaxle Mounting Bolt
Torque...................................................... 64 N·m
Y-1319
(6.5 m·kg; 47 lb-ft)
Figure 6-31
Lower Rear Shock Absorber Bolt
24. Remove four transaxle mounting bolts Torque............................................... 24 - 39 N·m
(Figure 6-31, (1)) from each side of axle. (2.4 - 3.8 m·kg; 30 - 37 lb-ft)
25. With the help of an assistant, lift up and slide
the transaxle assembly from vehicle. Suspension Connecting Rod Nut
Torque...................................................... 90 N·m
(9.2 m·kg; 66 lb-ft)
Lug Nut Torque ....................................... 88 N·m
(9.0 m·kg; 65 lb-ft)

Disassemble the Transaxle - YDRA
24
23 31
22 12
30
21
16
20 29
28
27
25
26
14
11
19 32
11
19
11 25
19
11
19 33
8 11
17
7 16 35 34
15 18 35 36
13
38 37
12
11 39
40
10
9 41
6 42
5
43
4 44 56
45
46 55
47
38
54
48
3
3 5
2 6
1
49
50
51 Y-1425
53 52
Figure 6-32


1. Brake Lever and Shaft Assembly 28. Retaining Ring
2. Brake Return Spring 29. Differential Carrier Assembly
3. Flat Washer (two used) 30. Side Gear, Short (Left Side)
4. Case Assembly, Right Side 31. Shim (as required)
5. Flat Washer, Speed Limiter Shaft 32. Bolt, 5/16-18 x 1.25 Self-Tapping
(two used) (15 used)
6. Retaining Ring, Speed Limiter Shaft 33. Bracket, Speed Limiter Cable
(two used) 34. Case Assembly, Left Side
7. Vent Hose 35. Washer, Idler Gear (two used)
8. Spring, Ball Ramp Return 36. Idler Gear Assembly
9. Ball (6 used) 37. Retaining Ring
10. Ball Ramp Plate 38. Ball Bearing (two used)
11. Friction Plate (five used) 39. Thrust Washer
12. Bearing (two used) 40. Reverse Gear
13. Friction Plate, 37 spline 41. Shift Dog
14. Axle Assembly, Right Side 42. Mid Shaft
15. Side Gear, Long (Right Side) 43. Forward Gear
16. Needle Bearing 44. Thrust Washer
17. Carrier Reaction Plate 45. Retaining Ring
18. Shift Fork and Shaft Assembly 46. Mid Shaft Gear
19. Steel Reaction Plate, 0.090 in. thick 47. Spacer
(five used) 48. Retaining Ring
20. Axle Assembly, Left Side 49. Speed Limiter Lever and Shaft
21. Spring, Brake Release (two used) Assembly
22. Top Plate 50. Clip
23. Flat Head Capscrew, 5/16-18 x 2.5 in. 51. J-Clip
(four used) 52. Bracket, Brake Cable
24. Flat Head Capscrew, 5/16-18 x 1.0 in. 53. Bolt, 5/16-18 x 0.75 in. (three used)
(three used)
54. Input Shaft
25. Oil Servicing Plug (two used)
55. Shim (as required)
26. Shift Lever and Shaft Assembly
56. Seal, Dual Lip
27. Flat Washer, Shifter Shaft

Remove the Main Case and Gears

1. Remove transaxle from car. See Remove the
Transaxle - YDRA on page 6-10.
2. Remove the lower oil servicing plug and drain
the oil from transaxle. Keep transaxle in the
normal installed position while draining oil.
Y-1397
Figure 6-34
5. Use a pry bar and spread the case apart
(Figure 6-34) at two locations.
Y-1396
Figure 6-33 Y-1398
3. Place the transaxle in the vertical position. Figure 6-35

Use the special tool fixture for properly 6. Remove idler gear retaining ring
holding the transaxle during disassembly or (Figure 6-35, (1)).
assembly (Figure 6-33).
7. Remove the input shaft (Figure 6-35, (2)) and
Special Tool: idler gear (Figure 6-35, (3)) from the case at
Tool Fixture ................................ P/N YGCC-005 the same time.
4. Remove 15 bolts that fasten the two case 8. Remove any remaining thrust washers.
halves together.


Disassemble the Brake
1
2
Y-1401
Figure 6-38
1. Use a 3/16 in. hex socket to remove seven flat
head hex socket screws (Figure 6-38, (1))
Y-1399
that secure the top plate (Figure 6-38, (2)) to
Figure 6-36 the case. Remove the top plate.
9. Remove the intermediate shaft assembly
(Figure 6-36) along with shift fork and shaft
assembly.
1 6
Y-1408
Figure 6-39
Y-1400
2. Slide out the friction plates and reaction
plates from spacer tubes (Figure 6-39, (1)).
Figure 6-37
10. Remove the ring gear assembly
(Figure 6-37).

2
2
Y-1407 Y-1402

3. Remove side gear and friction plate assembly.
Remove remaining reaction plate NOTE:
(Figure 6-40).
All four spacer tubes (Figure 6-42, (2)) should
remain secured to the case.
1
5. Remove six balls (Figure 6-42, (1)).
2 Disassemble the Side Gear
2
Y-1405
Figure 6-41
4. Remove ball ramp plate (Figure 6-41, (1)) 1
and spring (Figure 6-41, (2)).
3
Y-1365
Figure 6-43
NOTE:
Right side gear is shown. Left side gear does
not couple to a friction plate.
1. Press off the external bearing

(Figure 6-43, (3)) from the side gear
(Figure 6-43, (2)).
2. Remove the splined friction brake plate
(Figure 6-43, (1)) (right side gear only).


3. Press out the internal needle bearing with Remove Axle Assembly
recommended tool.
Special Tool: NOTE:
Needle Bearing Remover ................P/N 650304 Axle assemblies can remain installed in the
case when servicing internal drive train and
Remove the Brake Lever and Spring brake components unless replacement of the
bearings or seals is necessary.
NOTE:
The lever assembly should not need to be
removed unless the seal is leaking or spring is
broken.
Y-1367
Figure 6-46
1. Remove retaining ring from case
(Figure 6-46).
Y-1403
2. Pull axle assembly out of case. Use a
Figure 6-44 non-metallic hammer to drive the axle out if
1. Remove retaining ring (Figure 6-44, (1)) and necessary.
washer (Figure 6-44, (2)).
6
3
2 1
Y-1404
Figure 6-45
2. Unhook the spring leg (Figure 6-45, (1)) from
the case groove using pliers.
3. Remove the lever (Figure 6-45, (2)), spring
and washer (Figure 6-45, (3)) from the case.

Disassemble the Carrier Assembly Inspect condition of brake shaft bearing and seal.
Replace if necessary.
1
3. Inspect condition of axle seals and bearings.
Replace if necessary.
2 4. Inspect brake plates for wear:
(a) Inspect all components for uneven or
excessive wear.
3 4
4
3
5 Y-1487
Figure 6-47
1. Capscrew (eight used)
2. Ring Gear
Figure 6-48
3. Pinion Gear (two used)
4. Dowel Pin (two used) (b) Measure the depth of the cross-grooves
5. Differential Carrier on the brake friction plates.
(c) Measure the thickness of the steel
1. Remove the capscrews (Figure 6-47, (1)) reaction plates.
and remove the ring gear (Figure 6-47, (2))
Replace components that are damaged or not
from the carrier (Figure 6-47, (5)).
2. Remove the pinion gears (Figure 6-47, (3))
and slide the dowel pins (Figure 6-47, (4)) out Specification:
of the carrier assembly. Brake Friction Plate Groove Depth
<Limit>................................. 0.38 mm (0.015 in.)
NOTE: Brake Friction Plate Thickness
The shaft is pressed into the carrier at the <Limit>................................. 1.91 mm (0.075 in.)
factory and cannot be serviced separately. Splined Friction Plate Thickness
<Limit>................................. 2.92 mm (0.115 in.)
Reaction Plate Thickness
Inspect the Transaxle <Limit>................................. 2.03 mm (0.080 in.)
5. Measure spring free length. Replace any
CAUTION spring that is less than specification.
Do not wash the brake disc in a parts cleaning Specification:
solvent. Damage to the brake disc will occur Brake Spring Free Length
and braking performance will be affected. <Limit>..................................... 38.1 mm (1.5 in.)
Only use a clean lint-free shop towel to wipe
off the brake discs.
Wash all components except the brake discs with

parts cleaning solvent. Dry the components prior
to inspection.


Assemble the Transaxle
Assemble the Side Gear
Bearing A
2
Bearing text
facing out this
side
1
3
Side Gear
Y-1383 Y-1365
Figure 6-49
Figure 6-50
3. Slide friction plate (Figure 6-50, (1)) over
NOTE:
spline (Figure 6-50, (2)) (left side gear only).
Apply a small amount of multipurpose bearing 4. Press bearing (Figure 6-50, (3)) onto side
grease to the needle bearing before final gear.
assembly into the transaxle.
1. Place new needle bearing in side gear bore

with the text facing out.
2. Press needle bearing to the specified depth
(Figure 6-49, (A)).
Specification:
Needle Bearing Installed Depth:
Right Side Gear....................... 41.02 ± 5.08 mm
(1.615 ± 0.20 in.)
Left Side Gear ......................... 30.73 ± 5.08 mm
(1.210 ± 0.20 in.) 6

Assemble the Axle
8
7
6
5
10
2
A
1 Y-1384
Figure 6-52
4. Install the seal sleeve ring 28.4 ± 0.5 mm
9
(1.12 ± 0.020 in.) from the end of the axle
Y-1387 (Figure 6-52, (A)).
Figure 6-51 Assemble the Transaxle

1. Axle Shaft
2. Bearing NOTE:
3. Retaining Ring Lubricate all internal components with SAE80
4. Spacer W90 API GL- 5 Limited Slip High Performance
5. Wheel Hub Gear Oil during assembly.
6. Axle Nut
7. Nut Retainer 1. Ensure all parts are clean and free of debris.
8. Cotter Pin
9. Sleeve Seal Ring 2. If removed, install the brake lever bushing and
seal. Caution should be taken during
10. Lug Bolts
installation to not damage the internal surface
of the bushing or the ID of the seal.
NOTE:
Left axle is shown. Right axle is similar.
1. If removed, press a new bearing onto axle

using a hydraulic press. Support the bearing
on the inner race during the pressing
operation.
2. Slide on the spacer tube and assemble the
hub onto the axle shaft.
3. Install and tighten the axle nut to
specification. Install the nut retainer and
cotter pin.
Specification:
Rear Axle Nut
Torque .............................................88 - 102 N·m
(9 - 10.4 m·kg; 65 - 75 lb-ft)

2 1
Y-1404 Y-1367

3. Install the brake lever (Figure 6-53, (2)), 7. Install the retaining rings into grooves
washer (Figure 6-53, (3)) and spring (Figure 6-55).
(Figure 6-53, (1)) to the housing. Hook the
spring leg onto the boss on the case.
1
Y-1403
Figure 6-56
Y-1369
6
Figure 6-54 8. Visually inspect the axle seal to ensure it is
properly seated around the axle seal sleeve
4. Install washer (Figure 6-54, (2)) and retaining (Figure 6-56, (1)).
ring (Figure 6-54, (1)). Ensure the retaining
ring is properly seated.
CAUTION
5. Lubricate the sleeve seal surface with
multipurpose grease before installing the axle Use care not to gouge the gasket mounting
into the case. surface when removing old gasket material.
NOTE: 9. Clean gasket surfaces on both case halves.

Care should be taken not to knock out the
internal axle seals when installing the axles.
6. Install axle assemblies into case halves. Use

a non-metallic hammer to assist with
installation.

1
4 1 2
2
3
Y-1402A Y-1406

10. Secure the right case half in the bench fixture 16. Install the first steel reaction plate
as shown in (Figure 6-57). (Figure 6-59, (1)) as shown over spacer
11. Ensure both dowel pins (Figure 6-57, (1)) are tubes 2 and 4.
installed in the case. 17. Install two springs (Figure 6-59, (2)) onto
12. Install thrust washers. Secure with retaining spacer tubes 2 and 4 as shown.
rings.
13. Install six steel balls (Figure 6-57, (3)) into
the pockets in the case. Ensure spacer tubes
are secure.
14. Install mid shaft bearing (Figure 6-57, (4)) in
the case. Ensure bearing is fully seated in the
bore.
Y-1407
Figure 6-60
18. Install the side gear and plate assembly into
the bearing bore (Figure 6-60). Use a
non-metallic hammer to ensure the
subassembly is fully seated in the bearing
bore.
Y-1405
Figure 6-58
15. Install the ball ramp plate (Figure 6-58, (1))
and return spring (Figure 6-58, (2)).

Y-1408
Figure 6-61
WARNING
The arrangement of the plates is critical. The
order of installation must be followed or
braking performance will be adversely
affected.
19. Install the remaining plates in the order listed

Y-1410
below.
CAUTION
All remaining steel reaction plates must be
slipped over spacer tubes 1 and 3
(Figure 6-61, (1)).
Center and align all friction plates.
See Figure 6-32 for assembly order.

6
(a) Carrier reaction plate (center and align to
other friction plates in stack)
(Figure 6-32, (17)).
Y-1411
(b) Friction plate (Figure 6-32, (11)).
(c) Steel reaction plate (Figure 6-32, (19)). Figure 6-62
(d) Friction plate (Figure 6-32, (11)). 20. Check the gap between the top plate
(e) Steel reaction plate (Figure 6-32, (19)). mounting surface on the case and the top
friction plate with a caliper (Figure 6-62). The
(f) Friction plate (Figure 6-32, (11)). gap should be between 0.254 and 1.778 mm
(g) Steel reaction plate (Figure 6-32, (19)). (0.010 and 0.070 in).
(h) Friction plate (Figure 6-32, (11)).
(i) Steel reaction plate (Figure 6-32, (19)).
(j) Friction plate (Figure 6-32, (11)).

WARNING
Double-check the sequence of the plates in
the stack before final assembly. It is critical to 1
have the brake plate stack order correct or
braking performance and safety will be
compromised.
Y-1377
Figure 6-64
22. Center and align the six tabs
(Figure 6-64, (1)) for all of the friction plates.
i
2
Y-1409
Figure 6-63
NOTE: 3 4
Alternately tighten screws in a crisscross
pattern.
21. Secure the top plate to the case using seven

new flat head hex socket screws
(Figure 6-63). The four longer screws are 4
3
piloted through the spacer tubes that are 5 Y-1487
pressed into the case half. Tighten fasteners
to specification in a crisscross pattern. Check Figure 6-65
the upper friction plate for free movement 1. Capscrew (eight used)
after the top plate is installed to ensure no 2. Ring Gear
binding occurs.
Specification: 4. Dowel Pin (two used)
Brake Assembly Top Plate Screw 5. Differential Carrier
Torque ...............................................24 - 29 N·m
(2.5 - 3.0 m·kg; 18 - 21 lb-ft) 23. Install dowel pins (Figure 6-65, (4)) into
carrier (Figure 6-65, (5)).
24. Install pinion gears (Figure 6-65, (3)) onto the
dowel pins.
25. Apply medium-strength thread lock and
sealer Yamaha part number
ACC-24221-TL-00 to the threads of the
capscrews (Figure 6-65, (1)).


26. Install the ring gear (Figure 6-65, (2)) to the (c) Subtract the stack measurement from the
differential carrier assembly with capscrews. nominal bearing pocket depth
Tighten to specification. measurement of 17.12 mm (0.674 in.).
Specification: The desired gap between the gear stack,
shim and bearing pocket should be set at
Ring Gear Capscrews 0.35 ± 0.07 mm (0.014 ± 0.003 in.). Install
Torque ...............................................65 - 79 N·m shims as required. All shims should be
(6.6 - 8.1 m·kg; 48 - 58 lb-ft) installed in the left side case bearing
pocket.
Y-1413
Y-1414
Figure 6-66
Figure 6-67
27. Install the ring gear assembly by inserting the
six posts through the brake plate stack 28. Install shim(s) as required in left side case
(Figure 6-66). Slightly rock the ring gear (Figure 6-67).
assembly back and forth while situating it into
the stack.
NOTE:
If the ring gear assembly is not fully seated, the
transaxle output will not be free to differentiate
after assembly. This will be due to the case
halves pinching the ring gear assembly.
6
Determine the Output Shaft Shim Thickness
NOTE:
Determining the required shim thickness is only
Y-1415
necessary when installing new cases, side
gears or ring gear assembly. Figure 6-68
29. Install left side gear into the left side case
(Figure 6-68).
(a) Temporarily set the side gear over the ring
gear assembly.
(b) From the case gasket face, measure the
distance to the top surface of bearing on
side gear. Record the value as “stack
measurement.”

Determine the Input Shaft Shim Thickness

The required gap between the input shaft
bearings and the case bearing bores is
0.25 ± 0.12 mm (0.010 ± 0.005 in.).
(a) Measure the overall length (from bearing
to bearing) of the input shaft.
(b) Subtract the measured length from the
theoretical bore-to-bore measurement of
199.2 mm (7.843 in.). Subtract an
additional 0.25 mm (0.010 in.) from this
value.
(c) Select shims to obtain a measurement of
±0.07 mm (±0.003 in.) of the calculated
value in step b.
1. Install input shaft seal flush with the case
bore. Apply a thin coat of multipurpose grease
to the lips of the seal.
Y-1416
1
3
Y-1417 2
Figure 6-69
30. Assemble mid shaft components.
Y-1419
31. Place the shift fork into the groove of the shift
dog. Lower the mid shaft and shift fork and Figure 6-70
shaft assembly in place in the housing
(Figure 6-69).
NOTE:
The idler gear and input shaft must be installed
at the same time. Ensure the idler gear is
oriented properly as shown in (Figure 6-70).


2. Install a thrust washer (Figure 6-70, (2)) and 6. Apply a thin layer of Loctite 5699 High
retaining ring (Figure 6-70, (3)) on the idler Performance RTV Silicone gasket sealant (or
gear shaft (Figure 6-70, (1)). equivalent) (Figure 6-72) to gasket mounting
3. Install the input shaft assembly and idler gear surface. Apply sealant around the bolt hole
at the same time. Use a non-metallic hammer pattern to prevent leakage.
to ensure the input shaft is seated in the
bearing bore.
I
Y-1422
Y-1420
Figure 6-73
Figure 6-71
7. Carefully lower the right side case onto the
4. Install the shift lever components into the left side case. Ensure the shift lever fork
case. Install outer washer and retaining ring (Figure 6-73, (1)) engages the pin
(Figure 6-71, (1)). (Figure 6-73, (2)) on the shift fork.
Y-1421 Y-1423
NOTE: NOTE:
Ensure the sealant is applied to clean surfaces. Alternately tighten bolts in a crisscross pattern.
Apply around the internal side of the bolt holes.
8. Install 15 5/16-18 x 1.50 in. self-tapping bolts

5. Use a solvent such as lacquer thinner to clean (Figure 6-74).
all oil and grease residue from the case
9. Tighten all bolts alternately to specification.
sealing surfaces.

Specification: 16. Check for leaks before filling with oil.

Transaxle Case Bolt (a) Temporarily install both oil servicing plugs
Torque ...............................................27 - 34 N·m and tighten to specification.
(2.8 - 3.5 m·kg; 20 - 25 lb-ft) (b) Apply a 34 kPa (5 psi) maximum air source
10. Wipe away excess sealant. through the vent tube and check for leaks
at the seals, ports, O-rings and gasket
11. Check for free rotation of the differential by locations.
spinning one axle by hand. This should
require minimal effort, 2 - 3 N·m (18 - 30 17. Fill transaxle with 1750 ml (44 oz) SAE80
lb-in.), by hand. If resistance is found, a W90 API GL-5 Limited Slip High Performance
problem with the assembly is indicated. Gear Oil.
Disassemble and correct the cause of the 18. Install oil servicing plug and tighten to
binding. specification.
12. Place the transaxle in the normal installed 19. Install vent hose.
position.
13. Install the brake bracket to the case with three
bolts. Tighten bolts to specification.
Specification:
Brake Cable Bracket-to-Case Bolt
Torque ...............................................23 - 27 N·m
(2.3 - 2.8 m·kg; 204 - 240 lb-in.)
Y-1424
Figure 6-75
14. Install the shift cable bracket. Tighten bolts to
specification.
Specification:
Shift Cable Bracket-to-Case Bolt
Torque ...............................................23 - 27 N·m
(2.3 - 2.8 m·kg; 204 - 240 lb-in.)
15. Install lower oil servicing plug. Tighten to
specification.
Specification:
Torque ................................................... 16.3 N·m
(1.66 m·kg, 144 lb-in.)

Transaxle - YDRE (Electric Car) DRIVE TRAIN
TRANSAXLE - YDRE
(ELECTRIC CAR)
Remove the Transaxle - YDRE 1
1. Park the vehicle on a flat surface.

2. Block the front wheels.
3. Remove the seat.
2 1
Y-1207
Figure 6-78
8. Disconnect the wire connector
(Figure 6-78, (1)) from the speed sensor.
9. Slide transaxle breather tube out of brake
cable bracket.
Y-1193
10. Jack up the rear of the vehicle and place jack
stands under the rear frame.
Figure 6-76
11. Place a hydraulic jack under the transaxle to
4. Remove seven plastic rivets support it.
(Figure 6-76, (1)) and two bolts 12. Remove the rear wheels.
(Figure 6-76, (2)). Remove the bag tray
insert.
1
3 1
2 6
2
1 Y-1229
Figure 6-79
13. Remove the cotter pin (Figure 6-79, (1)) from
Y-1206
pin (Figure 6-79, (2)). Remove pin and
Figure 6-77 washers from brake arm.
6. Disconnect wires (Figure 6-77, (1)) from the 14. Remove three bolts (Figure 6-79, (3)) holding
traction motor. brake cable bracket (Figure 6-79, (4)) to
7. Remove wire tie and remove harness from transaxle and move cable and bracket toward
clamp bracket (Figure 6-77, (2)). the front of vehicle.

DRIVE TRAIN Transaxle - YDRE (Electric Car)
Install the Transaxle - YDRE

Installation is done in the reverse of removal with
2 1 2 the following notes:
• Tighten all fasteners to the specified torque.
• Adjust the brake cable.
Specification:
Transaxle Mounting Bolt
Torque...................................................... 64 N·m
(6.5 m·kg; 47 lb-ft)
Lower Rear Shock Absorber Bolt
Torque............................................... 24 - 39 N·m
(2.4 - 3.8 m·kg; 17 - 28 lb-ft)
Y-1230 Suspension Connecting

Rod Nut Torque....................................... 90 N·m
Figure 6-80 (9.2 m·kg; 66 lb-ft)
(Figure 6-80, (1)). Traction Motor Cable “A” Nut
Torque..................................................... 6.8 N·m
16. Remove the rear shock lower mounting bolts (0.6 m·kg; 60 lb-in.)
(Figure 6-80, (2)).
17. Using the hydraulic jack, slowly lower the Traction Motor Cable “F” Nut
transaxle and rear suspension assembly to Torque..................................................... 5.4 N·m
the floor. (0.5 m·kg; 47 lb-in.)
1 1
Y-1231
Figure 6-81
18. Remove four transaxle mounting bolts
(Figure 6-81, (1)) from each side of axle.
19. With the help of an assistant, lift up and slide
the transaxle assembly from vehicle.


Disassemble the Transaxle - YDRE
13
18
17
20
16
12 21
19
11
22
10 24
23
26
9 25
15 27
16
8
29
14 28
1
7
23
3
30
6 28
5
4 31
23
3
28
23
2
32
28
36 23
28
40
38
37
35
34
33
6
39
Y-1385
Figure 6-82
1. Axle Assembly, Right Side 13. Axle Assembly, Left Side

2. Bolt, 5/16-18 x 1.25 Self-Tapping 14. Seal, Dual Lip
(10 used) 15. Intermediate Shaft Assembly
3. Oil Servicing Plugs 16. Flat Washer (two used)
4. Label, Transmission Identification 17. Brake Return Spring
5. Vent Hose, 1/4 in. ID 18. Brake Lever and Shaft Assembly
6. Shim, 0.006 in. (as required) 19. Bolt, 5/16-18 x 0.75 in.
7. Ball Bearing 20. Spring, Ball Ramp Return, 1.5 in.
8. Side Gear, Short (Right Side) 21. Ball (six used)
9. Needle Bearing 22. Ball Ramp Plate
10. Differential Carrier Assembly 23. Steel Reaction Plate, 0.090 in. thick
11. Side Gear, Long (Left Side) (five used)
12. Ball Bearing 24. Brake Cable Bracket

25. Friction Plate, 37 Spline Disassemble the Main Case and Gears
26. Case Assembly, Left Side 1. Remove transaxle from car. See Remove the
27. Carrier Reaction Plate Transaxle - YDRE on page 6-31.
28. Friction Plate (five used)
2. Remove the oil servicing plug and drain the oil
29. Retaining Ring, 25 mm
from transaxle. Keep transaxle in the normal
30. Input Shaft Assembly installed position while draining oil.
31. Case Assembly, Right Side
32. Spring, Brake Release, 2 in. (two used)
33. Top Plate
34. Flat Head Capscrew, 5/16-18 x 1 in.
(three used)
35. Flat Head Capscrew, 5/16-18 x 2.5 in.
(four used)
36. Bolt, 5/16-18 x 1.5 in. Washer Head
(four used)
37. O-Ring, Motor Flange
38. Motor Flange
39. Bolt, 5/16-18 x 0.875 in. (four used)
40. Seal, Triple Lip
Y-1358
Figure 6-83
3. Place the transaxle in the vertical position.
Use the special tool fixture for properly
holding the transaxle during disassembly or
assembly (Figure 6-83).
Special Tool:
Tool Fixture .................................P/N YGCC-005

2
1
Y-1382 Y-1361

4. Make an alignment mark across the motor 8. Carefully pry the input shaft (Figure 6-86, (1))
flange and transaxle housing where they join. from the case. Be sure to keep shaft straight
5. Remove four motor flange bolts while prying.
(Figure 6-84). 9. Remove the intermediate shaft assembly
6. Remove 14 bolts that fasten the two case (Figure 6-86, (2)).
halves together. 10. Remove the ring gear assembly and side
gear.
Disassemble the Brake
6
Y-1360
Figure 6-85
7. Use a pry bar and spread the case apart Y-1362
(Figure 6-85) at three locations.
Figure 6-87
1. Use a 3/16 in. hex socket to remove seven flat
head hex socket screws (Figure 6-87, (1))
that secure the top plate (Figure 6-87, (2)) to
the case. Remove the top plate.

1 2
Y-1373A Y-1363

2. Lift out the friction plates, reaction plates and
springs (Figure 6-88, (1)). NOTE:
3. Remove friction plate and side gear assembly All four spacer tubes (Figure 6-90, (2)) should
(Figure 6-88, (2)) and the carrier reaction remain installed in the case.
plate.
5. Remove six balls (Figure 6-90, (1)).

1
Disassemble the Side Gear
Y-1405
1
Figure 6-89
3
4. Remove the ball ramp (Figure 6-89, (1)) and
spring (Figure 6-89, (2)). Y-1365
Figure 6-91
NOTE:
Left side gear is shown. Right side gear does
not couple to a friction plate.
1. Press off the external bearing

(Figure 6-91, (3)) from the side gear
(Figure 6-91, (2)).
2. Remove the splined friction brake plate
(Figure 6-91, (1)) (left side gear only).


3. Press out the internal needle bearing with Remove the Axle Assembly
recommended tool.
Special Tool: NOTE:
Needle Bearing Remover ................P/N 650304 Axle assemblies can remain installed in the
case when servicing internal drive train and
Remove the Brake Lever and Spring brake components unless replacement of the
bearings or seals is necessary.
NOTE:
The lever assembly should not need to be
removed unless the seal is leaking or spring is
broken.
2
Y-1367
Figure 6-94
1. Remove retaining ring from case
(Figure 6-94).
Y-1366
2. Pull axle assembly out of case. Use a
Figure 6-92 non-metallic hammer to drive axle out if
1. Remove retaining ring (Figure 6-92, (1)) and necessary.
washer (Figure 6-92, (2)).
6
2 1
Y-1368
Figure 6-93
2. Unhook the spring (Figure 6-93, (3)) leg from
the case groove using pliers.
3. Remove the lever (Figure 6-93, (1)), spring
and washer (Figure 6-93, (2)) from the case.

Disassemble the Carrier Assembly

5
1 3
3 4
6 1
4 2
3 Y-1386
5 Y-1487
Figure 6-96
Figure 6-95
1. Dowel Pin (two used)
1. Capscrew (eight used) 2. Spacer Tube (four used)
2. Ring Gear 3. Brake Shaft Bushing
3. Pinion Gear (two used) 4. Left Housing Assembly
4. Dowel Pin (two used) 5. Brake Shaft Seal
5. Differential Carrier 6. Axle Seal
1. Remove the capscrews (Figure 6-95, (1)) 1. Inspect condition of brake shaft bearing and
and remove the ring gear (Figure 6-95, (2)) seal. Replace as necessary.
from the carrier (Figure 6-95, (5)). 2. Inspect condition of axle seals and bearings.
2. Remove the bevel gears (Figure 6-95, (3)) Replace as necessary.
and slide the dowel pins (Figure 6-95, (4)) out 3. Inspect brake plates for wear:
of the carrier assembly.
(a) Inspect all components for uneven or
excessive wear.
NOTE:
The shaft is pressed into the carrier at the
factory and cannot be serviced separately.
Inspect the Transaxle
CAUTION
Do not wash the brake disc in a parts cleaning
solvent. Damage to the brake discs will occur
and braking performance may be affected.
Only use a clean, lint-free shop towel to wipe Figure 6-97
off the brake discs.
(b) Measure the depth of the cross grooves on
the brake friction plates.
Wash all components except the brake discs with
(c) Measure the thickness of the steel
parts cleaning solvent. Dry the components prior
reaction plates.
to inspection.


Replace components that are damaged or not Specification:
within specification. Needle Bearing Installed
Specification: Depth:
Left Side Gear ..........................41.02 ± 5.08 mm
Brake Friction Plate Groove (1.615 ± 0.020 in.)
Depth <Limit>......................0.25 mm (0.010 in.)
Brake Steel Reaction Plate Right Side Gear .......................30.73 ± 5.08 mm
Thickness <Limit>...............1.91 mm (0.075 in.) (1.210 ± 0.020 in.)
4. Measure spring free length. Replace any
spring that is less than specification.
Specification:
Ball Ramp Plate Return
Spring Free Length
<Limit> .....................................25.4 mm (1.0 in.)
Brake Plate Stack Return
Spring Free Length 2
<Limit> .....................................38.1 mm (1.5 in.)

1
Assemble the Side Gear 3
Bearing A Y-1365
Figure 6-99
3. Slide friction plate (Figure 6-99, (1)) over
spline (Figure 6-99, (2)) (left side gear only).
Bearing text
facing out this 4. Press bearing (Figure 6-99, (3)) onto side
gear.
side
Side Gear
Y-1383
Figure 6-98
6
NOTE:
Apply a small amount of multipurpose bearing
grease to the needle bearing before final
assembly into the transaxle.
1. Place new needle bearing in side gear bore

with the text facing out.
2. Press needle bearing to the specified depth
(Figure 6-98, (A)).

Assemble the Axle
8
7
6
5
10
2 A
1
Y-1384
Figure 6-101
9 4. Install the seal sleeve ring 28.4 ± 0.5 mm

(1.12 ± 0.020 in.) from the end of the axle
Y-1387 (Figure 6-101, (A)).

1. Axle Shaft
2. Bearing
3. Retaining Ring NOTE:
4. Spacer Lubricate all internal components with SAE80
5. Wheel Hub W90 API GL-5 Limited Slip High Performance
6. Axle Nut Gear Oil during assembly.
7. Nut Retainer
8. Cotter Pin
1. Ensure all parts are clean and free of debris.
9. Sleeve Seal Ring
10. Lug Bolts 2. If removed, install the brake lever bushing and
seal. Caution should be taken during
Figure 6-100
installation to not damage the internal surface
of the bushing or the ID of the seal.
NOTE:
Left axle is shown. Right axle is similar.
1. If removed, press new bearing onto axle

using a hydraulic press. Support the bearing
on the inner race during the pressing
operation.
2. Slide on the spacer tube and assemble the
hub onto the axle shaft.
3. Install and tighten the axle nut to
specification. Install the nut retainer and
cotter pin.
Specification:
Rear Axle Nut
Torque .............................................88 - 102 N·m
(9 - 10.4 m·kg; 65 - 75 lb-ft)

2 1
Y-1367
Y-1368
3. Insert the brake lever (Figure 6-102, (1)), 7. Install retaining rings into grooves
washer (Figure 6-102, (2)) and spring (Figure 6-104).
(Figure 6-102, (3)) into the housing. Hook
spring leg onto boss on the case.
1
Y-1366
Figure 6-105
Y-1369
6
8. Visually inspect the axle seal to ensure it is
Figure 6-103 properly seated around the axle seal sleeve
4. Install washer (Figure 6-103, (2)) and (Figure 6-105, (1)).
retaining ring (Figure 6-103, (1)). Ensure the
retaining ring is properly seated. NOTE:
5. Lubricate the sleeve seal surface with Use care not to gouge the gasket surface when
multipurpose grease before installing the axle removing old gasket material.
into the case.
NOTE:
9. Clean gasket surfaces on both case halves.
10. Set the left case half in an upright position
Care should be taken not to knock out the (Figure 6-83).
internal axle seals when installing the axles.
11. Ensure both dowel pins are installed in the
case.
6. Install axle assemblies into case halves. Use
a non-metallic hammer to assist with
installation.

2
5
1
4
3
Y-1363 Y-1371

12. Install six steel balls (Figure 6-106, (1)) into 14. Install the first steel reaction plate
pockets in the case. Ensure spacer tubes (Figure 6-108, (3)) as shown over spacer
(Figure 6-106, (2)) are secure. tubes 2 and 4.
15. Install both springs (Figure 6-108, (4)) onto
spacer tubes 2 and 4 as shown.
1
16. Install the side gear and plate assembly
(Figure 6-108, (5)) into the bearing bore. Use
a non-metallic hammer to ensure the
2 subassembly is fully seated in the bearing
bore.
Y-1405
Figure 6-107
13. Install the ball ramp plate (Figure 6-107, (1))
and return spring (Figure 6-107, (2)).

Y-1373 Y-1375
Figure 6-109
WARNING
The arrangement of the plates is critical. The
order of installation must be followed or
braking performance will be adversely
affected.
17. Place the remaining plates in the order listed

below.
NOTE:
All remaining steel reaction plates must be Y-1376
slipped over spacer tubes 1 and 3 Figure 6-110

(Figure 6-109, (1)).
18. Check the gap between the top plate
Center and align all friction plates.
mounting surface on case and the top friction
Reference (Figure 6-82) for assembly graphic. plate with a caliper (Figure 6-110). The gap
should be between 0.25 and 1.77 mm
(0.010 and 0.070 in.).
6
(a) Carrier plate (center and align to other
friction plates in stack)
(Figure 6-109, (27)). WARNING
(b) Friction plate (Figure 6-82, (28)). Double-check the sequence of the plates in
(c) Steel reaction plate (Figure 6-82, (23)). the stack before final assembly. It is critical to
have the brake plate stack order correct or
(d) Friction plate (Figure 6-82, (28)). braking performance and safety will be
(e) Steel reaction plate (Figure 6-82, (23)). compromised.
(f) Friction plate (Figure 6-82, (28)).
(g) Steel reaction plate (Figure 6-82, (23)).
(h) Friction plate (Figure 6-82, (28)).
(i) Steel reaction plate (Figure 6-82, (23)).
(j) Friction plate (Figure 6-82, (28)).

Y-1374 Y-1377

20. Center and align the six tabs
NOTE: (Figure 6-112, (1)) for all of the friction plates.
i
Alternately tighten screws in a crisscross

1
pattern.
19. Secure the top plate to the case using seven 2

new flat head hex socket screws. The four
longer screws are piloted through the spacer
tubes that are pressed into the case half.
Tighten fasteners to specification in a 3 4
crisscross pattern. Check the upper friction
plate for free movement after the top plate is
installed to ensure no binding occurs.
Specification:
Brake Assembly Top Plate Screw
Torque ...............................................24 - 29 N·m
4
(2.5 - 3.0 m·kg; 18 - 21 lb-ft) 3
5 Y-1487
Figure 6-113
1. Capscrew (eight used)
2. Ring Gear
4. Dowel Pin (two used)
5. Differential Carrier
21. Install dowel pins (Figure 6-113, (4)) into

carrier (Figure 6-113, (5)).
22. Install pinion gears (Figure 6-113, (3)) onto
dowel pins.
23. Apply medium strength thread lock and sealer
Yamaha part number ACC-24221-TL-00 to
the threads of the capscrews
(Figure 6-113, (1)).


24. Install the ring gear (Figure 6-113, (2)) to the
carrier assembly with capscrews. Tighten to
specification.
Specification:
Ring Gear Capscrew
Torque ...............................................65 - 79 N·m
(6.6 - 8.1 m·kg; 48 - 58 lb-ft)
25. Install the carrier gear assembly by inserting
the six posts through the brake plate stack.
Slightly rock the ring gear assembly back and
forth while situating it into the stack.
NOTE:
If the ring gear assembly is not fully seated, the Y-1378
transaxle output will not be free to differentiate Figure 6-114

after assembly. This will be due to the case
26. Install shim(s) as required (Figure 6-114).
halves pinching the ring gear assembly.
Determine the Output Shim Thickness
NOTE:
Determining the required shim thickness is only
necessary when installing new cases, side
gears or ring gear assembly.
(a) Temporarily set the side gear over the ring

gear assembly.
(b) From the case gasket face, measure the
distance to the top surface of bearing on
Y-1379
side gear. Record the value as “stack
measurement.”
(c) Subtract the “stack measurement” from
the nominal bearing pocket depth
Figure 6-115
27. Install right side gear into the right side case.
6
measurement of 14.04 mm (0.553 in.).
The desired gap between the gear stack,
shim and bearing pocket should be set at
0.35 ± 0.07 mm (0.014 ± 0.003 in.). Install
shims as required. All shims should be
installed in the right side case bearing
pocket.

2 3
1
Y-1380 Y-1381

28. Install intermediate shaft and gear assembly
(Figure 6-116, (1)) with bearings into left side NOTE:
case.
Alternately tighten bolts in a crisscross pattern.
29. Install input shaft (Figure 6-116, (2)). Use a
non-metallic hammer to assist installing the
input shaft assembly into the case bearing 32. Bolt case halves together. Install four
bore. 5/16-18 x 1.50 in. self-tapping bolts into the
locations shown in (Figure 6-117).
NOTE: 33. Install the remaining 10 5/16-18 x 1.25 in.
self-tapping bolts.
Ensure the sealant is applied to clean surfaces.
Apply around the internal side of the bolt holes. 34. Tighten all bolts to specification.
Specification:
30. Use a solvent such as lacquer thinner to clean Transaxle Case Bolt
all oil and grease residue from the case Torque............................................... 27 - 34 N·m
sealing surfaces. (2.8 - 3.5 m·kg; 20 - 25 lb-ft)
31. Apply a thin layer of Loctite 5699 High 35. Wipe away excess sealant.
Performance RTV Silicone gasket sealant (or
equivalent) (Figure 6-116, (3)) to gasket
mounting surface. Apply sealant around the
bolt hole pattern to prevent leakage.


38. Check for free rotation of the differential by
spinning one axle by hand. This should
1 require minimal effort 2 - 3, N·m (18 - 30
lb-in.), by hand. If resistance is found, a
problem with the assembly is indicated.
Disassemble and correct the cause of the
binding.
39. Place the transaxle in the normal installed
position.
40. Install the brake bracket to the case using
three bolts. Tighten bolts to specification.
Specification:
Brake Cable Bracket-to-Case Bolt
Torque............................................... 23 - 27 N·m
Y-1359
(2.3 - 2.8 m·kg; 204 - 240 lb-in.)
Figure 6-118
41. Leak check the transaxle before filling with oil.
NOTE: (a) Temporarily install both oil servicing plugs.
(b) Apply a 5 psi (maximum) air source
Ensure O-ring groove and mating surfaces are
through the vent tube and check for leaks
clean and free of debris.
at the seals, ports, O-rings and gasket
locations.
36. Install O-ring (Figure 6-118, (1)) onto motor 42. Install lower oil servicing plug. Tighten to
flange. Lubricate O-ring and shaft seal with specification.
multipurpose grease before installation. 43. Fill transaxle with 1300 ml (44 oz) SAE80
W90 API GL-5 Limited Slip High Performance
Gear Oil.
44. Install fill plug and tighten to specification.
Specification:
Torque................................................... 16.3 N·m
(1.66 m·kg; 144 lb-in.)
Y-1382
Figure 6-119
37. Align marks made during disassembly and
install motor flange onto case. Tighten bolts to
specification.
Specification:
Motor Flange-to-Case Bolt
Torque ...............................................27 - 34 N·m
(2.8 - 3.5 m·kg; 20 - 25 lb-ft)


CHASSIS
Table of Contents
— Chassis Repair —
General Repair ...................................................................................... 7-3
Remove and Install the Floor Mat ................................................... 7-3
Front and Rear Bumper......................................................................... 7-4
Remove the Front Bumper .............................................................. 7-4
Install the Front Bumper .................................................................. 7-4
Remove the Rear Bumper............................................................... 7-4
Install the Rear Bumper................................................................... 7-4
Seat ....................................................................................................... 7-5
Remove the Seat............................................................................. 7-5
Install the Seat................................................................................. 7-5
Sun Roof ............................................................................................... 7-5
Remove the Sun Roof ..................................................................... 7-5
Install the Sun Roof ............................................................................... 7-7
Remove the Front Cowling.............................................................. 7-9
Install the Front Cowling................................................................ 7-11
Rear Body ........................................................................................... 7-11
Remove the Rear Body ................................................................. 7-11
Install the Rear Body ..................................................................... 7-14
Front Wheel and Tire Service..............................................................
Remove the Wheels ......................................................................
7-15
7-16
7
Inspect the Wheels........................................................................ 7-17
Remove the Bearing and Seal................................................. 7-17
Install the Bearing and Seal..................................................... 7-18
Brake Cable......................................................................................... 7-18
Remove ......................................................................................... 7-18
Install ............................................................................................. 7-19

CHASSIS
Pedal Group Components................................................................... 7-20
Remove the Pedal Assembly ........................................................ 7-22
Disassemble the Throttle Pedal .................................................... 7-23
Assemble the Throttle Pedal ......................................................... 7-25
Disassemble the Brake Pedal ....................................................... 7-27
Inspect and Repair Springs, O-rings and Bearings ....................... 7-29
Inspect the Parking Brake ............................................................. 7-30
Assemble the Brake Pedal ............................................................ 7-30
Install the Pedal Assembly ............................................................ 7-32
Steering ............................................................................................... 7-34
Remove Steering Assembly .......................................................... 7-36
Disassemble Steering Assembly................................................... 7-38
Inspect the Steering Component................................................... 7-40
Assemble the Steering Assembly.................................................. 7-42
Install the Steering Assembly ........................................................ 7-43
Front Suspension Components........................................................... 7-46
Remove the Front Suspension...................................................... 7-47
Inspect the Front Suspension........................................................ 7-48
Replace Lower Arm Bushing ................................................... 7-49
Install the Front Suspension.......................................................... 7-50
Rear Suspension Components ........................................................... 7-51
Remove the Rear Suspension ...................................................... 7-53
Inspect the Rear Suspension ........................................................ 7-54
Install the Rear Suspension .......................................................... 7-54
Frame Assembly Components ............................................................ 7-55

General Repair CHASSIS
Chassis Repair
WARNING
WARNING 1
NEVER get under a raised car that is not
properly supported by jack stands. Many
procedures within this section require that the
car be raised using a floor jack. Be sure to
place the jack in only the defined locations
and always support a raised car with jack Y-1146
stands. See Recommended Jack Points on
page 1-7. Figure 7-2
2. Pry center pin (Figure 7-2, (1)) from plastic
rivets and remove five large and six small
plastic rivets.
GENERAL REPAIR 3. Remove floor mat.
Remove and Install the Floor Mat
Y-1150
Y-1254
Figure 7-3
4. Put floor mat in place on car. Ensure the tabs
7
are inserted into the slots (Figure 7-3, (1)) on
Figure 7-1 the steering column housing.
1. Use a rivet removal tool to pull the center pin
from the plastic rivet and to remove the rivet NOTE:
body.
Two different size plastic rivets are used to
retain the floor mat. Be sure to install them in
the correct locations.
5. Install plastic rivets and press pins until fully

seated.

CHASSIS Front and Rear Bumper
FRONT AND REAR BUMPER Install the Front Bumper

Installation is done in reverse of removal. Tighten
Remove the Front Bumper bolts to specification.
Specification:
1 Front Bumper Bolt
Torque...................................................... 22 N·m
(2.2 m·kg; 194 lb-in.)
Specification:
Front Bumper Bracket Bolt
Torque................................................... 5 - 8 N·m
(0.5 - 0.8 m·kg; 44 - 71 lb-in.)
Remove the Rear Bumper
2
2
Y-1429
Figure 7-4
1
1
Y-1430
Figure 7-6
Remove two bolts holding bracket to frame
(Figure 7-6, (1)) and remove the front bumper
(Figure 7-6, (2)).
Install the Rear Bumper

Installation is done in reverse of removal. Tighten
Y-1180
bolts to specification.
Figure 7-5
Specification:
Remove two bolts holding bracket to frame Rear Bumper Bolt
(Figure 7-5, (1)) and remove the front bumper. Torque...................................................... 22 N·m
(2.2 m·kg; 194 lb-in.)
Specification:
Rear Bumper Bracket Bolt
Torque................................................... 5 - 8 N·m
(0.5 - 0.8 m·kg; 44 - 71 lb-in.)

Seat CHASSIS
SEAT
Y-905A Y-1392
Remove the Seat 3. Remove front support boot (Figure 7-9, (1))
from cowl and slide upward.
Rotate seat up and lift off from tabs.
Install the Seat

Place seat on tabs and rotate down into place.
SUN ROOF
Remove the Sun Roof
Y-111_M
Figure 7-10
1 4. Remove bolts securing front supports to the
frame (Figure 7-10). Remove front supports.
Y-1394
7
Figure 7-8
1. Remove bolts, nuts and washers
(Figure 7-8, (1)) securing roof to each
support.
2. Remove the sun roof.

CHASSIS Sun Roof
Y-1518
Figure 7-11
Y-111_L
Figure 7-13
6. Remove screws securing drain tubes to the
rear supports. Remove the drain tubes.
Y-1519
Figure 7-12
5. Remove the tie straps (Figure 7-11, (1)) and
(Figure 7-12, (2)) securing the drain tubes to
the frame below the body.
Y-111_K
Figure 7-14
7. Remove bolts securing rear supports to the
seat support. Remove rear supports.

Install the Sun Roof CHASSIS
INSTALL THE SUN ROOF
Y-111_K
Figure 7-15
1. Insert the rear sun roof supports into the rear
seat support and secure using hex bolts
(Figure 7-15). Tighten to specification.
Y-111_L
Specification:
Sun Top Support Bolt Figure 7-17
Torque ...............................................12 - 19 N·m
(1.2 - 2.0 m·kg; 106 - 168 lb-in.) 3. Attach the drain tubes to the sun roof support
using binding head screws (Figure 7-17).
Specification:
Drain Tube Binding Head Screws
Torque................................................... 5 - 8 N·m
(0.5 - 0.8 m·kg; 45 - 71 lb-in.)
Y-000_P
7
Figure 7-16 Y-1390
2. Insert the drain tubes through the rear body. Figure 7-18
4. Attach the roof grommets to the drain tubes
ensuring the grommets are fitted over the
drain tube (Figure 7-18).

CHASSIS Install the Sun Roof
Y-111_M
Figure 7-19
5. Attach the forward sun roof support to the
frame using four hex bolts (Figure 7-19).
Specification:
Sun Top Support Bolt
Torque ...............................................12 - 19 N·m Y-1393
(1.2 - 2.0 m·kg; 106 - 168 lb-in.)
Figure 7-21
8. Place the sun roof on top on the supports.
Ensure the drain tube grommets on the rear
supports are fitted over the sun roof drain
holes.
1
Y-1394
Figure 7-22
Y-1392
9. Secure the sun roof in place using eight hex
Figure 7-20
bolts, 16 plain washers and eight acorn nuts
6. Slide the sun roof support boots over the (Figure 7-22, (1)). Tighten to specification.
forward sun roof supports. Specification:
7. Clip the sun roof support boot Sun Top-to-Support Nut
(Figure 7-20, (1)) in place. Torque................................................... 5 - 8 N·m
(0.5 - 0.8 m·kg; 45 - 71 lb-in.)

Install the Sun Roof CHASSIS
Y-1518
Figure 7-23
Y-1247
2
Figure 7-26
NOTE:
To disconnect the main switch connector, push
up on the latch.
3. Disconnect the main switch and oil level

indicator lamp connector (YDRA) or direction
switch connector (YDRE) (Figure 7-26).
Y-1519
4. Remove five upper floor mat plastic rivets.
Figure 7-24
10. Secure the lower drain tubes with a strap tie
(Figure 7-23, (1)) and (Figure 7-24, (2)) to 1 2
the frame at the intersection of the main 3
frame and the rear seat pillar.
Remove the Front Cowling

1. Remove sun roof. See Sun Roof on page 7-5.
Y-1155
7
Figure 7-27
1
5. Remove plastic rivet (Figure 7-27, (1)). Slide
steering column cover (Figure 7-27, (2)) and
grommet (Figure 7-27, (3)) up the steering
column.
Y-1227
Figure 7-25
2. Remove screw (Figure 7-25, (1)) and remove
the beverage holder.

CHASSIS Install the Sun Roof
Y-1248 Y-1249

6. Remove four hex socket head screws 8. Remove five plastic rivets (Figure 7-30, (1)).
(Figure 7-28, (1)) securing dash panel and
remove the dash panel.
Y-1340
Figure 7-31
Y-1333
9. To remove rivets (Figure 7-31, (1)), use a
Figure 7-29
punch to push pin down through center.
7. Remove the plastic rivet (Figure 7-29, (1))
securing the lower center of the cowl.

Rear Body CHASSIS
1 1
Y-1250
Figure 7-32 Y-1453
10. Remove two hex head bolts Figure 7-33

(Figure 7-32, (1)). 5. YDRA: Remove nut retaining the choke cable
11. Remove cowling from chassis. (Figure 7-33) and pull choke cable back
through the body.
Install the Front Cowling

Installation is done in reverse of removal.
REAR BODY
Remove the Rear Body
1. Remove sun roof.
2. Remove front cowling. See Remove the Front
Cowling on page 7-9.
3. Raise the rear wheels and support with jack Y-1452
stands.
Figure 7-34
6. YDRA: Rotate shift lever into REVERSE
position.
SM-03-202 SM-03-202
Figure 7-35
7. Remove retaining ring (Figure 7-35, (1)) from
handle shaft. Remove shift handle
(Figure 7-35, (2)).

CHASSIS Rear Body
1 1
Y-1140
Y-1334
8. Remove four plastic rivets (Figure 7-36, (1)). 10. Remove rear access panel (Figure 7-38, (1)):
(a) Pry center pin (Figure 7-38, (2)) from
plastic rivets and remove two plastic rivets.
2 1
Y-1193
Figure 7-37
(Figure 7-37, (1)) and two bolts Y-1142
(Figure 7-37, (2)). Remove the bag holder Figure 7-39
insert.
(b) Gently pry up on front edge to release tabs
and pull panel rearward to remove
(Figure 7-39).

Rear Body CHASSIS
1 1
Y-1341 Y-1343

11. Remove two bolts (Figure 7-40, (1)) from 14. Remove hidden plastic rivet (Figure 7-42, (1))
each side of the seat back support, and located inside each side of body ahead of the
remove seat back and sweater basket as an wheel well opening.
assembly.
2
1
Y-1342 Y-1344

15. Remove front-side plastic rivet
NOTE: (Figure 7-43, (1)) from each side sill
assembly.
Transaxle has been removed for clarity of
photograph. 7
12. Remove plastic rivets (Figure 7-41, (1 and
2)) from each rear inner fender.
13. Remove inner fenders.

CHASSIS Rear Body
Install the Rear Body

1 Installation is done in the reverse of removal.
Specification:
Seat Back Support Bolt
Torque...................................................... 30 N·m
(3.1 m·kg; 22 lb-ft)
Y-1345
Figure 7-44
16. Remove two screws (Figure 7-44, (1)) in the
floor panel from each side sill assembly.
17. Roll rocker panel down to remove. Repeat
with remaining rocker panel.
Y-1346
Figure 7-45
18. Remove plastic rivet (Figure 7-45, (1)) from
each side of body.
19. Remove rear body.

Front Wheel and Tire Service CHASSIS
FRONT WHEEL AND TIRE SERVICE
12
11 10
9
8
7
6
5
4
2 1
SM-03-345A
Figure 7-46
1. Lug Nut 7. Outer Bearing

2. Tire and Wheel Assembly 8. Spacer
3. Dust Cover 9. Front Hub
4. Cotter Pin 10. Inner Bearing
5. Axle Nut 11. Seal
6. Conical Washer 12. Steering Knuckle
7

CHASSIS Front Wheel and Tire Service
Remove the Wheels

1. Place the vehicle on a level surface.
2. Apply parking brake.
3. Loosen front wheel lug nuts.
1
4. Raise the front wheels and support with jack
stands beneath the frame. See
Recommended Jack Points on page 1-7.
5. Remove front wheel.
Y-1258
Figure 7-49
8. Remove the dust cover (Figure 7-49, (1)).
Y-1256
Figure 7-47
6. Rotate the hub (Figure 7-47) and check for 1
roughness. If roughness is felt, replace the 2
bearings.
Y-1164
Figure 7-50
9. Remove the cotter pin (Figure 7-50, (1)), hub
nut (Figure 7-50, (2)) and conical washer.
10. Remove the front hub. Use a soft-faced
hammer to aid removal, if necessary.
Y-1257
Figure 7-48
7. Gently rock the hub back and forth
(Figure 7-48) to check for looseness. If loose,
tighten hub nut to specification and recheck. If
still loose, replace the bearings.

Front Wheel and Tire Service CHASSIS

Inspect the Wheels
WARNING
1. Inspect the wheel for cracks, bends or

warping. Replace if necessary. 2
1
3
1
SM-03-204A
1. Bearing (two used)

2. Seal
3. Spacer
SM-03-203A
Figure 7-53
Figure 7-51
2. Remove the bearings and spacer using a
2. Inspect the hub for cracks and damage. suitable bearing puller.
3. Inspect the wheel bearings for evidence of 3. Clean the inside of the hub.
roughness, rust or other damage.
4. Inspect the oil seal for wear or damage. NOTE:
Replace as necessary.
Ensure the spacer is in place between the
Remove the Bearing and Seal bearings and correctly oriented.
7
1. Tool
2. Inner Race
Y-1199 3. Bearing Ball
Figure 7-52 4. Outer Race
Figure 7-54
1. Pry the seal out of the hub.

CHASSIS Brake Cable
BRAKE CABLE
CAUTION
Use a tool that contacts ONLY the outer race Remove
of the bearing when installing. NEVER strike
or press against the inner race or the bearing 1. Jack up the car and remove the right rear
balls. wheel.
4. Install new bearings using a press and

suitable tool.
5. Install a new seal flush with the bore of the 1
hub.
Install the Bearing and Seal

1
2
3
Y-1317A
4
Figure 7-56
5
2. Remove the cotter pin, washer and clevis pin
SM-03-348 (Figure 7-56, (1)) and remove the clevis from
the brake arm.
1. Hub
2. Conical Washer
3. Nut 1
4. Cotter Pin
5. Dust Cover
Figure 7-55
NOTE:
The conical washer is bowl-shaped. Ensure the
washer is installed with the bowl facing the nut.
1. Install the hub, conical washer and nut

Y-1457
(Figure 7-55, (2)). Tighten nut to
specification. Figure 7-57
Specification: 3. Slide the brake removal tool YGCC-006
Front Hub Flange Nut (Figure 7-57, (1)) over the brake cable and
Torque .................................................... 114 N·m slide it against the bracket to compress the
(11.6 m·kg; 84 lb-ft) retainer.
2. Install a new cotter pin and dust cover. Special Tool:
3. Install the wheel and tighten lug nuts to Brake Cable Removal Tool ...............YGCC-006
specification.
Specification:
Lug Nut Torque ....................................... 88 N·m
(9.0 m·kg; 65 lb-ft)

Brake Cable CHASSIS

Install
1. Push the cable into the bracket until the cable
snaps into place. Pull on cable to be sure it is
locked into the bracket.
Y-1458
Figure 7-58
4. Pull the cable toward the front of the car to
release the cable from the bracket.
Y-1317A
Figure 7-60
2 2. Install clevis on brake arm and secure in
place with clevis pin, washer and cotter pin
(Figure 7-60, (1)).
3. Route the cable along the frame and up to the
pedal assembly. Use wire ties where needed.
1
Y-1191B
Figure 7-59 2
5. Remove the floor mat and the service panel

to gain access to pedal assembly.
6. Remove the clevis pin (Figure 7-59, (1)).
7. Loosen the jam nut (Figure 7-59, (2)) and 1
unthread all the way off cable.
8. Pull the cable back and slide inner cable
through the slot in pedal assembly.
9. Remove the cable from the car. Y-1191B
7
Figure 7-61
4. Slide the inner cable through the slot in the
pedal assembly and slide the threaded part of
the cable into the hole.
5. Thread nut (Figure 7-61, (2)) onto cable.
6. Install the clevis on the brake pedal and install
clevis pin, washer and cotter pin
(Figure 7-61, (1)).
7. Adjust the parking brake. See Adjust the
Parking Brake on page 3-29. Install service
cover and floor mat.

CHASSIS Pedal Group Components
PEDAL GROUP COMPONENTS
37
26
14
15
19
19 13
12
2
27 23
9
39
17 42 21
40 1
33 14
20 22 29
18 11
16
3
31
32 6
18 40 16
30
40
17
40
18
15 40
34
43
10 3
31
36 4
10
24
38 35
40
41
5
7
8
28
Y-1200
Figure 7-62

Pedal Group Components CHASSIS

1. Brake Rod 23. Torsion Spring, Parking Brake
2. Clevis 24. Torsion Spring, Throttle Pedal
3. Pop Rivet 25. Throttle Pedal
4. Bolt, Hex Flange Head 26. Parking Brake Pedal
5. Screw 27. Brake Pedal
6. Bolt, Crown-Head 28. Pedal Base
7. Bolt, Hex Flange Head (YDRE only) 29. Parking Brake Sector
8. Hex Nut, Serrated Flange 30. Actuator Plate
9. Jam Nut 31. Latch Plate
10. Locknut 32. Outer Sleeve
11. Pivot Pin, 8 mm 33. Inner Sleeve
12. Pivot Pin, 10 mm 34. Shaft
13. Pin 35. Sleeve
14. Retaining Ring 36. Release Strap
15. Retaining Ring 37. Parking Pedal Pad
16. Flat Washer 38. Brake Pad
17. Thrust Washer 39. Sector Pad
18. Bearing, Plain 40. O-ring
19. Flange Bearing, Plain 41. Throttle Sensor (YDRE only)
20. Torsion Spring, Brake Pedal 42. Spring Pin
21. Extension Spring 43. O-ring
22. Torsion Spring, Sector

Remove the Pedal Assembly

2. Turn main switch OFF.
4. Remove the floor mat. See Remove and
Install the Floor Mat on page 7-3.
Y-1261A
Figure 7-65
7. Disconnect the throttle position sensor
connector (Figure 7-65, (1)) (YDRE).
Y-1259
Figure 7-63
5. Remove the service lid (Figure 7-63). 1
3
Y-1191A
Figure 7-66
1
8. Remove brake cable (Figure 7-66, (1)) and
throttle cable (YDRA) (Figure 7-66, (2)) from
Y-1224
the pedal base.
Figure 7-64 9. Remove seven locknuts (Figure 7-66, (3)).
6. Disconnect the throttle stop switch connector 10. Remove the pedal assembly.
(Figure 7-64, (1)) (YDRA).


Disassemble the Throttle Pedal
Y-1471
Figure 7-69
Y-1469
4. Remove the retaining ring (Figure 7-69, (1))
Figure 7-67 from the opposite end of the throttle pedal
shaft.
1. Put the pedal assembly in a bench vise using
bench vise pads or pieces of rubber to grip
and protect the assembly.
2. Remove the two 4 mm screws from the
throttle position sensor (YDRE) 1
(Figure 7-67, (1)).
CAUTION
Failure to use bench vise pads can result in
damage to the base casting of the pedal
assembly.
Y-1472
2 Figure 7-70
5. Remove the throttle pedal clamp screw
(Figure 7-70, (1)) with a 13 mm socket.
7
Y-1470
Figure 7-68
3. Remove the throttle position sensor from the
pedal shaft (Figure 7-69, (2)) (YDRE).

2
3 2
Y-1473
Figure 7-71
NOTE:
Place an 8 mm hex wrench (Figure 7-71, (1)) Y-1475
between the parking brake sector and the brake Figure 7-73
rod. This will raise the bottom of the parking
brake sector (Figure 7-71, (2)) to allow 7. When the shaft disengages from the throttle
clearance for the top of throttle shaft pedal, the throttle shaft can be removed by
(Figure 7-71, (3)) during removal. pulling on the brake actuator plate
(Figure 7-73, (1)). Be sure to save the flat
washer (Figure 7-73, (2)) that will fall below
I
the pedal base as the shaft is removed.
Y-1474
Figure 7-72
6. Remove the throttle shaft/actuator plate
assembly by gently tapping the shaft through Y-1476
the pedal base on the throttle position sensor
side of the shaft with a 1/4-inch drive with a Figure 7-74
3/16-inch socket/extension combination. 8. The throttle spring (Figure 7-74, (1)) and
sleeve (Figure 7-73, (2)) can now be pulled
from the pedal support base.

Y-1479
Figure 7-77
3. Ensure the shaft and pedal are aligned so
1
that the base of the pedal (Figure 7-77, (1)) is
positioned parallel to the stop position
(Figure 7-77, (2)) on the brake pedal
Y-1477 actuator.
Figure 7-75
9. Remove and replace the O-rings
(Figure 7-75, (1)) in pedal support base and
the O-ring seal on the throttle shaft.
10. Inspect the throttle spring, inner sleeve and
shaft bearings for corrosion or deterioration
and replace if necessary.
Assemble the Throttle Pedal

1. Position the spring/inner sleeve assembly in
the pedal base and slide the throttle shaft
through the pedal base until it meets the 2
pedal opening in the base.
Y-1480
Figure 7-78
1
4. Loosen the throttle stop bolt
(Figure 7-78, (2)) to allow clearance for
compressing the pedal spring.
7
Y-1478
Figure 7-76
2. Position the washer on the pedal shaft and
slide the pedal shaft (Figure 7-76, (1))
through the pedal clamp.

Y-1483
Y-1481 Figure 7-81

Figure 7-79 6. Hold the spring in place with a pair of 4-inch
vise grips (Figure 7-81) and press on the
brake actuator shaft until the spring end and
throttle shaft are firmly seated.
2 1
Y-1482
Figure 7-80 Y-1472
5. Put a flat-head screwdriver between the pedal Figure 7-82

base and the shaft to wind the spring 7. Install the throttle pedal clamp screw and
(Figure 7-79, (1)) so the end of the spring tighten to specification.
can be inserted into the hole
(Figure 7-80, (2)) in the brake actuator. Specification:
Throttle Pedal Clamp Screw ............. 8 - 11 N·m
(0.8 - 1.1 m·kg; 71 - 97 lb-in.)


Disassemble the Brake Pedal
Y-1471
Figure 7-83
8. Install the retaining ring (Figure 7-83, (1)) for
the throttle pedal shaft. Y-1488
Figure 7-85
1. Release the brake rod (Figure 7-85, (1)) from
the release strap (Figure 7-85, (2)).
1
Y-1469
Figure 7-84
Y-1489
9. Install the throttle position sensor
(Figure 7-84, (1)) (YDRE) onto the throttle Figure 7-86
pedal shaft and secure with two screws. 2. Loosen the brake pedal screw with a 13 mm
socket and a 15 mm open-faced wrench
(Figure 7-86).
7

1
2
1
Y-1492
Figure 7-89
Y-1490
5. Remove the brake rod retaining ring
Figure 7-87 (Figure 7-89, (1)).
3. Pull the brake pedal screw (Figure 7-87, (1))
away from the pedal base and save the 2
washers (Figure 7-87, (2)) that will fall
beneath the pedal base when the screw is
removed.
Y-1493
Figure 7-90
6. Remove the pin (Figure 7-90, (1)) and brake
Y-1491
rod (Figure 7-90, (2)).
Figure 7-88
4. Remove the torsion spring (Figure 7-88, (1)).
Y-1494
Figure 7-91
7. Remove the parking brake pedal retaining
ring (Figure 7-91, (1)).

1
1
2
2
Y-1497
Figure 7-94
10. Remove the parking brake sector pin
Y-1495
(Figure 7-94, (1)) and remove the parking
Figure 7-92 brake sector (Figure 7-94, (2)).
CAUTION
Failure to use bench vise pads can result in
damage to the base casting of the pedal
assembly.
8. Put the brake pedal in a bench vise and

remove the parking brake pivot pin 1
(Figure 7-92, (1)) and parking brake torsion
spring (Figure 7-92, (2)) to release the
parking brake pedal.
Y-1498
Figure 7-95
11. To remove the pivot tube, put the brake pedal
in a press. Press the outer sleeve
(Figure 7-95, (1)) off first and then remove
the spring. Press the inner sleeve off the outer
sleeve.
7
1 Inspect and Repair Springs, O-rings
and Bearings
When the brake pedal assembly is fully
disassembled, inspect the springs, O-rings and
bearings for corrosion or wear. Replace if
Y-1496 necessary.
Figure 7-93
9. Remove the parking brake sector retaining
ring (Figure 7-93, (1)).

Inspect the Parking Brake Inspect the parking brake pedal pad
(Figure 7-96, (1)), brake pedal pad
(Figure 7-97, (2)) and parking brake sector pad
(Figure 7-98, (3)) for wear or damage.
If pads are worn or damaged, replace using
Loctite 454 adhesive as required.
1
Assemble the Brake Pedal
Y-1499
Figure 7-96
Y-1502
Figure 7-99
1. Put brake pedal in a bench vise and position
the parking brake sector and spring
(Figure 7-99).
2
2. Install pin (Figure 7-99, (1)). Secure pin with
retaining ring.
1
Y-1500
Figure 7-97
3 Y-1503
Figure 7-100
3. Position the parking brake pedal on the brake
pedal. Insert the parking brake pivot pin
(Figure 7-100, (1)) into the pedal until it holds
the parking brake pedal loosely on the brake
pedal.
Y-1501
Figure 7-98

Y-1506
Y-1504
Figure 7-103
Figure 7-101
6. Attach the retaining ring (Figure 7-103, (1)) to
4. Install pin halfway into spring the end of the parking brake pivot pin.
(Figure 7-101, (1)).
1
1
Y-1507
Y-1505
Figure 7-104
Figure 7-102
7. Attach the brake rod to the parking brake
pedal using the brake rod clevis pin
CAUTION (Figure 7-104, (1)). Ensure that the hooked
Wrap the end of the vise grips with electrical end of the brake rod (Figure 7-104, (2)) is
tape to avoid damaging the opposite side of facing the brake pedal.
the pedal. 8. Install the retaining ring on the brake rod
5. Put the arm of the parking brake torsion

clevis pin.
7
spring in the slot located in the brake pedal
(Figure 7-102, (1)). Carefully compress the
spring using a 4-inch pair of vise grips, while
pushing in on the parking brake pivot pin.

1
1
Y-1508
Y-1488
Figure 7-105
Figure 7-107
9. Hook the brake rod sector torsion spring
(Figure 7-105, (1)) around the slotted pin in 12. Install the brake rod (Figure 7-107, (1)) into
the brake pedal and pull the spring onto the the release strap (Figure 7-107, (2)).
rod.
Install the Pedal Assembly
1
3
1
2
Y-1490
Figure 7-106 Y-1191A
Figure 7-108
10. Install the brake pedal screw
(Figure 7-106, (1)) through the pedal and 1. Install pedal assembly.
install the washers (Figure 7-106, (2)) on the 2. Install seven locknuts (Figure 7-108, (3)) and
screw. tighten to specification.
11. Install the nut on the brake pedal screw and Specification:
tighten to specification.
Pedal Base Locknut
Specification: Torque...................................................... 19 N·m
Brake Pedal Screw.................................. 52 N·m (1.9 m·kg; 168 lb-in.)
(5.3 m·kg; 38.4 lb-ft)
3. Install brake cable (Figure 7-108, (1)) and
throttle cable (YDRA) (Figure 7-108, (2)) to
pedal base.
4. Connect the throttle stop switch connector.
5. Connect the throttle position sensor
connector (YDRE).


6. Adjust the throttle and brake cables. (See
Check and Adjust the Speed Limiter on
page 3-24 and Adjust the Parking Brake on
page 3-41.)
Y-1259
Figure 7-109
7. Install the service lid and floor mat
(Figure 7-109). See Remove and Install the
Floor Mat on page 7-3.

CHASSIS Steering
STEERING
7
8
6
5
1
4
28
27 3
10
31
32 2
9 22 2
20
21 30
19
13
23
31
14
15 26
32 12
24
25
17 16
18
29
23
26
11 21
22
27
28
9 10
Y-1431
Figure 7-110

Steering CHASSIS
1. Column, Steering 17. Spring, Pressure
2. Bolt, Flange 18. Pad, Pressure
3. Holder 19. Ring, Stopper
4. Rod, Steering 20. Seal
5. Holder, Handle Upper 21. Band
6. Wheel, Steering 22. Seal, Dust
7. Nut, Self-Locking 23. Rod, Tie
8. Washer 24. Bushing, Cap
9. Nut, Self-Locking 25. Gear Subassembly
10. Pin, Cotter 26. Washer, Lock
11. Steering Assembly 27. Nut
12. Gear, Pinion 28. Joint, Universal
13. Retaining Ring 29. Bolt, Flange
14. Bearing 30. Joint
15. Gear, Rack 31. Bolt
16. Cover, Adjust 32. Washer, Plate

CHASSIS Steering
Remove Steering Assembly

1
3. Raise the front wheels using a hydraulic jack
and place suitable jack stands under the
frame. See Recommended Jack Points on
page 1-7.
4. Remove the front wheels. See Front Wheel
and Tire Service on page 7-15.
NOTE:
Although it is not required, removal of the front
bumper will provide easier access to the Y-1151
steering components. See Remove the Front Figure 7-112

Bumper on page 7-4.
NOTE:
Loosely install the steering wheel nut on the
33 shaft to keep it from falling through the column.
44 2
2
Afterward, if necessary, remove shaft from top
55 of column.
39 N•m (4.0 m•kg, 28.8 ft•lb)

7. Remove upper U-joint pinch bolt
(Figure 7-112, (1)). Pull the steering shaft up
out of the U-joint. Remove the shaft
completely from the steering column if
necessary.
SM-03-276
Figure 7-111
NOTE: 2
The scorecard holder is removed by pressing

the mounting pins from the back of the steering
wheel.
5. Remove the scorecard holder

(Figure 7-111, (2)).
NOTE:
Y-1152A
If the steering wheel cannot be removed by
hand, gently tap the back of the steering wheel Figure 7-113
near the steering column using a non-metallic 8. Remove lower U-joint pinch bolt
hammer. (Figure 7-113, (2)). Remove the shaft and
U-joints from the steering gear pinion shaft.
6. Remove steering wheel nut
(Figure 7-111, (3)), washer
(Figure 7-111, (4)) and steering wheel
(Figure 7-111, (5)).

Steering CHASSIS
1 2
3
2
Y-1139 Y-1155

9. Remove cotter pin (Figure 7-114, (1)) and
remove locknut (Figure 7-114, (2)) from each NOTE:
side. Remove tie-rod end from knuckle arms.
Removal of the steering column is not
necessary to perform the remainder of the
NOTE: steering component repair. Remove the
Hold the tie-rod stud with a 17 mm wrench steering column only if required.
when removing the locknut.
11. Remove pin (Figure 7-116, (1)), cover
(Figure 7-116, (2)) and grommet
(Figure 7-116, (3)).
Figure 7-115
10. Remove four steering gear mounting bolts
Y-1154
Y-1156
7
Figure 7-117
(Figure 7-115, (1)). Remove steering
assembly from frame. 12. Remove four bolts (Figure 7-117, (1)) from
under the steering column mount. Remove
steering column from the chassis.

CHASSIS Steering
Disassemble Steering Assembly 3. Inspect tie-rod ball joints for the following
conditions and replace if necessary:
(a) Rough movement (Figure 7-120, (1)).
(b) Noticeable free play (Figure 7-120, (2)).
3 (c) Warped or cracked housing
(Figure 7-120, (3)).
1
2
2 1
SM-03-281
Figure 7-118
1. Hold the tie-rod end with a wrench
(Figure 7-118, (3)) and loosen jam nut
(Figure 7-118, (2)). Remove tie-rod end
(Figure 7-118, (1)) and nut from each tie rod. 3
2 Y-1158
Figure 7-121
4. Bend lock plates (Figure 7-121, (1)) away
from each flat (Figure 7-121, (2)) on ball joint.
5. To loosen tie-rod from rack gear, use a thin
28 mm wrench on the ball joint flats
(Figure 7-121, (2)) and a 19 mm wrench on
1 the tie-rod flats (Figure 7-121, (3)). Remove
tie rods.
Y-1157
Figure 7-119
1
2. Remove tie straps (Figure 7-119, (1))
securing the boots. Remove both boots
(Figure 7-119, (2)).
3
1
Y-1170
Figure 7-122
6. Note the paint marks (Figure 7-122, (1)).
Y-1183 These will be used during assembly.
Figure 7-120

Steering CHASSIS
1 2 3 1
Y-1171 Y-1173

7. Remove adjustment cover 9. Remove retaining ring (Figure 7-125, (1)).
(Figure 7-123, (1)), spring (Figure 7-123, (2))
and pressure pad (Figure 7-123, (3)).
NOTE: 1
Lightly grip the pressure pad with needle nose

pliers to make removal easier.
Y-1174
Figure 7-126
10. Remove pinion shaft with bearing
(Figure 7-126, (1)).
Figure 7-124
Y-1172
7
NOTE:
Use care not to damage the bearing by driving
the punch too deep. Drive the punch on an
angle and only deep enough to penetrate the
seal case.
8. Use a punch to break oil seal (Figure 7-124).

Pry seal out of housing.

CHASSIS Steering
NOTE:
If either the inner pinion bearing insert or rack
bearing are damaged, the entire steering gear
housing must be replaced.
1
Y-1175
Figure 7-127
1
CAUTION
Note the orientation of the rack gear during
removal. It will need to be installed in the
same orientation. Y-1178
Figure 7-129
11. Remove rack gear (Figure 7-127, (1)) from
housing. NOTE:
Inspect the Steering Component The three notches in the housing bore are
normal and are not due to wear.
3. Inspect rack bearing insert

1
(Figure 7-129, (1)).
3
2 1
Y-1176
Figure 7-128
1. Check the pinion shaft bearing
(Figure 7-128, (1)) for looseness or rough
Y-1177
spots by rotating with fingers. If rotation is
rough, replace the bearing. Figure 7-130
2. Inspect end bearing surface 4. Inspect inner pinion bearing
(Figure 7-128, (2)) and sealing surface (Figure 7-130, (1)).
(Figure 7-128, (3)) for damage or pitting.

Steering CHASSIS
1 1
SM-03-297
Figure 7-131
5. Inspect the rack gear (Figure 7-131, (1)) and
pinion gear (Figure 7-131, (2)) teeth. Look for Y-1163
damage or wear, especially in the center area
Figure 7-133
where contact is the greatest. If the wear is
uneven or damage is evident, suspect 10. Inspect U-joints (Figure 7-133, (1)) for
misadjustment or lack of lubricant. looseness or binding.
6. Inspect pressure pad for excessive wear.
7. Inspect boots for tears or cracks.
8. Check for bent tie-rods.
3 1
4
5
7
SM-03-298
Figure 7-132
9. Inspect tie-rod ends for the following
conditions and replace if necessary:
(a) Rough movement (Figure 7-132, (1)).
(b) Noticeable free play (Figure 7-132, (2)).
(c) Bent stud (Figure 7-132, (3)).
(d) Warped or cracked housing
(Figure 7-132, (4)).
(e) Torn or cracked boot (Figure 7-132, (5)).
Replace the tie-rod end if any of the above
conditions are found.

CHASSIS Steering
Assemble the Steering Assembly
Rack center mark shall be painted yellow to

slash part in the position of rack center.
(width about 2mm) Marking position shall be
oposite to yoke side.
1
A' A'
Y-1175
Figure 7-135
1. Ensure the rack gear (Figure 7-135, (1)) is
oriented correctly. Install in the housing.
2. Install the pinion and secure with the retaining
ring.
3. Install a new pinion shaft seal.
4. Pack 12.5 cc (12 g; 0.42 oz)
multipurpose-type grease into the pinion shaft
end of the steering gear.
Y-1447 1
Figure 7-134
NOTE:
Lubricate the following items during assembly
with lithium soap-based grease:
• Bearings
• Rack gear
• Pinion gear Y-1170
• Oil seal lip Figure 7-136

5. Install the adjustment cover and turn in until
lightly seated. Back out until paint marks
align.

Steering CHASSIS
Install the Steering Assembly
1
NOTE:
If the upper and lower steering column
bushings were removed during assembly, they
must be installed dry. Do not use grease on the
OD to ease assembly into the steering column.
1. Install the upper and lower steering column

bushings if removed.
2. Lubricate the ID of the upper and lower
bushing bores.
Y-1160
Figure 7-137
6. Install the tie-rod ends. Ensure the tab on the
retainer aligns with notch (Figure 7-137, (1))
in end of rack gear. Install tie-rods and tighten
to specification.
Specification:
Tie Rod-to-Rack Gear
Torque ...................................................... 79 N·m
1
(8.1 m·kg; 58 lb-ft)
Y-1156
Figure 7-139
3. Install the steering column and secure using
four bolts (Figure 7-139, (1)). Tighten to
specification.
Specification:
Steering Column Bolt
Torque...................................................... 21 N·m
(2.1 m·kg; 186 lb-in.)
4. Install the steering shaft in the steering
7
Y-1161
column and loosely install the steering wheel
Figure 7-138 nut to prevent the shaft from falling through.
7. Support the ball joint and bend retainer onto
both flats to secure tie-rod end. Use care not
to damage the rack gear with the hammer
(Figure 7-138).
8. Install tie-rod boots with new tie straps to
secure the boots.

CHASSIS Steering
Y-1182 Y-1151

5. Install a jam nut onto each tie-rod and 10. Connect the steering shaft upper U-joint to
position approximately 27.5 mm (1.10 in.) the steering column shaft.
from the end (Figure 7-140).
6. Install tie-rod end until it contacts the jam nut.
Back off until the stud faces down.
2
a b
1 3
Y-1152
Y-1157B
Figure 7-143
Figure 7-141
7. Center the rack so each tie-rod end is NOTE:
approximately the same distance
(Figure 7-141, (a, b)) from the end of the Be sure to correctly align the paint marks
housing. (Figure 7-143, (3)) to ensure the U-joint is
correctly oriented when installed on the pinion
8. Rotate the pinion shaft in the direction shaft.
requiring the least amount of rotation to align When oriented properly, the upper U-joint pinch
the paint marks (Figure 7-141, (1)) of the bolt (Figure 7-142, (1)) will enter from the top
pinion shaft and housing. and the lower U-joint pinch bolt
9. Install the steering assembly and tighten bolts (Figure 7-143, (2)) will enter from the
to specification. passenger side.
Specification:
Steering Gear Box Bolt 11. Align paint marks (Figure 7-143, (3)) on the
Torque ...................................................... 48 N·m pinion shaft and U-joint. Install the steering
(4.9 m·kg; 35 lb-ft) shaft lower U-joint to the pinion shaft.
12. Install the U-joint pinch bolts and tighten to
specification.

Steering CHASSIS
Specification:
Steering U-Joint Pinch Bolt
Torque ...................................................... 22 N·m
(2.2 m·kg; 194 lb-in.)
Y-1139
Figure 7-144
13. Connect the tie-rod ends (Figure 7-144, (1))
to the inner hole of the knuckle arms. Hold the
tie-rod end stud (Figure 7-144, (2)) with
17 mm wrench and tighten nuts to
specification.
Specification:
Tie Rod End-to-Knuckle Arm
Torque ...................................................... 39 N·m
(4.0 m·kg; 29 lb-ft)
14. Secure nuts with new cotter pins.
15. Install front tire and wheel assemblies. See
16. Set the front wheels to straight ahead.
Without rotating the steering shaft, carefully
install the steering wheel in the appropriate
position.
17. Install the steering wheel retaining washer
and nut and tighten to specification. Install the
scorecard holder. 7
Specification:
Steering Wheel Nut Torque .................... 35 N·m
(3.6 m·kg; 26 lb-ft)
18. Adjust toe-in. See Wheel Alignment on
page 3-38.

CHASSIS Front Suspension Components
FRONT SUSPENSION COMPONENTS
7
15
14
21
12 6
11
7
9
3 17
14
3 10
2 5
1 2
18
16 19 4
17 27 24
8 23
11
7
12 26
25
28
22 29
8
8
30
7
Y-1432
Figure 7-145
1. Front Lower Arm Assembly 16. Collar

2. Bushing, Solid 17. Cover, Thrust
3. Bushing 18. Bolt, Flange
4. Knuckle, Steering 19. Nut
5. Arm, Knuckle 20. Shock Absorber Assembly (not shown)
6. Bolt, Flange 21. Bolt, Flange
7. Nut, U-Flange 22. Hub, Front
8. Pin, Cotter 23. Bolt, Serration
9. Bolt, Flange 24. Bearing
10. Spacer 25. Bearing
11. Bushing, Solid 26. Collar
12. Cover, Thrust 27. Oil Seal
13. Knuckle, Steering (not shown) 28. Washer
14. Bolt, Flange 29. Nut, Castle
15. Shock Absorber Assembly 30. Cover, Hub Dust

Front Suspension Components CHASSIS

Remove the Front Suspension
3. Raise the front wheels and support with jack
stands beneath the frame. See
Y-1166
Figure 7-148
6. Check that there is no free play between the
steering knuckle and knuckle arm
SM-03-306
(Figure 7-148) and that both bolts are tight.
Figure 7-146 (a) If free play is present, check knuckle and
knuckle arm for wear:
4. Remove front wheel (Figure 7-146, (1)) and
hub (Figure 7-146, (2)). See Front Wheel and • If no wear is present, replace and tighten
Tire Service on page 7-15. bolts to specification.
• If worn, replace knuckle arm and/or
steering knuckle.
Y-1139
Figure 7-147
5. Remove cotter pin (Figure 7-147, (1)) from
tie-rod end. Hold the tie-rod end stud with 17 Figure 7-149
Y-1167 7
mm wrench and remove locknut
(Figure 7-147, (2)). Remove tie-rod end from 7. Check steering knuckle-to-sleeve free play
the knuckle arm. (Figure 7-149).

3
5
3
6 4
4
6
6 5
1
4 2
2 Y-1538
5
Y-1454
Figure 7-151
Figure 7-150 8. Remove locknut (Figure 7-151, (1)), lower

shock absorber bolt (Figure 7-151, (2)),
(a) If free play is present, remove cotter pin locknut (Figure 7-151, (3)) and upper shock
(Figure 7-150, (1)), locknut absorber bolt (Figure 7-151, (4)). Remove
(Figure 7-150, (2)) and flange bolt shock absorber assembly.
(Figure 7-150, (3)).
9. Remove locknuts (Figure 7-151, (5)) and
(b) Remove thrust covers (Figure 7-150, (5)) lower arm-to-frame bolts (Figure 7-151, (6)).
bushings (Figure 7-150, (4)) and spacer Remove lower arm.
(Figure 7-150, (6)) from steering knuckle.
(c) Inspect and measure the components for Inspect the Front Suspension
wear: 1. Inspect the shock absorbers. See Inspect the
Specification: Shock Absorbers on page 3-20.
Spacer OD minimum ....................... 17.025 mm 2. Inspect the lower arm for bends, cracks or
(0.6702 in.) other damage.
Spacer ID maximum ........................ 10.050 mm 3. Inspect and measure the lower arm-to-shock
(0.3956 in.) absorber washers, spacer and bushings for
wear. Replace if necessary.
Bushing ID maximum ...................... 17.041 mm Specification:
(0.6709 in.)
Spacer OD minimum ........................18.016 mm
• If no wear is present, replace and tighten (0.7092 in.)
bolts to specification. See Install the Spacer ID maximum .........................12.050 mm
Front Suspension on page 7-50. (0.4744 in.)
• If worn, replace components as
necessary. Bushing ID maximum.......................18.042 mm
(0.7103 in.)
4. Inspect the lower arm-to-frame bushings for
wear or damage. Replace if necessary.

Front Suspension Components CHASSIS

Replace Lower Arm Bushing
A CORRECT B INCORRECT
1
1
1
3
2 2
2 2
SM-03-318A
Y-1165
Figure 7-153
Figure 7-152
CAUTION
5. Check condition of spindle seal
(Figure 7-152, (1)) and replace if necessary. Never press on the center collar of a rubber
See Remove the Bearing and Seal on bushing. Select a tool (Figure 7-153, (3)) that
page 7-17. will press on the outer collar
6. Check the bearings for evidence of rust, (Figure 7-153, (2)) only.
damage or roughness when rotated. Replace
if necessary. See Remove the Bearing and 1. Press the bushing out using a hydraulic press
Seal on page 7-17. (Figure 7-153, (1)) and tool
(Figure 7-153, (3)).
2. Inspect the bore for damage.
3. Press a new bushing into the arm until
centered.

Install the Front Suspension

Installation is done in the reverse of removal with Specification:
the following notes: Lower Arm-to-Frame Bolt
• Always install new cotter pins. Torque...................................................... 53 N·m
(5.4 m·kg; 39 lb-ft)
• Install new flange bolt.
Lower Front Shock Absorber Bolt
• Install new knuckle arm-to-steering knuckle Torque............................................... 75 - 85 N·m
bolts. (7.6 - 8.6 m·kg; 55 - 62 lb-ft)
• Lubricate the spacers and thrust washers with Upper Front Shock Absorber Bolt
lightweight lithium-based grease. Torque............................................... 40 - 50 N·m
(4.0 - 5.0 m·kg; 30 - 37 lb-ft)
Steering Knuckle King Pin Bolt
Torque...................................................... 35 N·m
1
(3.6 m·kg; 26 lb-ft)
Knuckle Arm-to-Steering Knuckle
Bolt Torque.............................................. 48 N·m
(4.9 m·kg; 35 lb-ft)
Steering Gear Bolt Torque ..................... 48 N·m
(4.9 m·kg; 35 lb-ft)
Tie-rod-to-Knuckle Arm
Torque...................................................... 39 N·m
Y-1181 (4.0 m·kg; 29 lb-ft)
Figure 7-154
Hub Flange Nut Torque ........................ 114 N·m
(11.6 m·kg; 84 lb-ft)
CAUTION
Lug Nut Torque ....................................... 88 N·m
The hub retaining washer is bowl-shaped and (9.0 m·kg; 65 lb-ft)
must be installed correctly. Install the bowl
facing toward the nut.
• Install a new hub retaining conical washer and

nut. Secure with a new cotter pin.
• Tighten all fasteners to specification.

Rear Suspension Components CHASSIS
REAR SUSPENSION COMPONENTS

YDRA (Gas Car) Components
14
3
12
13
13 14
3
12
13
3
13
8
9
11 6 7
11 10 8
3
7 9
5
2
4 Y-1433
Figure 7-155
1.
2.
Rear Suspension Arm Assembly
Bushing
8.
9.
Nut, Self-Locking
Washer, Plate
7
3. Bolt, Flange 10. Rod, Connecting
4. Nut 11. Bolt, with Washer
5. Bolt 12. Shock Absorber Assembly, Rear
7. Bolt, Flange 14. Nut, Flange

CHASSIS Rear Suspension Components
YDRE (Electric Car) Components
14
12
13
13
14
12
13
13
8
11 7
9
6
10
11 8
6
9
7
5
2
4 Y-1434
Figure 7-156
1. Rear Suspension Arm Assembly 8. Nut, Self-Locking

2. Bushing 9. Washer, Plate
3. Bolt, Flange 10. Rod, Connecting
4. Nut 11. Bolt, with Washer
5. Bolt 12. Shock Absorber Assembly, Rear
7. Bolt, Flange 14. Nut, Flange

Rear Suspension Components CHASSIS

Remove the Rear Suspension
1. Park the vehicle on a level surface. 1
2. Block the front wheels. Raise the rear wheels 2

and place suitable stands under the frame.
See Recommended Jack Points on page 1-7.
2
1 1
Y-1233
Figure 7-158
7. Remove front mount center bolt
(Figure 7-158, (1)).
8. Remove rear suspension arm assembly
(Figure 7-158, (2)) from chassis.
Y-1318
Figure 7-157 1
3. Remove both rear wheels and tires.
NOTE:
When removing the shock absorbers, support
the rear arm with a jack.
2

bolts (Figure 7-157, (1)) and remove
connecting rod.
5. Remove the lower shock absorber bolts Y-1234
(Figure 7-157, (2)). Slowly lower the rear arm Figure 7-159
down using the hydraulic jack.
9. Remove two bolts (Figure 7-159, (1)) and
6. Remove the transaxle.
remove front mount (Figure 7-159, (2)).
• YDRA: Remove the engine and transaxle.
See Remove the Engine on page 5-12 and
Transaxle - YDRA (Gas Car) on page 6-10.
• YDRE: Remove the traction motor and
transaxle. See Transaxle - YDRE (Electric
Car) on page 6-31.
7

CHASSIS Rear Suspension Components
Inspect the Rear Suspension Install the Rear Suspension

1. Inspect shock absorbers. See Inspect the Installation is done in the reverse of removal.
Shock Absorbers on page 3-20.
• Tighten all fasteners to specification.
2. Inspect the rear arm for bends, cracks or
other damage. Specification:
3. Inspect the rear arm front mount for damage. Front Mount-to-Frame Bolt
Attempt to move it back and forth to check for Torque...................................................... 32 N·m
excessive free play. Replace as necessary. (3.3 m·kg; 24 lb-ft)
4. Inspect the connecting rod for damage and Front Mount Center Bolt and Nut
bends. Check the bushings for damage or Torque.................................................... 135 N·m
wear. (13.8 m·kg; 100 lb-ft)
Rear Arm to Transaxle Bolt
Torque...................................................... 64 N·m
(6.5 m·kg; 47 lb-ft)
Upper and Lower Rear Shock Absorber Bolt
Torque............................................... 24 - 39 N·m
(2.4 - 3.8 m·kg; 17 - 28 lb-ft)
Suspension Connecting Rod Nut
Torque...................................................... 90 N·m
(9.2 m·kg; 66 lb-ft)

Frame Assembly Components CHASSIS
FRAME ASSEMBLY COMPONENTS

YDRA (Gas Car) Components
3 2
7
3
3
4
5
6
6
Y-1435
Figure 7-160
7
1. Frame Assembly 5. Bracket, Brake Pedal
2. Footrest 6. Nut, Spring
3. Bolt (four used) 7. Bracket, Dash Upper
4. Support, Pedal Bracket 8. Bolt, Flange

CHASSIS Frame Assembly Components
YDRE (Electric Car) Components
3
2
9
3
3
10
6
7
4
5
11
1
Y-1436
Figure 7-161
1. Frame Assembly 7. Bracket, Brake Pedal

2. Footrest 8. Nut, Spring
3. Bolt 9. Bracket, Dash Upper
4. Bracket 10. Bolt, Flange
5. Bolt, Flange 11. Model/Serial Number Plate
6. Support, Pedal Bracket

ELECTRICAL
Table of Contents
— Wiring Diagrams and Electrical Component Location —
YDRA Wiring Diagram........................................................................... 8-4
YDRA Reverse Buzzer Circuit............................................................... 8-5
YDRA Ignition Circuit............................................................................. 8-6
YDRA Component Location .................................................................. 8-7
YDRE Wiring Diagram........................................................................... 8-8
YDRE Reverse Buzzer Circuit............................................................... 8-9
YDRE Component Location ................................................................ 8-10
— Electrical Test and Repair —
Main Switch ......................................................................................... 8-11
Test ............................................................................................... 8-11
Remove ......................................................................................... 8-11
Throttle Stop Switch ............................................................................ 8-12
Test ............................................................................................... 8-12
Remove the Throttle Stop Switch .................................................. 8-12
Install the Throttle Stop Switch ...................................................... 8-12
Reverse Buzzer................................................................................... 8-12
Test the Reverse Buzzer............................................................... 8-12
Remove the Reverse Buzzer ........................................................ 8-13
Install the Reverse Buzzer ............................................................ 8-13
— Repair - YDRA (Gas Car) —
Start Test....................................................................................... 8-15
Charge Test................................................................................... 8-15
Voltage Regulator................................................................................
Output Test....................................................................................
Remove the Starter/Generator ......................................................
8-16
8-16
8-17
8
Disassemble the Starter/Generator............................................... 8-18
Replace Armature Bearing ...................................................... 8-21
Assemble the Starter/Generator.................................................... 8-22
Install the Starter/Generator .......................................................... 8-22

ELECTRICAL
Start Solenoid Relay ........................................................................... 8-23
Function......................................................................................... 8-23
Function Test................................................................................. 8-23
Solenoid Bench Test ............................................................... 8-24
Oil Level Switch................................................................................... 8-25
Remove the Oil Level Switch ........................................................ 8-25
Test the Oil Level Switch............................................................... 8-25
Engine Stop Relay .............................................................................. 8-25
Test the Engine Stop Relay........................................................... 8-25
Remove the Engine Stop Relay .................................................... 8-26
Install the Engine Stop Relay ........................................................ 8-26
Reverse Buzzer Switch ....................................................................... 8-26
Test Reverse Buzzer Switch ......................................................... 8-26
Remove Reverse Buzzer Switch................................................... 8-26
Install Reverse Buzzer Switch....................................................... 8-27
Fuse .................................................................................................... 8-27
Location......................................................................................... 8-27
Test the Fuse ................................................................................ 8-27
Oil Level Indicator Lamp ..................................................................... 8-27
Test ............................................................................................... 8-27
Remove the Oil Level Warning Lamp............................................ 8-28
Install the Oil Level Warning Lamp................................................ 8-28
Transistor Controlled Ignition (TCI) ..................................................... 8-28
Remove the TCI ............................................................................ 8-28
Install the TCI ................................................................................ 8-28
Spark Plug Cap ................................................................................... 8-29
Test the Spark Plug Cap ............................................................... 8-29
Remove the Spark Plug Cap......................................................... 8-29
Install the Spark Plug Cap............................................................. 8-29
Replacing Starter/Generator Belt ........................................................ 8-29
— Repair - YDRE (Electric Car) —
Traction Motor Components................................................................ 8-30
General Specifications .................................................................. 8-31
Remove the Traction Motor........................................................... 8-31
Disassemble the Traction Motor.................................................... 8-32
Inspect and Test the Traction Motor.............................................. 8-34
Replace the Armature Bearing ................................................ 8-36
Assemble the Traction Motor ........................................................ 8-37
Install the Traction Motor............................................................... 8-40
Motor Control Unit ............................................................................... 8-41
Remove the Motor Control Unit..................................................... 8-41
Install the Motor Control Unit......................................................... 8-41
Speed Sensor ..................................................................................... 8-41
Test the Speed Sensor.................................................................. 8-41
Remove the Speed Sensor ........................................................... 8-42
Install the Speed Sensor ............................................................... 8-42

ELECTRICAL
Throttle Position Sensor ...................................................................... 8-43
Test the Throttle Position Sensor .................................................. 8-43
Remove the Throttle Position Sensor............................................ 8-43
Install the Throttle Position Sensor................................................ 8-43
Directional Switch - YDRE................................................................... 8-44
Test the Directional Switch - YDRE............................................... 8-44
Remove the Directional Switch - YDRE ........................................ 8-44
Install the Directional Switch - YDRE ............................................ 8-44
Solenoid .............................................................................................. 8-45
Test the Solenoid .......................................................................... 8-45
Fuse .................................................................................................... 8-46
Location......................................................................................... 8-46
Test the Fuse ................................................................................ 8-46
Tow Switch - YDRE............................................................................. 8-46
Test the Tow Switch - YDRE......................................................... 8-46
Remove the Tow Switch - YDRE .................................................. 8-46
Install the Tow Switch - YDRE ...................................................... 8-46
Charge Receptacle - YDRE ................................................................ 8-47
Remove Charge Receptacle - YDRE ............................................ 8-47
Install the Charge Receptacle - YDRE .......................................... 8-48

8-4
ELECTRICAL
BODY EARTH B
ENG. STOP
RELAY
B B B ENG. EARTH
BUZZER RL
P RL
BACK REV R R R R
SWITCH B P RW L L
FWD B P
B B
FWD + RG
RY RL BW BW RL RY
FWD/REV SW. REV + RL RG
FWD - RY B B RY
BY BY B RW L B
B RG BY BY RG B B L
REV - BW BW YDRA WIRING DIAGRAM
B B
L L
TCI
RW RW RW RW
ACCEL SW.
Br Br Br Br W
LIMIT SW. R
L
RY RW RL Br G
RG BW
OFF RG SHIFT ACTUATOR
ON BY RL BY W L
BW ACCESSORY KIT
G
LIMIT SW. B
Br
MAIN SW.
R Br Br R
OPTIONAL
R
Br
Figure 8-1
G G G BR
PILOT LAMP
Y BR BR
(12V3.4W)
COLOR CODE
B ....................Black G RW B OIL LEVEL SWITCH
B RW G B
L ......................Blue RW B
RW G
R RW B
G ...................Green RW G B
JN6-H2105-00
ENG. EARTH
Y...................Yellow R G
R ......................Red R G
B B
P ......................Pink
BLADE FUSE (4A)-ATM

BLADE FUSE (10A)-ATC
R
Br ..................Brown
VOLTAGE
REGULATOR
B
W ...................White B
B/R .........Black/Red BATTERY
Y/B .....Yellow/Black

RELAY STARTER GENERATOR
R/Y .......Red/Yellow Y-941
R/W ........Red/White
Wiring Diagrams and Electrical Component Location
YDRA Wiring Diagram
BODY EARTH B
ENG. STOP
RELAY
B B B ENG. EARTH
BUZZER RL
P RL
BACK REV R R R R
SWITCH B P RW L L
FWD B P
B B
FWD + RG
RY RL BW BW RL RY
FWD - RY B B RY
BY BY B RW L B
B RG BY BY RG B B L
REV - BW BW
YDRA Reverse Buzzer Circuit
B B
L L
TCI

RW RW RW RW
ACCEL SW.
Br Br Br Br W
LIMIT SW. R
L
RY RW RL Br G
RG BW
ON BY RL BY W L
BW
G
LIMIT SW. B
Br
MAIN SW.
R Br Br R
YDRA REVERSE BUZZER CIRCUIT
OPTIONAL
R
Br
Figure 8-2
G G G BR
PILOT LAMP
Y BR BR
(12V3.4W)
G RW B OIL LEVEL SWITCH

B RW G B
COLOR CODE RW B
RW G
B ....................Black R RW B RW G B
JN6-H2105-00
ENG. EARTH
L ......................Blue R G
G ...................Green
R G
Y...................Yellow
B B
BLADE FUSE (4A)-ATM

R ......................Red BLADE FUSE (10A)-ATC
P ......................Pink R
LEGEND
VOLTAGE
B
REGULATOR
Br ..................Brown
W ...................White B REVERSE BUZZER CIRCUIT
B/R .........Black/Red BATTERY
Y/B .....Yellow/Black RELAY STARTER GENERATOR
R/Y .......Red/Yellow
Y-941A
ELECTRICAL
8-5
8
8-6
BODY EARTH B
ENG. STOP
ELECTRICAL
RELAY
B B B ENG. EARTH
BUZZER RL
P RL
BACK REV R R R R
SWITCH B P RW L L
FWD B P
B B
FWD + RG
RY RL BW BW RL RY
FWD - RY B B RY
BY BY B RW L B
B RG BY BY RG B B L
REV - BW BW
YDRA IGNITION CIRCUIT
B B
L L
TCI
RW RW RW RW
ACCEL SW.
Br Br Br Br W
LIMIT SW. R
L
RY RW RL Br G
RG BW
ON BY RL BY W L
BW
G
LIMIT SW. B
Br
MAIN SW.
R Br Br R
Figure 8-3
OPTIONAL
R
Br
G G G BR
PILOT LAMP
Y BR BR
(12V3.4W)
G RW B OIL LEVEL SWITCH

B RW G B
COLOR CODE RW B
RW G
B ....................Black R RW B RW G B
JN6-H2105-00
ENG. EARTH
L ......................Blue R G
G ...................Green
R G
Y...................Yellow LEGEND

B B
BLADE FUSE (4A)-ATM

BLADE FUSE (10A)-ATC
R ......................Red
P ......................Pink R IGNITION CIRCUIT
VOLTAGE B
REGULATOR
Br ..................Brown
W ...................White B IGNITION CONTROL
B/R .........Black/Red BATTERY CIRCUIT
Y/B .....Yellow/Black RELAY STARTER GENERATOR
Y-941B
YDRA Ignition Circuit
YDRA Component Location ELECTRICAL
YDRA COMPONENT LOCATION
3 4
1 2
5
6
10 9
15 14
13 12 11 Y-1204
Figure 8-4
1. Pilot Lamp 9. Oil Level Switch

2. Reverse Buzzer 10. Spark Plug
3. TCI Ignition 11. Fuse
4. Flywheel 12. Battery - 12V
5. Starter/Generator 13. Fuse
6. Engine Stop Relay 14. Throttle Stop Switch
7. Voltage Regulator 15. Main Switch
8. Start Solenoid

8-8
OPTIONAL
OPTIONAL
CONNECTOR SUPPLIED
ELECTRICAL
BATTERY GAUGE (NOTE 1)
ON JW2-H2590-10 DIRECTIONAL SW.
WIRE HARNESS ONLY
GAUGE PIN-OUT
TOW/ REV FWD I.R.
1 BATTERY +
COLOR CODE STORAGE SW. 2 BATTERY - (NOTE 1) RY TRANSCEIVER
3 NOT USED ACCEL. SW.
B ....................Black Y
4 KEY SW.
OFF ON OFF ON BUZZER W
L ......................Blue R Br W B BR
G ...................Green RY RW W
Y...................Yellow MAIN SW. (NOTE 1)
W
RY RW W R
R ......................Red OFF RY R 1 Y RY
ON P B B BW
P ......................Pink RW B RY Y RY
RW Br
Br ..................Brown P B W
W ...................White RW B RW Br B BW
YDRE WIRING DIAGRAM
B/R .........Black/Red RW RY RY RW P B
RW RW Br
W R
Y/B .....Yellow/Black B W
RY RY
RY RY
R/W ........Red/White RY W
Y
RY BW
1. PRECIOUS METAL CONTACTS ARE REQUIRED.
TYPICAL SIGNAL IS 10mA. RW
R
2. THE 26 POSITION WIRE HARNESS CONECTOR D.C. MOTOR
PLUG PART NUMBER IS JAE MX23A26SF1.

UNUSED CIRCUIT CAVITIES REQUIRE DUMMY
R B R R B R F1 F2
PLUGS P/N M120-55780. RB G G
G
TACH
G
B B
Figure 8-5
FUSE (3 AMP)
3. REFERENCE "WIRING DIAGRAM, (NOTE 2) A1 A2
1", NO. JW2-OF003-00. 13 12 11 8 4 10 9
3 22
RY RB 5 21
6 1 20
7 19
RW RB 2 24 26 25
(P) (A1)
L BO
L B O
L B O
(F2)
BATTERY
(4x12v) L B O
MOSFET BOARD
ASSY. (F1)
R R CONTROL BOARD
PWM OUTPUT
ASSY
GATE DRIVER CIRCUIT
THROTTLE
RECEPTACLE RELAY POSITION
SENSOR
CONTROLLER (N) (A2)

B

Gy Gy
CHARGER DATA RECEIVE Y-940b

YDRE Wiring Diagram
OPTIONAL
(NOTE 1)
DIRECTIONAL SW.
REV FWD
I.R.
(NOTE 1) RY TRANSCEIVER
TOW/STORAGE SW,
COLOR CODE ACCEL. SW.
Y
B ....................Black OFF ON BUZZER W
OFF ON
L ......................Blue R Br WB B R
G ...................Green RY RW W
Y...................Yellow MAIN SW. (NOTE 1)
W 1. PRECIOUS METAL CONTACTS
R ......................Red RY RW W R ARE REQUIRED. TYPICAL
OFF RY R Y RY
SIGNAL IS 10mA.
P ......................Pink ON P B B BW
Br ..................Brown 2. THE 26 POSITION WIRE HARNESS
RW Br Y RY
CONNECTOR PLUG PART NUMBER
W ...................White P B W IS JAE MX23A26SF1. UNUSED
CIRCUIT CAVITIES REQUIRE DUMMY
YDRE Reverse Buzzer Circuit
B/R .........Black/Red RW Br B BW PLUGS P/N M120-55780.

Y/B .....Yellow/Black RW RY RY RW P B
W R
RW RW Br

R/W ........Red/White B W
RY
RY RY
LEGEND W
RY
Y
RY BW
REVERSE BUZZER CIRCUIT
RW
R
D.C. MOTOR
YDRE REVERSE BUZZER CIRCUIT
R B R R B R F1 F2
RB
Figure 8-6
G G
TACH
G G
B B
FUSE (3 AMP)
(NOTE 2)
A1 A2
1 2 3 6 10 4 5
11 18
RY RB 9 19
8 20
7 21
RW RB 12 16 14 15
(P) (A1)
L B O
L B O
L B O
BATTERY (F2)
L B O
(4x12v) MOSFET BOARD
ASSY. (F1)
R R CONTROL BOARD
PWM OUTPUT
ASSY
THROTTLE
GATE DRIVER CIRCUIT
RELAY POSITION
RECEPTACLE
SENSOR
CONTROLLER (N) (A2)

B
G RY
Y-940A
CHARGER DATA RECEIVE
ELECTRICAL
8-9
8
ELECTRICAL YDRE Component Location
YDRE COMPONENT LOCATION
A2 A1
1 2 3
F1 F2
5
4
6
13
8 7
12 Y-1205
11 10 9
Figure 8-7
1. Directional Switch 7. Motor Control Unit

2. Throttle Position Sensor 8. Tow Switch
3. Speed Sensor 9. Batteries (4 x 12V)
4. Traction Motor 10. Charging Receptacle
5. Relay Solenoid 11. Throttle Stop Switch
6. Fuse (3A) 12. Main Switch
13. Reverse Buzzer

Main Switch ELECTRICAL
Electrical Test and Repair

6. Connect the main harness to the switch.
WARNING
Remove
NOTE:
Yamaha recommends using the digital
multimeter P/N YU-A1927 for electrical tests
that require a multimeter.
1
MAIN SWITCH
Test Y-1525
Special Tool: Figure 8-9

Digital Multimeter........................ P/N YU-A1927 1. Remove cup holder from the top of dash.
2. Disconnect the wire harness (Figure 8-9, (1))
NOTE: from the switch.
Removal of the switch is not necessary to
perform test.
Y-1524
Figure 8-10
3. Remove the nut (Figure 8-10, (1)) from the
Y-1236 key switch and remove switch from dash.
Figure 8-8 4. Installation is the opposite of removal.
1. Disconnect the main harness from the switch.
2. Set meter to Ωx1.
3. Connect meter leads to terminals
8
(Figure 8-8, (1)). With the key turned OFF,
the meter reading should show no continuity.
4. With the key turned ON, the reading should
show continuity.
5. Replace the switch if results differ.

ELECTRICAL Throttle Stop Switch
THROTTLE STOP SWITCH 2. Remove two screws (Figure 8-12, (2)) and
remove switch.
Test Install the Throttle Stop Switch
Special Tool: Installation is done in the reverse of removal.
Digital Multimeter........................ P/N YU-A1927
NOTE:
REVERSE BUZZER
Removal of the switch is not necessary to Test the Reverse Buzzer
perform test.
NOTE:
Removal of the buzzer is not necessary to
perform test.
Figure 8-11
1. Disconnect main harness from switch.
Figure 8-13
3. Connect meter leads to switch connector
(Figure 8-11, (1 and 2)). 1. Disconnect main harness connector from
buzzer.
4. Meter reading should show no continuity.
2. Connect a 12V source (YDRA) or 48V source
5. Depress the throttle pedal. The meter should (YDRE) to the buzzer terminals.
show continuity.
3. If the buzzer does not sound, replace the
6. Replace the switch if results differ. buzzer.
Remove the Throttle Stop Switch
Y-1224A
Figure 8-12
1. Disconnect harness connector
(Figure 8-12, (1)).

Reverse Buzzer ELECTRICAL

Remove the Reverse Buzzer
1 2
Y-1241
Figure 8-14
1. Disconnect the buzzer from the electrical
harness.
2. Pull rubber retainer off the ears of the buzzer
and remove the buzzer.
Install the Reverse Buzzer

Installation is done in the reverse of removal.

ELECTRICAL Starter/Generator Components
Repair - YDRA (Gas Car)

STARTER/GENERATOR COMPONENTS
1
14
25
26
16 27
18 16
18 17
25
15 19
23
25
22
24 20
21
12
10 9
2
11
8
31
6
7 28
5
4
13
29 30
Y-1558
Figure 8-15
1. Starter/Generator Assembly 17. Washer

2. Armature Assembly 18. Washer
3. Bearing 19. Brush Holder Assembly
4. Bearing 20. Brush
5. Bearing Holder 21. Brush Spring
6. Stator Assembly 22. Brush Lead
7. Field Coil Assembly 23. Pan Head Screw
8. Screw Kit 24. Pan Head Screw
9. Nut 25. Brush Cover
10. Washer 26. Screw
11. Washer 27. Washer
12. Screw 28. Spacer
13. End Housing 29. Pulley
14. End Housing 30. Flange Nut
15. Screw 31. Screw
16. Nut

Starter/Generator Components ELECTRICAL

Start Test
1. Check that the battery is fully charged and in
good condition.
2. Verify the battery terminals are clean and
tight.
Belt on page 3-13.
4. Engage the park brake and block the wheels.
Y-1515
Figure 8-17
1. Remove the drive belt.
2. Start the engine and set engine speed to
about 2500 rpm.
3. Connect a multimeter to the battery. Measure
the charging voltage. Compare measurement
Figure 8-16 to the specification.
5. Use a jumper lead (Figure 8-16, (3)) to Specification:
connect positive (+) battery terminal
Starter/Generator
(Figure 8-16, (1)) and starter terminal F2
Charging Voltage .............................14.5 - 15.5V
(Figure 8-16, (2)).
at 2500 rpm
6. Use a jumper lead (Figure 8-16, (3)) to
connect the negative (-) battery terminal 4. If voltage is not within specification proceed to
(Figure 8-16, (4)) and starter terminal A1 step 5.
(Figure 8-16, (5)).
7. Starter should crank engine. Remove and
disassemble starter if starter will not crank
engine.
Charge Test
WARNING
• Be sure the drive belt is removed before
starting the engine.
• The speed limiter will not function, so you
must regulate the engine speed with the
throttle.

ELECTRICAL Voltage Regulator
VOLTAGE REGULATOR
Output Test
Special Tool:
Digital Multimeter ....................... P/N YU-A1927
When there is a problem with the charging
system this test is performed to determine if the
problem is with the starter/generator or the
voltage regulator. First determine if the system is
1 2 charging. See Charge Test on page 8-15. If it is
not charging, perform this test.
1. Remove drive belt. See Replace the Drive
Belt on page 3-13.
Y-1528
Figure 8-18
5. Shut off the engine.
6. Disconnect the wire connector from the
starter/generator.
8. Connect the (+) lead from the multimeter to
the red lead of the connector
(Figure 8-18, (2)). Connect the other lead
from the tester to the green lead of the
connector (Figure 8-18, (1)). Y-1515A
9. Measure the charging coil resistance. Figure 8-19

Compare measurement to specification.
2. Set the multimeter to DC 20V DC.
Specification:
3. Connect multimeter to the battery.
Charging Coil Resistance ..................................
4.5 - 5.5 Ω at 20°C (68°F)
10. If measurement is not at specification repair
or replace starter/generator.

Voltage Regulator ELECTRICAL
1 2
2
Y-1448
Figure 8-21
3. Disconnect the negative (-) battery lead.
4. Disconnect the red relay lead from motor
(Figure 8-21, (1)).
5. Disconnect the black negative (-) battery lead
from motor (Figure 8-21, (2)).
6. Disconnect the red/green charge coil leads
(Figure 8-21, (3)).
Y-1533
Figure 8-20 1
4. Disconnect the wire connector from the

voltage regulator. 3
5. Connect a jumper wire from the black wire 4
terminal (Figure 8-20, (1)) and connect it to
the green wire terminal (Figure 8-20, (2)).
6. Start the engine and increase speed to 2
approximately 2500 rpm.
SM-03-016
7. Read the voltage on the tester. If the system
begins charging and reads a minimum of 15.5 Figure 8-22
volts, replace the regulator. 7. Loosen the two flange bolts (Figure 8-22, (1))
8. If the system still is not charging remove the that secure the starter/generator to its
starter/generator and repair or replace it as mounting bracket.
needed. 8. Loosen the lower tensioner locknut
(Figure 8-22, (2)).
Remove the Starter/Generator 9. Loosen adjuster bolt locknut
1. Park on level surface and engage the parking (Figure 8-22, (3)).
brake. 10. Back off the tensioner bolt (Figure 8-22, (4))
2. Remove the seat. and remove the belt.
11. Remove the remaining loosened hardware
and remove the starter/generator.

Disassemble the Starter/Generator

1. Remove the pulley nut and pulley.
2. Mark the end covers and field housing to ease
assembly. 3
3. Remove the brush covers.

2
Y-394
1
Figure 8-25
6. Fabricate a brush spring puller
(Figure 8-25, (3)) using a piece of wire or
paper clip.
7. While holding the spring (Figure 8-25, (2))
Y-393 away from the brush (Figure 8-25, (1)),
remove the brush. Repeat with the remaining
Figure 8-23
brushes.
NOTE:
Hold the brush holder tabs with pliers when
removing stubborn lead connecting screws to
1
avoid twisting the tabs.
4. Remove the lead connecting screws

(Figure 8-23, (1)).
Y-1449
Figure 8-26
8. Remove the through bolts (Figure 8-26, (1)).
9. Separate the brush end cover and brushes
1
from the stator housing.
10. Remove the armature and end cover from the
Y-712
stator housing.
Figure 8-24
5. Check brush spring force using a spring scale
(Figure 8-24, (1)). Check the reading as the
spring just lifts off the brush. Replace the
springs during assembly if the force is not
Specification:
Brush Spring Force ........................ 340 - 460 gf
(12.0 - 16.2 ozf)

0.005 ~ 4.5 ~ 5.5

0.007
x1
Y-396
Figure 8-27
11. Remove three screws (Figure 8-27, (1)) and Y-113
separate the end housing from the armature.
Figure 8-29
Inspect the Starter/Generator 3. Set multimeterto Ωx1.
Special Tool: 4. Connect multimeter tester probes to terminals
F1 and F2 to measure the resistance of the
series field coils.
Specification:
Series Field Coil
Resistance .......................... 0.005 - 0.007 ohms
at 20°C (68°F)
5. Connect multimeter probes to the red wire
and green wire terminals to measure
resistance of the shunt coil.
Specification:
Y-397
Shunt Field Coil
Resistance .................................. 4.5 - 5.5 ohms
Figure 8-28 at 20°C (68°F)
6. Check for short to ground (case).
CAUTION
7. Replace the stator housing assembly if
• Always wear safety glasses when using readings are not within specification.
compressed air.
8. Inspect the armature for evidence of wear or
• Reduce air pressure to 207 kPa (30 psi) damage.
air.
1. Clean the interior of the stator housing and

both end covers using compressed air.
2. Inspect the stator housing and end covers for
cracks or other damage.
8

Figure 8-30
9. Lightly clamp the armature in a vise
(Figure 8-30, (1)) with soft jaws
(Figure 8-30, (2)). Clean the commutator
using #600 grit emery cloth
(Figure 8-30, (3)).
Figure 8-32
11. Measure depth (Figure 8-32, (3)) of mica
between commutator segments. If not within
specification, scrape mica using a hacksaw
blade (Figure 8-32, (2)) that is ground to fit.
Y-398 Carefully clean between segments after
Figure 8-31 scraping mica (Figure 8-32, (1)).
10. Measure the diameter of the commutator Specification:
using a micrometer or caliper. Replace the Mica Undercut (minimum) ...................0.25 mm
armature if not within specification. (0.010 in.)
Specification:
Commutator Diameter
(wear limit)................................39 mm (1.54 in.)


Replace Armature Bearing
2
Figure 8-33
1
12. Use multimeter to measure the resistance
between all segments of the commutator
(Figure 8-33, (1)).
Specification:
Armature Winding Resistance.............. 0 ohms
13. Set meter to highest ohm setting. Check for a
short between the armature laminations and
all segments of the commutator
(Figure 8-33, (2)). Meter should show no
continuity.
Y-114
14. Replace the armature if readings are not
15. Turn the bearing and check for roughness or (a) Remove bearing (Figure 8-34, (1)) with a
looseness. Replace bearing as necessary. bearing puller (Figure 8-34, (2)).
C
C
3
3
4 4
Y-711
Figure 8-35
CAUTION
• NEVER press against or strike the outer
race (Figure 8-35, (3)) during bearing
installation. Use a tool that presses only
against the inner race (Figure 8-35, (4)).
• Ensure the bearing is square to the shaft
when installing.
8
(b) Install a new bearing with a press.

Assemble the Starter/Generator

Assembly is done in the reverse of disassembly.
a
1
Y-115
Figure 8-36
16. Measure brush length. If the wear indicator
(Figure 8-36, (1)) is no longer visible or the
dimension (Figure 8-36, (a)) is less than 1
specification, replace the brushes.
Specification: Y-1450
Starter/Generator Brush Length Figure 8-37
<Limit> ....................................16 mm (0.630 in.)
• Push brush back and allow the spring to hold
brush from the side (Figure 8-37, (1)). Push
each brush into place prior to installing brush
covers.
• Install new components as necessary.
• Install belt pulley, washer and nut. Tighten to
specification.
Specification:
Starter/Generator Pulley Nut
Torque...................................................... 91 N·m
(9.3 m·kg; 67 lb-ft)
Install the Starter/Generator
SM-03-016
Figure 8-38
1. Flange Bolt
2. Tensioner Locknut
3. Adjuster Jam Nut
4. Adjuster Bolt

Start Solenoid Relay ELECTRICAL

1. Place the starter/generator on the engine and
install two flange bolts. Do not tighten at this
time.
2. Loosely install the tensioner locknut. 3
3. Install the belt and adjust to the correct
tension. See Starter Belt on page 3-23.
4. Tighten all bolts and nuts.
5. Connect wires and cables.
6. Connect negative (-) battery cable.
2
START SOLENOID RELAY 1
Function Y-1235
The solenoid coil, when activated by closing the Figure 8-40

engine stop switch, closes the solenoid contacts,
thus providing the starter with current. It also acts (a) If the solenoid clicks but engine does not
as a safety device, preventing the vehicle from crank, disconnect cables and test
abruptly starting when the main switch is continuity across the contact posts
operated. (Figure 8-40, (3)) while solenoid is
activated.
Function Test • Continuity good - suspect a defective
Special Tool: starter/generator
Digital Multimeter........................ P/N YU-A1927 • No continuity - suspect a defective
solenoid
1. Remove the seat.
2. Remove the drive belt. See Replace the Drive (b) If the solenoid does not click, disconnect
Belt on page 3-13. wires (Figure 8-40, (1 and 2)) and
measure resistance across primary
OFF
terminals. See Solenoid Bench Test on
ON page 8-24.
• Resistance correct - suspect a defective
throttle pedal switch or wire harness
wiring
• Resistance not within specification -
suspect a defective solenoid
Y-913b
Figure 8-39
3. Turn the main switch to ON.
4. Press the throttle pedal. The solenoid should
click and the engine should crank over.

ELECTRICAL Start Solenoid Relay
Solenoid Bench Test Remove the Solenoid

1. Disconnect negative (-) battery cable.
3
3
2
1 2
1
Y-1235
Y-1235
Figure 8-41
Figure 8-42
1. Disconnect red/white lead (Figure 8-41, (1))
and black lead (Figure 8-41, (2)) from 2. Disconnect all leads and cables
solenoid primary terminals. (Figure 8-42, (1, 2 and 3)) from solenoid.
2. Measure resistance across the primary 3. Remove attaching bolts and remove solenoid.
terminals. If not within specification, replace
solenoid. Install the Solenoid
Specification: 1. Install the solenoid and tighten fasteners
Starter Solenoid Coil securely.
Resistance ±10% .........21 ohms @ 20°C (68°F) 2. Connect cables to terminal posts
3. Check the cable connections at the solenoid (Figure 8-42, (3)).
contact posts (Figure 8-41, (3)). Clean and Specification:
tighten as necessary. Solenoid Terminal Post Nut
Specification: Torque........................................................ 6 N·m
Solenoid Terminal Post Nut (0.6 m·kg; 53 lb-in.)
Torque ........................................................ 6 N·m 3. Connect black (Figure 8-42, (2)) and
(0.6 m·kg; 53 lb-in.) red/white (Figure 8-42, (1)) leads to the
4. Turn main switch OFF. primary terminals.
5. Install drive belt. See Replace the Drive Belt 4. Connect the negative (-) battery cable.
on page 3-13.

Oil Level Switch ELECTRICAL
OIL LEVEL SWITCH ENGINE STOP RELAY

Remove the Oil Level Switch Test the Engine Stop Relay
The engine oil level switch can only be accessed Special Tool:
when the engine is disassembled. See Remove Digital Multimeter ....................... P/N YU-A1927
the Camshaft Components on page 5-20.
Test the Oil Level Switch

Special Tool: 1 2
NOTE:
Removal of the switch is not necessary to 4 3
perform test.
1 Y-1239
Figure 8-44
1. Black
2. Black
3. Blue
4. Red
Belt on page 3-13.
2. Disconnect TCI wire harness 2-wire
Y-1238
connector at engine (blue and black wires).
Figure 8-43
4. Check continuity between blue
1. Disconnect engine harness connector (Figure 8-44, (3)) and black
(Figure 8-43, (1)) from the oil level switch. (Figure 8-44, (2)) wires at the relay
2. Set meter to Ωx1. connector. Meter should show continuity.
3. Ensure the engine oil level is within the 5. Leave the meter leads connected and turn the
normal operating range. main switch on and depress the throttle pedal.
4. Connect one meter lead to the switch The relay should make a click sound and the
connector and the other to engine ground. meter should show no continuity.
5. Meter reading should show no continuity. • Relay clicks but meter shows continuity -
replace the relay.
6. Drain oil from crankcase. Meter should now
show continuity. • Relay does not click - go to next step.
7. Replace the low oil switch if results differ.
8

ELECTRICAL Reverse Buzzer Switch
6. Set meter to DC Volts. REVERSE BUZZER SWITCH

7. Connect black meter lead to the black
terminal (Figure 8-44, (1)). Connnect red Test Reverse Buzzer Switch
meter lead to the red terminal
(Figure 8-44, (4)). Special Tool:
8. Turn the main switch on and depress the Digital Multimeter ....................... P/N YU-A1927
throttle pedal. The meter should show battery
voltage. NOTE:
• Meter shows battery voltage but relay does Removal of the switch is not necessary to
not click - replace relay. perform test.
• Meter shows no voltage - check main fuse,
throttle switch and associated circuits.
Remove the Engine Stop Relay

R BK Ωx1
_ +
Y-1339
Figure 8-46
1. Disconnect main harness from switch.
3. Connect meter leads to switch connector.
4. Move shift control to FORWARD. Meter
reading should show no continuity.
Y-1235A
5. Move shift control to REVERSE. Meter should
Figure 8-45
show continuity.
1. Remove the rear access panel. 6. Replace switch if results differ.
2. Remove the relay (Figure 8-44, (1)) from the
rubber retainer. Remove Reverse Buzzer Switch
3. Disconnect the relay from the wire harness.
Install the Engine Stop Relay

1
Y-1335
Figure 8-47
1. Disconnect harness connector.
2. Remove screws (Figure 8-47, (1)) and
remove switch.

Fuse ELECTRICAL
Install Reverse Buzzer Switch OIL LEVEL INDICATOR LAMP
Test
FUSE Special Tool:
Location
NOTE:
The drink holder must be removed to access
the indicator lamp connector.
1 1. Remove the bulb. See Remove the Oil Level

Warning Lamp on page 8-28.
Y-1266
Figure 8-48
The main fuse is located in the main harness Figure 8-49
where it runs along the frame below the battery. 2. Set meter to Ωx1.
Test the Fuse 3. Touch one meter probe to the bulb case and
the other to the center terminal (Figure 8-49).
1. Locate and remove fuse (Figure 8-48, (1)).
4. Meter reading should show continuity.
2. Visually inspect looking for evidence of a
5. Replace the bulb if results differ.
burned element or test continuity with an
ohmmeter.
3. If fuse is defective, replace with one of same
type and amperage rating.
Specification:
Main Fuse ..................................................... 10A
Figure 8-50
6. Disconnect main harness connector from the
indicator lamp socket.
7. Install the bulb.
9. Connect one meter probe to each terminal of
the socket connector (Figure 8-50).
8
10. Meter reading should show continuity.
11. Replace the socket if results differ.

ELECTRICAL Transistor Controlled Ignition (TCI)
Remove the Oil Level Warning TRANSISTOR CONTROLLED

Lamp IGNITION (TCI)
Remove the TCI
1. Remove engine. See Remove the Engine on
page 5-12.
2. Remove the flywheel cover. See Remove the
Flywheel Magneto on page 5-18.
Y-1260
1
Figure 8-51
1. Remove the drink holder.
2. Disconnect the lamp wire harness connector. SM-03-381A
3. Remove the lamp and socket from the Figure 8-52

grommet in the dash.
3. Disconnect the spark plug lead
Install the Oil Level Warning Lamp (Figure 8-52, (1)).
4. Remove two bolts (Figure 8-52, (2)).
5. Remove TCI unit.
Install the TCI

Adjust air gap to specification. See Test and
Adjust Transistor Control Ignition (TCI) on
page 5-4.

Spark Plug Cap ELECTRICAL
SPARK PLUG CAP REPLACING

Test the Spark Plug Cap
STARTER/GENERATOR BELT
See Starter Belt on page 3-23.
Special Tool:
x 100
– +
Y-753
Figure 8-53
2. Connect meter leads as shown (Figure 8-53).
3. If meter reading is not within specification,
replace the spark plug cap.
Specification:
Spark Plug Cap
Resistance ±10%............................4 - 6 k-ohms
@ 20°C (68°F)
Remove the Spark Plug Cap

1. Disconnect the spark plug cap from the spark
plug.
2. Twist the spark plug cap counterclockwise to
remove from spark plug lead.
Install the Spark Plug Cap
NOTE:
A few drops of isopropyl alcohol will ease
assembly.
1. Twist spark plug cap clockwise onto end of

spark plug lead.
2. Install spark plug cap to spark plug.

ELECTRICAL Traction Motor Components
Repair - YDRE (Electric Car)

TRACTION MOTOR COMPONENTS
1
30
1
31
1
17 18 1
20
1
16 1
11
14 1
10
9
1
8
1
13 7
1
1 28
29 1 23
1
1
12 6
1
1
15
1
22
1
21
1
19
5
1
4
1
3
1
2
1
1
1
25
1
27
1
24
1
26
Y-1437
Figure 8-54
1. Relief, Strain 17. Screw

2. Armature Assembly 18. Pick-Up Assembly
3. Field Coil Assembly 19. Insulator
4. Spring, Brush 20. Insulator
5. Brush Holder Assembly 21. Washer, Special
6. Brush Set 22. Washer, Special
7. Bushing, Terminal 23. Nut
8. Washer 24. Bolt
9. Washer 25. Washer, Lock
10. Washer, Plain 26. Washer, Plate
11. Nut 27. Grommet
12. Bearing 28. Washer, Plate
13. Bearing 29. Nut
14. Bracket, Front 30. Nut, Special
15. Bolt 31. Washer
16. Magnet

Traction Motor Components ELECTRICAL

General Specifications Remove the Traction Motor
Item Specification
1. Remove the seat.
Model DM430-06
2. Remove the rear access panel.
Rated Output 2.6 kW (3.5 hp) for 30
3. Disconnect the negative (-) battery lead.
minutes
Operating Voltage 48V DC 1
Operating Current 10A
Set Torque 13.42 N·m (1.4 m·kg;
9.9 lb-ft)
Speed 2475 rpm
(maximum allowable) 2905 rpm 2
Weight 22 kg (48.5 lb)
1
Y-1206
Figure 8-55
4. Disconnect four leads from motor terminals
(Figure 8-55, (1)).
5. Remove wire tie that secures the harness to
the wire support (Figure 8-55, (2)).
Y-1207
Figure 8-56
6. Disconnect speed sensor lead
(Figure 8-56, (1)).
7. Use a hydraulic floor jack and DC Motor
Cradle to support the traction motor.
Special Tool:
DC Motor Cradle ..........................P/N YG-40105
8

Y-1208
Figure 8-57 Y-1211
8. Remove three bolts (Figure 8-57, (1)) that Figure 8-59

secure the motor.
2. Mark the end cover and field housing to
simplify assembly.
NOTE:
Only two bolts are shown.
9. Remove the traction motor.
Disassemble the Traction Motor

1
Y-1212
Figure 8-60
1 3. Remove through bolts (Figure 8-60, (1)).
Y-1209
Figure 8-58
1. Mark the sensor orientation on the end
housing (Figure 8-58, (1)). Remove four bolts
(Figure 8-58, (2)) and remove sensor
assembly.


6. Lift end cover squarely off the bearing.
7. Measure brush length. If less than
specification, replace with new.
Specification:
Traction Motor Brush
Length (minimum) .............. 14.48 mm (0.57 in.)
Y-1219
Figure 8-63
8. Push the brush back through brush holder
until the spring (Figure 8-63, (1)) holds it in
place. Repeat on the remaining three
brushes.
Y-1217
Figure 8-61
4. Remove the armature and end cover as an
assembly from the field housing and frame.
Y-1220
Figure 8-64
9. Remove four screws (Figure 8-63, (1)).
10. Remove nuts, lock washers and flat washers
8
from both studs.
Y-1218
Figure 8-62
5. Remove screws (Figure 8-62, (1)) that
secure the bearing retainer.

Inspect and Test the Traction Motor

1 Special Tool:
WARNING
• Always wear safety glasses when using
compressed air.
• Reduce air pressure to 207 kPa (30 psi)
air.
2 2
1. Clean the interior of the frame and bracket
Y-1222 using compressed air.
Figure 8-65 2. Inspect the outer surface for cracks or
damage.
11. Push studs through end cover as the brush
holder is lifted out of the cover.
1 2
4 3
Y-1242
Figure 8-66
3. Check continuity between terminal F1 and
ground and terminal F2 and ground, to check
for shorted field windings. Meter should
indicate greater than 1 M-ohm @ 24°C
(75°F).
4. Connect meter leads to terminals F1 and F2
to measure field coil resistance. Replace field
and frame assembly if not within specification.
Field Winding Resistance.... 0.716 ohms ±10%
@ 24°C (75°F)

5. Measure resistance between all segments of 9. Lightly clamp the armature in a vise
the commutator to measure armature winding (Figure 8-69, (1)) with soft jaws
resistance. Replace armature if not within (Figure 8-69, (2)). Clean the commutator
specification. using #600 grit emery cloth
(Figure 8-69, (3)).
Armature Winding
Resistance ........................... 0.0176 ohms ±10%
@ 24°C (75°F)
6. Set meter to highest ohms setting. Check for
a short between the armature laminations
and all segments of the commutator
(Figure 8-67, (2)). Meter should read 1 meg
ohm or higher.
7. Replace the armature if readings are not
Y-650
Figure 8-70
10. Measure the diameter of the commutator
using a micrometer or caliper. Replace the
armature if not within specification.
Commutator Diameter
(wear limit) ............................... 63 mm (2.48 in.)
Y-709
Figure 8-68
8. Roll the bearings and check for roughness or
looseness. Replace bearing as necessary.
See Replace the Armature Bearing on
page 8-36.

Replace the Armature Bearing
Y-710
Figure 8-72
(a) Remove bearing (Figure 8-72, (1)) with a
bearing puller (Figure 8-72, (2)).
C
C
3
Figure 8-71 3
11. Measure depth (Figure 8-71, (3)) of mica

between commutator segments. If not within
specification, scrape mica using a hacksaw 4 4
blade (Figure 8-71, (2)) that is ground to fit.
Y-711
Carefully clean between segments after
scraping mica (Figure 8-71, (1)). Figure 8-73
Mica Undercut
Standard .....................................1 mm (0.04 in.) CAUTION
<minimum>..........................0.25 mm (0.010 in.)
• NEVER press against or strike the outer
race (Figure 8-73, (3)) during bearing
installation. Use a tool that presses only
against the inner race (Figure 8-73, (4)).
• Ensure the bearing is square to the shaft
when installing.
(b) Install a new bearing with a press.


Assemble the Traction Motor
4
1 3
2 2
Y-1221
Y-1222 Figure 8-76

Figure 8-74 1. Nut
2. Internal Star Washer
NOTE:
3. Flat Washer
4. Fiber Washer
Some brush wires (Figure 8-74, (1)) are routed
under the brush holder when installed. Ensure 14. Install the fiber washer, flat washer, star
they are routed where they will not be pinched washer and nut on each stud. Tighten nut
when the brush holder is installed. securely. Do not overtighten.
12. Align the studs (Figure 8-74, (2)) as the

brush holder is installed. Be sure no wires will
be pinched when the brush holder is installed.
Y-1220
Figure 8-77
15. Install and tighten four screws
Y-1222A (Figure 8-77, (1)).
Figure 8-75
13. Ensure the insulators are installed with the
8
white mark (Figure 8-75, (1)) visible.

1
2
Y-1220A Y-1336

19. Turn the assembly over with armature spline
NOTE: on work bench.
Use care not to damage the brushes when 20. Use an 8-32 x 1-1/4 inch pilot screw
installing the armature. Ensure the brushes are (Figure 8-80, (1)) to hold the bearing retainer
pushed into their brush holders and held in while installing the other screw
place by the springs. (Figure 8-80, (2)). Remove the pilot screw
and install the second screw.
16. Ensure all brushes are held back by the

springs and that the brush wires are routed
inside the metal tabs (Figure 8-78).
1
Y-1218
Figure 8-81
21. Tighten the bearing retainer screws
Y-1223A (Figure 8-81, (1)).
Figure 8-79
17. Support the end cover so it is supported at
least 1/2 inch above the bench top. Carefully
lower the armature and bearing into the end
cover being careful to keep it square to the
cover. The bearing should slide easily into the
bearing bore in the end cover.
18. Push brushes into position (Figure 8-79).

Y-1212
Figure 8-84
24. Install and tighten four through bolts
(Figure 8-84, (1)).
Y-1217
Y-1210
Figure 8-82
Figure 8-85
22. Install the armature and cover assembly into
the field housing. 25. Ensure sensor gasket is in good condition
and in place.
2
1
Y-1211 Y-1209
8
23. Align the mark (Figure 8-83, (1)) made during 26. Install speed sensor assembly using mark
disassembly. (Figure 8-86, (1)) made during disassembly
to align. Install and tighten four screws
(Figure 8-86, (2)).

Install the Traction Motor
1 2
Y-1206
Y-1208
Figure 8-89
Figure 8-87
3. Connect the motor cable leads and tighten
1. Install the traction motor and secure with nuts (Figure 8-89, (1)) to specification.
three bolts (Figure 8-87, (1)). Tighten bolts to
specification. Specification:
Specification: Traction Motor Cable “A” Nut
Torque..................................................... 6.8 N·m
Traction Motor Bolt (0.6 m·kg; 60 lb-in.)
Torque ...................................................... 12 N·m
(1.2 m·kg; 106 lb-in.) Specification:
Traction Motor Cable “F” Nut
Torque..................................................... 5.4 N·m
(0.5 m·kg; 47 lb-in.)
4. Secure cable to wire support
1
(Figure 8-89, (2)) with a wire tie.
5. Install the negative (-) battery lead and tighten
to specification.
Specification:
Battery Terminal Nut
Torque........................................................ 9 N·m
(0.9 m·kg; 80 lb-in.)
Y-1207
Figure 8-88
2. Connect the speed sensor leads
(Figure 8-88, (1)).

Motor Control Unit ELECTRICAL
MOTOR CONTROL UNIT Specification:

Battery Cable Torque .............................. 9 N·m
Remove the Motor Control Unit (0.9 m·kg; 80 lb-in.)
1. Discharge the motor control unit. See Safety
Lockout Procedure on page 1-7. SPEED SENSOR
2. Place tow switch in the TOW position.
3. Disconnect negative (-) battery lead. Test the Speed Sensor
4. Remove the rear access panel. Special Tool:
Speed Sensor Test Cord ......... P/N YG-42221-A
NOTE:
7
2 The sensor must remain installed to perform the
following test.
1
5 3
4 1. Block both front wheels.
6 2. Raise only one rear wheel off the floor and
support with a jack stand. See
Y-1535A
Figure 8-90
1
1. A1
2. POS
3. A2/NEG
4. F1
5. F2
6. Main Harness Connector
7. Mounting Screw (three used)
5. Disconnect the A1, POS and A2/NEG wires.

Y-1207
6. Disconnect wires F1, F2 and the main
harness connector. Figure 8-91
7. Remove three mounting screws. 3. Disconnect the speed sensor
8. Remove motor control unit. (Figure 8-91, (1)) from the main harness.
4. Connect the Speed Sensor Test Cord
Install the Motor Control Unit between the sensor and the main harness.
1. Install MCU and tighten three mounting 5. Connect the multimeter red probe to the test
screws securely. cord green wire and the black probe to the
2. Install A1, POS and A2/NEG wires.
3. Install wires F1, F2 and main harness
test cord black wire.
6. Slowly rotate the rear wheel and look for a
voltage reading that swings from
8
connector. 0V DC to 5V DC ±10%.
4. Install rear access panel.
5. Connect negative (-) battery lead and tighten
to specification.

ELECTRICAL Speed Sensor
Remove the Speed Sensor Install the Speed Sensor
Y-1207 Y-1210

1. Disconnect the speed sensor 1. Ensure sensor gasket is in good condition
(Figure 8-92, (1)) from the main harness. and in place.
2. Install speed sensor assembly using mark
made during disassembly to align. Install and
2 tighten four screws.
3. Connect the sensor to the main harness.
Y-1209
Figure 8-93
2. Mark the sensor orientation on the end
housing (Figure 8-93, (1)). Remove four
screws (Figure 8-93, (2)) and remove sensor
assembly.
3. Inspect the magnet (Figure 8-93, (3)) for
damage or foreign material.
(a) If contaminated, clean and retest.
(b) If damaged or if test fails a second time,
replace the magnet, sensor or traction
motor as necessary.

Throttle Position Sensor ELECTRICAL
THROTTLE POSITION SENSOR

Test the Throttle Position Sensor
Special Tool:
2
1. Remove the floor mat and lift out the service
cover.
2. Disconnect the main harness connector from
the motor controller. 1
Figure 8-96
2. Disconnect the main harness connector
(Figure 8-96, (1)) from the sensor.
3. Remove two screws (Figure 8-96, (2)) and
slide sensor off shaft.
Install the Throttle Position Sensor

5 6 7
5. Blue
6. Black
7. Orange
Figure 8-95
NOTE:
Use a digital multimeter for the following tests.
Use (Figure 8-95) to identify the correct
location of the wires.
3. Check resistance between the following pairs

of terminals:
(a) Blue-to-black: 5 k-ohms (pedal in any
position).
(b) Orange-to-black: 0 - 150 ohms with pedal
at rest, gradually and evenly increasing to
5 k-ohms as pedal is fully depressed.
4. Replace the throttle position sensor if the
readings differ. 8
Remove the Throttle Position
Sensor
1. Remove the floor mat and lift out the access
cover.

ELECTRICAL Directional Switch - YDRE
DIRECTIONAL SWITCH - YDRE Remove the Directional Switch -

YDRE
Test the Directional Switch - YDRE
1. Remove beverage holder.
NOTE:
Some of the following steps require
back-probing connectors. Use extreme care not
to damage the terminal or wire seal when
performing those steps.
1. Remove beverage holder.
1
2
Y-1264
Figure 8-98
3
3. Squeeze tabs on each end of switch and push
switch through dash panel.
Install the Directional Switch - YDRE

Y-1328
1. Red/White
2. Yellow
3. White
Figure 8-97
2. Disconnect direction switch 3-wire connector.
3. With direction switch in FORWARD, check
continuity between switch harness red/yellow
and white wires.
4. With direction switch in REVERSE, check
continuity between switch harness red/yellow
and yellow wires.
Replace switch if either test fails.

Solenoid ELECTRICAL
SOLENOID • No continuity - suspect a defective

solenoid
Test the Solenoid (b) If solenoid does not click, disconnect
connector (Figure 8-100, (3)) and
Special Tool: measure resistance across primary
Digital Multimeter........................ P/N YU-A1927 terminals (Figure 8-100, (2)).
1. Remove the rear access panel. • Resistance correct - suspect a defective
2. Check the cable connections at the solenoid throttle pedal switch or wire harness
contact posts. Clean and tighten as wiring
necessary. • Resistance not within specification -
suspect a defective solenoid
OFF
ON Specification:
Solenoid Coil
Resistance ±10% ......... 21 ohms @ 20°C (68°F)
5. Turn main switch OFF.
Y-913b
Figure 8-99
Specification:
Solenoid Terminal Post Nut
Torque ........................................................ 6 N·m
(0.6 m·kg; 53 lb-in.)
3. Turn the main switch ON.
2
3
Y-1265A
Figure 8-100
4. Press the throttle pedal. The solenoid should
click and car should begin to move.
(a) If solenoid clicks but car does not move,
test continuity across the contact posts
8
(Figure 8-100, (1)) while solenoid is
activated.
• Continuity good - suspect a defective
motor control unit or traction motor

ELECTRICAL Fuse
Remove the Solenoid FUSE

Location
3
3
Y-1240
Y-1265
Figure 8-102
Figure 8-101
1. Main Fuse (3A)
3. Disconnect cables from studs
The main fuse is located in the main harness
(Figure 8-101, (1)).
adjacent to the tow switch.
4. Disconnect harness connector
(Figure 8-101, (2)). Test the Fuse
5. Remove bolts (Figure 8-101, (1)) and remove
1. Locate and remove fuse.
solenoid.
2. Visually inspect looking for evidence of a
Install the Solenoid burned element or test continuity with an
ohmmeter.
3. If fuse is defective, replace with one of same
Specification: type and amperage rating.
Solenoid Terminal Post Nut Specification:
Torque ........................................................ 6 N·m Main Fuse........................................................3A
(0.6 m·kg; 53 lb-in.)
TOW SWITCH - YDRE

Test the Tow Switch - YDRE
1. Disconnect tow switch harness connector.
2. Move tow switch to the RUN position.
3. Check continuity between the switch
terminals. Meter should show continuity.
Replace tow switch if results differ.
Remove the Tow Switch - YDRE

2. Loosen nut and remove switch.
Install the Tow Switch - YDRE


Charge Receptacle - YDRE ELECTRICAL
CHARGE RECEPTACLE - YDRE

Remove the Charge Receptacle -
YDRE
1. Lockout the vehicle. (See Safety Lockout
Procedure on page 1-7).
2. Remove the seat.
Y-1655
Figure 8-105
5. Drill the inner cylinder of the 3 rivets securing
the charging guide to the rear body using a
4mm drill bit (Figure 8-105).
Y-1653
Figure 8-103
3. Disconnect the negative and positive battery
terminals using a 14mm socket/driver
combination (Figure 8-103).
Y-1656
Figure 8-106
6. Remove the charging receptacle and outer
core of the rivets from the rear body
(Figure 8-106).
Y-1654
Figure 8-104
4. Cut the cable ties securing the negative and
positive charging receptacle wire leads
(Figure 8-104).
Y-1657
Figure 8-107
7. Loosen the charging plug mounting bolts
8
using a 1/4" socket/driver combination
(Figure 8-107).

ELECTRICAL Charge Receptacle - YDRE
Install the Charge Receptacle -

YDRE
A. B.
Y-1658
Figure 8-108
8. Remove the charging receptacle Y-1660
(Figure 8-108A), noting the orientation of the Figure 8-110

negative and positive symbols on the
charging receptacle for reassembly purposes 1. Plug the motor control unit wire lead into the
(Figure 8-108B). new charging receptacle (Figure 8-110).
Y-1661
Figure 8-111
2. Position the charging receptacle onto the
Y-1659
mounting bracket/bolts ensuring the correct
Figure 8-109 orientation as previously noted
9. Unplug the motor control unit wire lead from (Figure 8-111).
the charging receptacle (Figure 8-109).
Y-1662
Figure 8-112
3. Tighten the charger plug mounting bolts using
a 1/4" socket/driver combination and torque to
1.4 - 1.8 N•m (Figure 8-112).

Charge Receptacle - YDRE ELECTRICAL
Y-1663
Figure 8-113 Y-1666
Figure 8-116
6. Verify a secure fit and proper alignment of the
charging receptacle/guide (Figure 8-116).
Y-1664
Figure 8-114
4. Position the charging plug guide and new
rivets in the rear body cut-out (Figure 8-113),
noting the orientation of the white arrow on
the charging receptacle (Figure 8-114).
Y-1667
Figure 8-117
7. Reattach the negative and positive battery
terminal leads (Figure 8-117). Torque to
9 - 10 N•m.
Y-1665
Figure 8-115
5. Rivet the charging plug guide to the rear body
(Figure 8-115), while applying pressure to the
back of the rear body to ensure proper fit.
Y-1668
Figure 8-118
8. Secure the charging receptacle wire leads to
the side of the batteries using cable ties
8
(Figure 8-118).
9. Plug the battery charger into the golf car
charging plug and ensure the charger cycles
to “CHARGING.”

ELECTRICAL Charge Receptacle - YDRE

TROUBLESHOOTING
Table of Contents
— Troubleshooting - YDRA (Gas Car) —
Starter Will Not Turn.............................................................................. 9-3
Engine Cranks and Has Spark But Will Not Start.................................. 9-4
Engine Cranks But is Weak or Has No Spark ....................................... 9-5
Engine Backfires ................................................................................... 9-5
Engine Intermittently Cuts Out .............................................................. 9-6
Engine Will Not Stop Running ............................................................... 9-6
Loss of Power or Speed ........................................................................ 9-7
Carburetor Floods ................................................................................. 9-8
Transaxle Will Not Shift Into Forward or Reverse ................................. 9-8
Transaxle is Noisy ................................................................................. 9-9
Transaxle is Leaking Oil ........................................................................ 9-9
Car Will Not Move Forward or Reverse................................................. 9-9
Excessive Vibration ............................................................................. 9-10
Engine is Seized; Will Not Turn Over .................................................. 9-10
— Troubleshooting - YDRE (Electric Car) —
Traction Motor ..................................................................................... 9-12
Resetting Motor Control Unit ............................................................... 9-13
MCU Main Harness Connector ........................................................... 9-13
Reverse Warning Buzzer Does Not Work ........................................... 9-14
Car Will Not Run at Rated Speed........................................................ 9-14
Car Will Not Operate in Either Direction - Solenoid Does Not Click.... 9-15
Car Will Not Operate in Either Direction - Solenoid Does Click .......... 9-16
No Regenerative Braking or Rollaway Protection ............................... 9-18
9
TROUBLESHOOTING
— Z-2 Diagnostic Tester —
Z-2 Harness Connections ................................................................... 9-19
Z-2 Tester...................................................................................... 9-19
Z-2 Tester Harness Adapter.......................................................... 9-19
Preliminary Checks and Guidelines .............................................. 9-19
Operating Instructions ......................................................................... 9-20
Z-2 Tester Failure Chart ...................................................................... 9-21
— Genius Diagnostic System —
Introduction ......................................................................................... 9-23
Genius Diagnostic System .................................................................. 9-23
Personal Digital Assistant (PDA)................................................... 9-23
Transmitter Unit............................................................................. 9-23
Software Installation ...................................................................... 9-23
Transmitter Unit Installation ................................................................ 9-24
Diagnostic Mode ................................................................................. 9-26
Data Screen .................................................................................. 9-27
Read Tab................................................................................. 9-28
Set Car # Tab .......................................................................... 9-29
Faults Screen ................................................................................ 9-30
Faults:...................................................................................... 9-30
Help ......................................................................................... 9-31
About Application .................................................................... 9-31
Read Tab................................................................................. 9-31
Erase Tab ................................................................................ 9-32
Troubleshooting Using Genius ............................................................ 9-33
Golf Car Programming Mode .............................................................. 9-40
Mode Select Screen ...................................................................... 9-41
Read Mode .............................................................................. 9-41

Starter Will Not Turn TROUBLESHOOTING
Troubleshooting - YDRA (Gas Car)
WARNING
STARTER WILL NOT TURN

Required Tools
Digital Multimeter............................... YU-A1927 NOTE:
Remove the following components before starting The car was originally equipped with a
procedure: maintenance-free battery. Never remove the
caps on a maintenance-free battery to check
• Seat electrolyte level.
• Rear access cover
• Beverage holder
• Pedal group access plate
Step Check Good Bad

1 Ensure battery terminals are Go to step 2. Clean and tighten to 9 N·m
clean and tight. (0.9 m·kg; 80 lb-in.).
2 Check battery charge and Go to step 3. Charge or replace battery.
condition using a battery load
tester. (See Discharge Load Test
on page 4-23.) Follow the battery
tester manufacturer’s guidelines.
If battery is dead charge battery
and test charging system. See
Charge Test on page 8-15 and
Output Test on page 8-16.
3 Check for a blown fuse. Go to step 4. Replace fuse.
4 Test main switch continuity. See Go to step 5. Replace switch.
Main Switch on page 8-11.
5 Test throttle stop switch. See Go to step 6. Replace stop switch.
Throttle Stop Switch on
page 8-12.
6 Test the starter by using jumper Go to step 7. Repair or replace as necessary.
wires to connect directly to the
battery. See Starter/Generator
Components on page 8-14.
7 Perform solenoid function test. Check start circuit wiring for Replace solenoid.
See Start Solenoid Relay on breaks or loose connections.
page 8-23.
9
TROUBLESHOOTING Engine Cranks and Has Spark But Will Not Start
ENGINE CRANKS AND HAS SPARK BUT WILL NOT START

Required Tools Remove the following components before starting
Compression Tester ...........................YU-33223 procedure:
• Seat
• Rear access panel
Step Check Good Bad

1 Fresh clean fuel in tank. Go to step 2. Fill with clean fresh fuel.
2 Gas cap vent is clear. Go to step 3. Clean or replace.
3 Vent hoses are routed properly Go to step 4. Clean or replace.
without crimps or contamination.
4 Fuel pump output. See Testing Go to step 5. • Inspect fuel filter for debris.
the Fuel Pump on page 5-3. • Inspect fuel and pulse hoses
for damage or kinks.
• Replace fuel pump.
5 Remove spark plug and check 0.7 - 0.8 mm (0.028 - 0.030 in.) Adjust or replace as necessary.
condition and gap. See Change Go to step 6.
the Transaxle Oil on page 3-31.
6 Check adjustment of throttle Go to step 7. Adjust or replace as necessary.
cables. See Check and Adjust the
Speed Limiter on page 3-24.
Check for misrouted or damaged
cables.
7 Speed limiter adjustment. See Go to step 8. Adjust or replace as necessary.
Check and Adjust the Speed
Limiter on page 3-24.
Inspect for damage.
8 Choke cable adjustment and Go to step 9. Adjust or replace as necessary.
operation. Ensure choke closes
completely. See Adjust the
Choke Cable on page 5-5.
9 Carburetor body, float, float Go to step 10. Clean and repair as necessary.
valve, pilot screw for
contamination. See Repair the
10 Inspect air filter elements for dirt Go to step 11. Clean or replace as necessary.
and blockage. See Clean the
Pre-Filter/Air Filter on page 3-15.
Check for blocked air inlet.
11 Perform compression test. See Go to step 12. • Follow guidelines in procedure.
Check the Engine Compression • Repair engine as necessary.
Pressure on page 3-16.
12 Valve clearance. See Change the Adjust as necessary.
Transaxle Oil on page 3-31.

Engine Cranks But is Weak or Has No Spark TROUBLESHOOTING
ENGINE CRANKS BUT IS WEAK OR HAS NO SPARK

Digital Multimeter............................... YU-A1927 procedure:
Spark Tester ....................................... YM-34487 • Seat
Verify the TCI does not produce the required
spark. See Spark Output Test on page 5-4.
Step Check Good Bad

1 Test the spark plug cap. See Resistance is 4 - 6 k-ohms ± 10% Replace spark plug cap.
Spark Plug Cap on page 8-29. @ 20°C (68°F). Go to step 2.
2 Disconnect TCI unit connector TCI Primary Resistance=0.9 - 1.5 Replace TCI unit.
from the main harness and test ohms @ 20°C (68°F)
TCI. See Test and Adjust TCI Secondary Resistance=10.5
Transistor Control Ignition (TCI) - 12.9 k-ohms @ 20°C (68°F)
on page 5-4. Go to step 3.
3 Check TCI air gap. See Test and TCI Air Gap = 0.3 - 0.5 mm Adjust and retest spark.
Adjust Transistor Control Ignition (0.012 - 0.020 in.)
(TCI) on page 5-4.
ENGINE BACKFIRES
Remove the following components before starting
procedure:
• Seat
Step Check Good Bad

1 Inspect idle stop screw for Go to step 2. Back screw out and back in until
damage and check adjustment. it just touches throttle lever. Turn
additional 1/4 turn.
Check for damaged or misrouted
cables.
3 Speed limiter adjustment. See Adjust or replace as necessary.
Inspect for damage.
9
TROUBLESHOOTING Engine Intermittently Cuts Out
ENGINE INTERMITTENTLY CUTS OUT

• Seat
Step Check Good Bad

1 Test fuel pump output. See Go to step 2. • Inspect fuel filter for debris.
Testing the Fuel Pump on • Inspect fuel and pulse hoses
page 5-3. for damage or kinks.
• Replace defective fuel pump.
2 Test TCI. See Test and Adjust TCI Primary Resistance Replace TCI unit.
Transistor Control Ignition (TCI) 0.9-1.5 ohms @ 20°C (68°F)
on page 5-4. TCI Secondary Resistance
10.5-12.9 k-ohms @ 20°C (68°F)
ENGINE WILL NOT STOP RUNNING

• Seat
Step Check Good Bad

1 Throttle stop switch for dirt and Go to step 2. Clean as required.
debris. Ensure connector is
securely connected.
2 Test throttle stop switch. See Go to step 3. Replace switch.
Throttle Stop Switch on
page 8-12.
3 Check TCI harness for damage. Go to step 4. Connect or repair.
Ensure connector is securely
connected.
4 Perform function test on engine Replace relay.
stop relay. See Engine Stop
Relay on page 8-25.

Loss of Power or Speed TROUBLESHOOTING
LOSS OF POWER OR SPEED

Run car alongside another car from the same Remove the following components before starting
fleet and compare speed or use a handheld GPS procedure:
to verify speed.
• Seat
• Rear access cover
Step Check Good Bad

1 Check for excessive drive belt Go to step 2. Replace drive belt.
wear. See Inspect the Drive Belt
on page 3-13.
Check for damages or misrouted
cables.
3 Speed limiter adjustment. See Go to step 4. Adjust or replace as necessary.
Inspect for damage.
4 Choke cable adjustment and Go to step 5. Adjust or replace as necessary.
operation. Ensure choke closes
completely. See Adjust the
Choke Cable on page 5-5.
5 Test fuel pump output. See Go to step 6. • Inspect fuel filter for debris.
Testing the Fuel Pump on • Inspect fuel and pulse hoses
page 5-3. for damage or kinks.
• Replace defective fuel pump.
6 Inspect air filter elements for dirt 0.7 - 0.8 mm (0.028 - 0.030 in.) Clean or replace as necessary.
and blockage. See Clean the Go to step 7.
Pre-Filter/Air Filter on page 3-15.
Check for blocked air inlet.
7 Remove spark plug and check Correct gap is 0.3 - 0.5 mm Adjust or replace as necessary.
condition and gap. See Change (0.012 - 0.020 in.).
the Transaxle Oil on page 3-31. Go to step 8.
8 Remove muffler and check for Go to step 9. Replace muffler.
restriction or damage. See
Muffler on page 5-11.
9 Test TCI. See Test and Adjust TCI Primary Resistance Replace TCI unit.
Transistor Control Ignition (TCI) 0.9-1.5 ohms @ 20°C (68°F)
on page 5-4. TCI Secondary Resistance
10.5-12.9 k-ohms @ 20°C (68°F)
9
TROUBLESHOOTING Carburetor Floods
CARBURETOR FLOODS
procedure:
• Seat
Step Check Good Bad

1 Inspect float needle for damage. Go to step 2. Replace carburetor assembly.
2 Inspect float needle seat for Go to step 3. Replace carburetor assembly.
damage.
3 Check float for damage or Replace carburetor assembly. Replace carburetor assembly.
evidence of leakage.
TRANSAXLE WILL NOT SHIFT INTO FORWARD OR REVERSE

procedure:
• Seat
• Seat back
• Rear body
Step Check Good Bad

1 Check shift lever for wear or Go to step 2. Replace.
damage.
2 Check movement of cable while Operation is smooth. Go to Repair, reroute or replace cables.
operating shift lever. step 3.
3 Remove shift mechanism from Go to step 4. Replace shifter fork.
transaxle and check for wear or
damage. See Transaxle - YDRA
(Gas Car) on page 6-10.
4 Disassemble and inspect Repair or replace as necessary.
transaxle.

Transaxle is Noisy TROUBLESHOOTING
TRANSAXLE IS NOISY
Step Check Good Bad
1 Check level of oil in transaxle. Go to step 2. Fill as necessary with SAE80
See Check the Transaxle Oil W90 API GL-5 Limited Slip High
Level on page 3-28. Performance Gear Oil.
2 Check wheels for loose lug nuts. Go to step 3. Check lug holes for wear. Tighten
nuts to 88 N·m (9.0 m·kg; 65
lb-ft).
3 Check for bent wheels. Go to step 4. Replace as necessary.
4 Check shift cable adjustment. Go to step 5. Adjust as necessary.
See Adjust the Shift Cable on
page 3-13.
5 Check for loose or misassembled Go to step 6. Repair as necessary.
rear axle bearing. See Inspect the
Rear Axle Bearing on page 3-37.
6 Check input shaft bearings. See Go to step 7. Repair as necessary.
Transaxle - YDRA (Gas Car) on
page 6-10 or See Transaxle -
YDRE (Electric Car) on
page 6-31.
7 Disassemble and inspect Go to step 8. Repair as necessary.
transaxle for damaged or
misassembled parts. See
Transaxle - YDRA (Gas Car) on
page 6-10 or See Transaxle -
YDRE (Electric Car) on
page 6-31.
TRANSAXLE IS LEAKING OIL

Step Check Good Bad
1 Check for loose rear axle bearing Go to step 2. Repair as necessary.
or leaking seal. See Inspect the
Rear Axle Bearing on page 3-37.
2 Check input shaft seal for Go to step 3. Replace as necessary.
leakage.
3 Inspect transaxle housings for Replace as necessary.
damage and leakage.
CAR WILL NOT MOVE FORWARD OR REVERSE

Step Check Good Bad
1 Check for locked or misadjusted Go to step 2. Adjust or repair as necessary.
brakes.
2 Inspect sheave assemblies for Go to step 3. Repair as necessary.
damage or wear.
3 Remove rear wheels and inspect Go to step 4. Replace as necessary.
hubs for damage or stripped
splines.
4 Inspect transaxle housings for
damage and leakage.
Replace as necessary.
9
TROUBLESHOOTING Excessive Vibration
EXCESSIVE VIBRATION
procedure:
• Seat
• Seat back
• Rear body
Step Check Good Bad

1 Inspect steering column, steering Go to step 2. Repair as necessary.
gear assembly, and tie rods and
tie-rod ends for wear or loose
fasteners. See Check the
Steering on page 3-11.
2 Check wheels for loose lug nuts. Go to step 3. Check lug holes for wear. Tighten
nuts to 88 N·m (9.0 m·kg; 65
lb-ft).
3 Check for bent wheels. Go to step 4. Replace as necessary.
4 Check for loose or broken engine Go to step 5. Tighten or replace as necessary.
mounting bolts.
5 Inspect rear arm for damage or Go to step 6. Tighten or repair as necessary.
loose or broken parts.
Inspect bushing for damage or
wear.
6 Check drive belt for uneven wear Belt width is greater than Replace worn drive belt.
or excess wear. See Inspect the 24.0 mm (0.95 in.).
Drive Belt on page 3-13. Go to step 7.
7 Inspect starter belt for wear and Go to step 8. Adjust or replace as necessary.
tension. See Starter Belt on
page 3-23.
8 Inspect primary sheave assembly Go to step 9. Repair as necessary.
for wear or damage. See
Disassemble and Inspect the
Primary Sheave Assembly on
page 6-6.
9 Inspect secondary sheave Go to step 10. Repair as necessary.
assembly for wear or damage.
See Remove the Secondary
Sheave Assembly on page 6-10.
10 Check for damaged front wheel Go to step 11. Replace wheel bearings.
bearings. See Inspect the Front
Wheel Bearing on page 3-27.
ENGINE IS SEIZED; WILL NOT TURN OVER

procedure:
• Seat

Engine is Seized; Will Not Turn Over TROUBLESHOOTING
Step Check Good Bad

1 Check engine oil level. Remove and disassemble Remove and disassemble
engine. engine.
9
TROUBLESHOOTING Traction Motor
Troubleshooting - YDRE (Electric Car)
TRACTION MOTOR
CAUTION
Ensure the rear wheels are raised off the
ground and the car is properly supported on
jack stands when performing the follow
troubleshooting procedures.
Condition Possible Cause Correction

Motor does not turn. Car is in the TOW position. Move tow switch to RUN position.
Brushes are off commutator. Adjust properly or replace.
Motor terminals are loose or Tighten or clean.
corroded.
Leads are broken. Check for breaks at bend or joint.
Replace or repair leads.
Field coil is open. Repair or replace traction motor as
necessary.
Armature coil is open. Repair or replace traction motor as
necessary.
Motor turns slowly. Terminals are loose or corroded. Retighten or clean.
Leads are nearly broken or Check for any defect of leads at
connections are faulty. bend or joint. Replace leads or
repair connections.
Mechanical problem inside motor. Disassemble and inspect traction
motor.
Motor is noisy. Mounting bolts are loose. Retighten.
Motor has foreign matter inside. Clean motor interior.
Bearings are faulty. Replace.
Bearing heat excessive Bearings are faulty or lack grease. Replace.
Improperly installed. Adjust or replace if necessary.
Poor motor performance Load exceeds specification. Adjust load to specification.
Armature is out of round. Repair or replace at a service shop.
Brushes are worn beyond limit. Replace.
Commutator is excessively rough. Smooth with sandpaper (500 ~
600-grit).
High mica segment. Recondition at a service shop.
Commutator is dirty with oil or dust. Clean with Yamaha
ACC-CNTCT-CL-NR cleaner and
wipe with a dry shop towel.
Armature coil has short-circuit or is Repair or replace at a service shop.
broken.
Vibration Motor installed loosely. Retighten.
Motor turns irregularly. Repair or replace at a service shop.

Resetting Motor Control Unit TROUBLESHOOTING
CAUTION
Position
Always discharge the motor control unit Wire Color Function
capacitor before performing any of the
following tests. See Safety Lockout Procedure
on page 1-7. 1 Not used
2 Not used
3 Red/Black Ground output to solenoid
4 Black Ground output to reverse
RESETTING MOTOR CONTROL buzzer
UNIT 5 Blue Input from TPS - 5000 ohms
Before performing any tests in this section, it is 6 Black Ground output to TPS
advisable to reset the motor control unit and 7 Orange Input from TPS - 0 - 5000
again verify the problem still exists. ohms
1. Turn the main switch OFF. 8 Red/White 48V input from main switch
2. Move tow switch to the TOW position. 9 Yellow 48V input from direction
3. Wait 30 seconds and turn the main switch switch - REVERSE position
ON. 10 White 48V input from direction
4. Turn tow switch to the RUN position. switch - FORWARD position
If this procedure corrects the problem, there are 11 Brown 48V input from throttle stop
two potential causes for this condition: switch
(a) The user operated the tow switch without 12 Red/Yellow 48V input from tow switch
allowing the system to reset. 13 Red/Yellow 48V input from tow switch
(b) There may be a poor or intermittent 14 Not used
connection.
15 Not used
16 Not used
MCU MAIN HARNESS 17 Not used
CONNECTOR 18 Not used
19 Red I.R. transceiver
NOTE: 20 Black I.R. transceiver
Figure 9-1 shows the open end of a 21 White I.R. transceiver
disconnected connector. 22 Black/White I.R. transceiver
23 Not used
24 Black Ground output to motor
speed sensor
25 Red 5V DC output to motor speed
1 2 3 4 5 6 7 8 9 10 11 12 13
sensor
14 15 16 17 18 19 20 21 22 23 24 25 26 26 Green 0 - 5V DC input from motor
speed sensor
Figure 9-1
9
TROUBLESHOOTING Reverse Warning Buzzer Does Not Work
REVERSE WARNING BUZZER DOES NOT WORK

procedure:
• Beverage holder
Step Check Good Bad

1 Car is in the TOW position. Go to step 2. Move tow switch to RUN position.
2 Check voltage at buzzer Go to step 3. Repair harness.
connector.
3 Check ground at buzzer Replace buzzer. Go to step 4.
connector.
4 Check continuity of wire between Replace motor control unit. Repair harness.
motor control unit connector
position 10 and reverse buzzer
connector.
CAR WILL NOT RUN AT RATED SPEED

procedure:
• Seat
Step Check Good Bad

1 Check brake adjustment. Go to step 2. Adjust brakes. See Adjust the
Parking Brake on page 3-29.
2 Check front wheel toe-in. Go to step 3. Adjust toe-in. See Wheel
Alignment on page 3-38.
3 Check that wheels turn freely and Go to step 4. Repair as necessary.
do not rub.
4 Check tire pressure. Go to step 5. Inflate to proper pressure. See
Check Tire Pressure on
page 3-11.
5 Check that all connections on Go to step 6. Clean and tighten as necessary.
motor control unit, traction motor
and batteries are clean and tight.
6 Check battery electrolyte level Go to step 7. Fill and charge batteries. See
and charge condition. Battery Charging on page 4-9.
7 Load test batteries. Go to step 8. Replace defective batteries.
8 Test throttle position sensor. See Go to step 9. Replace throttle position sensor.
Throttle Position Sensor on
page 8-43.
9 Remove, inspect and test the Repair or replace traction motor.
traction motor. See Traction
Motor Components on
page 8-30.

Car Will Not Run at Rated Speed TROUBLESHOOTING
CAR WILL NOT OPERATE IN EITHER DIRECTION - SOLENOID

DOES NOT CLICK
CAUTION this procedure:
Some of the following steps require • Seat
back-probing connectors. Use extreme care not
to damage the terminal or wire seal when • Rear access panel
performing those steps.
Step Check Good Bad

1 Car is in the RUN position. Cycle TOW switch. Go to step 2. Move tow switch to RUN position.
2 Check that battery connections Go to step 3. Clean and tighten and necessary.
are clean and tight.
3 Check for blown fuse. See Fuse Go to step 4. Replace fuse.
on page 8-46.
4 Check that all controller wire Go to step 5. Repair or replace as necessary.
connections are clean and tight.
5 Check for damaged wiring. Go to step 6. Repair or replace as necessary.
6 Check battery pack voltage. Go to step 7. Charge and test as necessary.
See Battery Charging on
page 4-9.
7 Confirm reverse buzzer operation Go to step 9. Go to step 8.
when direction lever is in
REVERSE.
8 Reset the motor control unit. See Problem is resolved. Check for Go to step 9.
Reverse Warning Buzzer Does loose or corroded connections.
Not Work on page 9-14.
9 Check for voltage at the fuse Go to step 10. Repair or replace wire.
holder.
10 Check for voltage at tow switch. Go to step 11. Repair or replace wire.
11 Bypass the tow switch. Car operates - replace the tow Car does not operate - go to step
switch. 12.
12 Key ON. Check for voltage at the Go to step 13. Repair or replace wire.
red wire at the solenoid with the
tow switch in the RUN position.
13 Key ON. Check for full battery Go to step 14. Repair or replace wire.
voltage between the motor
control unit positive (+) and
negative (-) terminals.
14 Key OFF. Connect jumper wire Go to step 15. Test and replace solenoid as
between solenoid black wire and necessary. See Solenoid on
motor control unit A2 terminal. page 8-45.
Solenoid should energize (click
sound).
15 Disconnect motor control unit Go to step 16. Repair or replace wire.
main harness connector. Check
continuity of red/black wire
between solenoid and connector.
16 Connect main harness connector Car should operate normally. Replace motor control unit.
to motor control unit and retest
car.
9
TROUBLESHOOTING Car Will Not Run at Rated Speed
CAR WILL NOT OPERATE IN EITHER DIRECTION - SOLENOID

DOES CLICK
back-probing connectors. Use extreme care
not to damage the terminal or wire seal when • Rear access panel
performing those steps. • Beverage holder
• Pedal access cover
Step Check Good Bad

1 Check that all controller wire Go to step 2. Repair or replace as necessary.
connections are clean and tight.
2 Check for damaged wiring. Go to step 3. Repair or replace as necessary.
3 Check for debris in the pedal Go to step 4. Clean as necessary.
group area.
4 Check battery pack voltage. Go to step 5. Charge and test as necessary.
See Battery Charging on
page 4-9.
5 Check that battery connections Go to step 6. Clean and tighten and necessary.
are clean and tight.
6 Test throttle position sensor. See Got to step 7. Replace TPS and check car
Throttle Position Sensor on operation.
page 8-43.
7 Key ON. Check for voltage at the Go to step 8. Repair or replace wire.
throttle switch red/white wire with
the tow switch in the RUN
position.
8 Key ON. Check for voltage at the Go to step 9. Replace the throttle stop switch.
throttle stop switch brown wire See Throttle Stop Switch on
with the tow switch in the RUN page 8-12.
position.
9 Key ON. Check for voltage at the Go to step 10. • Check fuse. See Fuse on
direction control switch page 8-46.
red/yellow wire with the tow • Check wiring.
switch in the RUN position.
• Test tow switch. See Tow
Switch - YDRE on page 8-46.
10 Key ON. Go to step 11. • Repair or replace wire.
Direction switch in FORWARD. • Test direction control switch.
Tow switch in the RUN position. See Directional Switch - YDRE
Check for voltage at the white
wire (terminal 4) on the motor on page 8-44.
control unit.
11 Key ON. Go to step 12. • Repair or replace wire.
Direction switch in REVERSE. • Test direction control switch.
Tow switch in the RUN position. See Directional Switch - YDRE
Check for voltage at the yellow
wire (terminal 5) on the motor on page 8-44.
control unit.
12 Key ON. Has continuity. Go to step 13. Replace solenoid. See Solenoid
Tow switch in the RUN position. on page 8-45.
Press throttle pedal.
Check continuity across the large
solenoid terminals.

Car Will Not Run at Rated Speed TROUBLESHOOTING
Step Check Good Bad

13 Test the traction motor field coil Replace the motor control unit. Repair or replace traction motor.
resistance, armature resistance
and for shorts to ground. See
Traction Motor Components on
page 8-30.
9
TROUBLESHOOTING No Regenerative Braking or Rollaway Protection
NO REGENERATIVE BRAKING OR ROLLAWAY PROTECTION

back-probing connectors. Use extreme care
not to damage the terminal or wire seal when • Rear access panel
performing those steps. • Beverage holder
Step Check Good Bad

1 Ensure the speed sensor 3-wire Go to step 2. Connect and retest car.
connector is securely connected.
2 Disconnect the speed sensor Go to step 3. Repair as necessary.
3-wire connector and inspect the
terminals for damage or
corrosion.
3 Check the continuity of the three Go to step 4. Repair the wires.
wires (red, green, black) between
the speed sensor and motor
control unit connector.
4 Check the voltage between the 5V DC ± 10%. Go to step 5. Replace motor control unit.
black and red wires at the speed
sensor connector (chassis side).
5 Check speed sensor output. See Replace motor control unit. Go to step 6.
Speed Sensor on page 8-41.
6 Remove speed sensor from Clean and reinstall. Clean or replace as necessary.
traction motor and inspect Repeat test.
magnet for damage or debris.
See Speed Sensor on page 8-41.

Z-2 Harness Connections TROUBLESHOOTING
Z-2 Diagnostic Tester
Z-2 HARNESS CONNECTIONS Z-2 Tester Harness Adapter
Z-2 Tester
3 3
1
1
2
2
4
5
Y-1323
Figure 9-3
Y-1324
1. Connector to MCU Connector
Figure 9-2
2. Connector to Chassis Harness
1. Connector to Harness Adapter Connector
2. Red Alligator Clips to Motor F1 and F2 3. Connector to Tester Harness
Field Terminals
3. Black Alligator Clips to Motor A1 and Preliminary Checks and Guidelines
A2 Terminals Before connecting the Z-2 tester to the golf car,
4. Black Alligator Clip to Ground visually inspect for:
5. Fuse - 7.5A
• Loose connections
• Shorted wiring
• Corroded battery terminals
• Blown fuse
• Reversed polarity to controller (due to incorrect
assembly)
If the above items are OK, test the batteries per
Yamaha Service Manual procedures. See
Batteries on page 4-1.
WARNING
• The rollaway and regenerative braking
functions will be disabled while the tester is
connected to the car.
• Raise and support a rear wheel for safety
when testing an electric car. See
9
TROUBLESHOOTING Operating Instructions
CAUTION
Do not store the Z-2 in high heat areas (like
the seat of a car in hot weather). The box can
1
melt or warp.
Attempting to operate the tester on a golf car
with battery terminals to the controller
reversed will destroy the controller, motor and
solenoid. Damage to the tester may also
result. 2
3
It is recommended that the first time you
connect the Z-2 tester to a golf car you use a
car that is functioning normally. This will
allow you to see what the LED lights should Y-1337
be doing. Figure 9-5
Never short the armature or field leads
together at the motor or controller. The 3. Connect the harness adapter to the controller
controller will be damaged and may fail (Figure 9-5, (1)) and the main harness
prematurely. (Figure 9-5, (2)).
When disconnecting the Z-2 tester from a golf 4. Connect the Z-2 tester connector to the
car, never pull the harness wires of the tester. harness adapter (Figure 9-5, (3)).
Always grasp the connector itself, not the
wires.
OPERATING INSTRUCTIONS
1
1. Disconnect the negative (-) battery leads from 2
the battery pack.
Y-1206a
Figure 9-6
5. Carefully connect the two black alligator clips
of the Z-2 tester to motor terminals A-1 and
1
A-2 (Figure 9-6, (1)).
6. Carefully connect the two red alligator clips of
the Z-2 tester to motor terminals F1 and F2
(Figure 9-6, (2)).
7. Connect negative battery leads to the battery
pack.
Y-1535B
Figure 9-4
2. Disconnect the multi-wire connector
(Figure 9-4, (1)) on the front of the controller.

Z-2 Tester Failure Chart TROUBLESHOOTING
Y-1338
Figure 9-7
8. Connect black ground lead with fuse alligator
clip (Figure 9-7, (1)) to the negative side of
the battery pack.
Z-2 TESTER FAILURE CHART

POSSIBLE CAUSE OF SERVICE MANUAL
LED INDICATOR NORMAL OPERATION
MALFUNCTION REFERENCE
Tow switch Lights when fuse is good Blown fuse See Tow Switch - YDRE
and tow switch is in RUN Loose fuse holder connection on page 8-46.
position. Open circuit
Bad tow switch
Key (main) switch Lights when tow switch is in Bad main switch See Main Switch on
RUN position and key is Open wire harness page 8-11.
turned on.
Throttle switch With tow switch in the RUN Light comes on before depressing See Throttle Stop
position and the main the pedal. Check: Switch on page 8-12.
switch on, this LED should • Throttle rod linkage adjustment
illuminate only after the • Pedal stopper bolt height
throttle pedal is depressed. • Debris in pedal linkage
It should go out when the
pedal is released. • Shorted switch
Light does not illuminate
• Open throttle switch
• Open circuit wire harness
Throttle position With tow switch on, the light Throttle position sensor See Throttle Position
sensor should get brighter as the TPS linkage loose inside Sensor on page 8-43.
throttle is pressed and Open circuit
dimmer as it is released.
Armature output Lights when the tow switch No light indicates no output from the See Traction Motor
indicator is in the RUN position, key controller. Check all other contacts Components on
is on and throttle pedal is before replacing the controller. (If page 8-30.
depressed. The further the the armature and field lights light
pedal is depressed, the but the motor won’t run, check the
brighter the light should motor.)
get.
9
TROUBLESHOOTING Z-2 Tester Failure Chart
Field output indicator Lights when the tow switch No light indicates no output from the See Traction Motor
is in the RUN position, key controller. Check all other inputs Components on
is on and throttle pedal is and solenoid contacts before page 8-30.
depressed. It should get replacing the controller. (If the
very bright initially, then get armature and field lights light but
a little dimmer. the motor won’t run, check the
motor.)
Tach/Speed sensor Should blink off and on as Remove sensor and clean. See Speed Sensor on
the car slowly moves page 8-41.
forward or in reverse. It Connect K & L YG-42221 and
may stay on solid if the car check per manual.
stops with the magnet lined
up with the sensor.
Forward and reverse Should light when the tow If neither the forward or reverse See Tow Switch - YDRE
direction switch switch is in the RUN light comes on check: on page 8-46.
position and the direction• Fuse
switch is in the forward • Tow switch
position. • Open to R/Y at direction switch
Both LEDs should never be If the forward and reverse light
illuminated at the same come on at the same time, check
time. for water in the direction switch.
If the reverse LED is inoperative (no
reverse) check for open circuit
yellow wire to the controller.
If the forward LED is inoperative (no

forward) check circuit white wire to
the controller.
Output cycling switches
Manually operates the reverse buzzer and solenoid
Reverse buzzer With tow switch in the RUN If the buzzer doesn’t operate check: See Reverse Warning
position, pressing the • Power to reverse buzzer Buzzer Does Not Work
button on the tester • Buzzer on page 9-14.
grounds the buzzer • Wiring
allowing it to operate
(bypasses controller).
Solenoid With the tow switch in the If the solenoid doesn’t click check: See Solenoid on
WARNING! Do not RUN position: • R/Y wire at solenoid for power page 8-45.
press this button until 1. Wait 30 seconds to be • Continuity of R/B wire to terminal
you have checked sure the solenoid is 11 of the controller
that the controller disengaged.
polarity to the 2. Press the button on the
batteries is correct. tester and listen for a
MCU and motor will solenoid click.
be damaged.

Introduction TROUBLESHOOTING
Genius Diagnostic System
INTRODUCTION Personal Digital Assistant (PDA)

The Genius Diagnostic System is a software Yamaha Golf-Car Company currently
program designed to access the diagnostic and recommends the Palm Tungsten E2 PDA for use
programming features of the motor control unit with the Genius Diagnostic System. The Palm
(MCU). The system is used in conjunction with a Tungsten E2 PDA offers the latest PDA
personal digital assistant (PDA)/infrared technology and is available from the Palm
transmitter unit combination to communicate with Yamaha Dealers/Distributors website at:
the motor control unit's internal program. For http://web.palm.com/yamahagolf. The website
convenience, the infrared transmitter unit may be offers Yamaha Dealers and Distributors up to
installed on the golf car or used as a handheld 25% off MSRP on all Palm PDAs and
device. accessories.
Transmitter Unit
GENIUS DIAGNOSTIC SYSTEM The golf car's transmitter unit wire harness input
has been relocated underneath the rear body, on
The Genius Diagnostic System allows the user to the driver's side of the golf car. A new transmitter
access the MCU to monitor usage and unit assembly (P/N JU2-HA2F0-10) is required to
performance data for diagnostic and install the transmitter unit in a fixed position. This
troubleshooting purposes. This includes the change does not affect the setup or operation of
following information: the Genius Diagnostic System and provides
easier access to the input plug.
Diagnostic Data
• Car Number Software Installation
• Amp Hours Refer to your PDA User's Manual for specific
• Battery Volts installation instructions.
• Hours
• Miles
• Mode
• Status
System performance is continually monitored and
fault codes identified for troubleshooting
purposes. The fault codes identify the problem
area and any necessary corrective action.
9
TROUBLESHOOTING Transmitter Unit Installation
TRANSMITTER UNIT
INSTALLATION 1
Y-1305
Figure 9-10
Y-1303 3. Remove wire harness cap (Figure 9-10, (1)).
Figure 9-8
Transmitter Unit .................. P/N JU2-HA2F0-00
1. Remove seat.
NOTE:
Refer to the Genius System Owner’s
Manual/Operator’s Manual for installation of the
transmitter unit in a fixed position.
Y-1308
1 Figure 9-11
4. Drill a 20 mm (0.750 in.) hole using a drill bit
or hole saw. Make hole approximately 100
mm (4 in.) to the left of the charging
receptacle.
Y-1304
1
Figure 9-9
2. Locate diagnostic wire harness connector
(Figure 9-9, (1)) underneath the rear body on
the driver’s side of car.
Y-1307
Figure 9-12
5. Insert the wire connector end of the
transmitter unit wiring harness
(Figure 9-12, (1)) through the body hole.

Transmitter Unit Installation TROUBLESHOOTING
2
1
Y-1306
Figure 9-13 Y-1310
Figure 9-16
6. Lightly press transmitter body until fully
seated and locked in place (Figure 9-13, (2)). 9. Route the harness around the right side seat
support and secure with a wire tie
(Figure 9-16, (1)).
1
Y-1307
Figure 9-14
7. Route the transmitter harness toward the Y-1311
passenger side of the car between the rear Figure 9-17
body and the rear body reinforcement. Use a
wire tie (Figure 9-14, (1)) to secure in place. 10. Pull the harness in front of the MCU bracket,
then behind the tow switch, securing the cable
to the clamp on the back of the tow switch
with a wire tie (Figure 9-17, (1)).
Y-1309
Figure 9-15
8. Route the harness around the number one
battery and secure to the battery lifting
brackets (Figure 9-15, (1)).
9
TROUBLESHOOTING Diagnostic Mode
DIAGNOSTIC MODE
PDA Operation Procedures
2 NOTE:
1
Refer to PDA operator manual for specific
operating information.
Y-1312
Figure 9-18
1
11. Secure the harness to the left side seat
support (Figure 9-18, (1)).
12. Loop the harness down and secure with a
wire tie (Figure 9-18, (2)).
13. Connect the MCU harness to the transmitter
unit harness (Figure 9-18, (3)). Y-1270
Figure 9-20
1. Turn on power to PDA. The Main Menu
screen will automatically open.
2. Select the Genius2 icon (Figure 9-20, (1)) for
Diagnostics.
Y-1313
Figure 9-19
14. Verify the operation of the transmitter
assembly by reading the MCU in the Genius 2
diagnostic mode.

Diagnostic Mode TROUBLESHOOTING
3
2
Y-1272
Y-1271
3. The Intro screen will appear briefly and then If the Options tab (Figure 9-22, (3)) is pushed, a
the Data screen (Figure 9-21, (2)) will appear drop box will appear and you will be given the
automatically. following options:
• Help
The Data screen will show you the following
Golf Car information: • About Application
• Car Number: Help
• Amp Hours:
• Battery Volts:
• Hours:
• Miles:
• Mode:
• Status:
Data Screen
From this screen you can select the following
option tabs:
Y-1273
• Options tab
Figure 9-23
• Faults tab
• Read tab The Help-Options screen will appear with the
following 5 topics:
• Set Car # tab
• This screen shows general car information.
• The Faults and Date Book buttons switch to
the Fault Screen.
• The Read and Address Book buttons read
the general car information.
• The Set and Memo-Pad buttons set the
displayed car number.
• The Scroll buttons change the displayed car
number up or down.
Select “OK” and you will return to the Data
screen.
9
About Application
Y-1275
Figure 9-25
Y-1274
Figure 9-24
• The About Application screen will appear
with the following information:
• This application displays general car
information and faults. It can set the car # and
clear older faults. MCU version and serial #
can also be displayed.
• Yamaha copyright.
• Select “OK” and you will return to the Data
screen. Y-1534
Figure 9-26
Read Tab
NOTE:
NOTE:
The PDA device must be aimed at and held
In order to view any information on the Data within 1 foot of the IR data port for successful
screen, it is recommended that you follow the communications. If one beep is heard,
steps below in the order that they are given. communication was successful; if not, the PDA
Data will be 0 until the Read command is will beep twice indicating a communication
executed. error.
1. Make sure that the golf car's tow/run switch is

set in the RUN position.
2. Aim and hold the PDA device within 1 foot of
the IR data port.
3. Select the Read tab (Figure 9-25, (1)).


Set Car # Tab
Y-1276
Y-1278
Figure 9-27
• A text message “Communicating” will appear Figure 9-29
on screen.
• If one “Beep” is heard, Communication was NOTE:
successful and the Data screen will The Car Number can be set within a range of
automatically appear with the updated numbers from 0 to 511 ONLY.
information. The Car Number will be 0 When setting the Car Number, the PDA device
(Default from factory) until the Set Car # automatically performs the same function as
command is executed. the Read tab. It is not necessary to select the
Read tab immediately after the Set Car #
function has taken place. You will see the
updated and current information for that golf
car. However, if the Car Number has previously
been set, you will only need to select the Read
tab while following the remaining steps to see
the current information for that golf car.
1. Make sure that the golf car's tow/run switch is

2. Select the key pad function on the PDA (See
PDA User's Manual).
3. Enter desired car number.
the IR data port.
Y-1277
Figure 9-28
• If two “Beeps” are heard, Communication
was unsuccessful and you will see a
Communication Error screen. Steps 1, 2 and
3 must be repeated. Select “OK” to return to
Data screen.
9
5. Select the Set Car # tab (Figure 9-29, (2)). Faults:

• A text message “Communicating” will appear
on screen.
• If one “Beep” is heard, Communication was
successful and the Data screen will
automatically appear with updated 1
information. The Car Number will be set until
changed.
Communication Error screen. Steps 1
through 5 must be repeated. Select “OK” to
return to Data screen.
If any Momentary Faults are displayed in Status,
see Troubleshooting Using Genius on page 9-33.
(See example below.) Y-1283
• Car Number: 001 Figure 9-30

• Amp Hours: 12 1. Select the Faults tab (Figure 9-30, (1)) to
• Battery Volts: 49.5 view any stored faults.
• Hours: 0
• Miles: 8
3
• Mode: 13
• Status: Throttle pedal down before key on
NOTE:
Any Momentary Faults displayed in Status 2
should be the primary focus during
troubleshooting steps.
Faults Screen
Y-1284
NOTE:
Figure 9-31
Momentary Faults will only be displayed on the
Data screen in Status. They will not be 2. The Fault screen (Figure 9-31, (2)) appears
displayed on the Faults screen. and any Stored Faults will be displayed.
• For Help, select the Faults tab
(Figure 9-31, (3)).
Up to 16 faults can be stored in the MCU. If more
than 16 faults have occurred, only the most
recent 16 will be displayed.
Momentary Faults are recorded only momentarily
and must be viewed at the time of generation in
Status on the Data screen. They are not viewable
on the Fault screen and are not stored in the
MCU.


About Application
The About Application screen will appear with the
4 following information:
• This application displays general car
information and faults. It can set the car # and
clear older faults.
• Expiration date of the software.
• Yamaha copyright.
Select “OK” and you will return to the Faults
screen.
Y-1285
Figure 9-32
• An Options tab (Figure 9-32, (4)) will then be
available with the following options:
• Help
• About Application
Help 1 2
The Help-Faults screen will appear with the

following 5 topics:
• This screen shows the last 16 faults recorded Y-1287
by the controller (MCU): Figure 9-33
• The Diagnostic and Date Book buttons
switch to the Diagnostic screen. Read Tab
• The Read and Address Book buttons read 1. Make sure that the golf car's tow/run switch is
the car's fault information. set in the RUN position.
• The Set and Memo Pad buttons clear the 2. Aim and hold the PDA device within 1 foot of
controller's fault info. the IR data port.
• The Scroll buttons scroll the fault list up or 3. Select the Read tab (Figure 9-33, (1)).
down. • A text message “Communicating” will appear
Select “OK” and you will return to the Faults on screen.
screen. • If one “Beep” is heard, Communication was
successful and the Faults screen will
automatically appear and display any
generated faults and/or Stored Faults.
Data screen.
9
Erase Tab
1. Make sure that the Golf Car's tow/run switch
is set in the RUN position.
the IR data port.
3. Select the Erase tab (Figure 9-33, (2)).
• A text message “Communicating” will appear
on screen.
successful and the Faults screen will
automatically appear and no faults will be
displayed.
Data screen.
To return to the Main Menu screen, select the
“Home” icon.
Faults are logged into a memo file on the PDA
under the name "_ Yamaha Car Diagnostic
Export…."
If a Communication error is persistent, even
though operation is within 1 foot and aimed
directly at the data port, cycle the Tow Switch.
Always refer to Troubleshooting - YDRE (Electric
Car) on page 9-12 when using the Genius2
Diagnostic System for Troubleshooting.
The Genius Diagnostic System is capable of
generating 24 known and listed faults; however,
additional undescribed faults may be listed. The
Troubleshooting section in this Manual will
describe in more detail the display text and fault
codes given on the PDA display.

Troubleshooting Using Genius TROUBLESHOOTING
TROUBLESHOOTING USING
GENIUS
Faults and Troubleshooting steps

PDA Display Text Fault Description Fault type/Reset mode
Troubleshooting steps
TPS reading out of adjustment 05– accelerator volts low without Momentary Fault, Auto Reset
start switch being closed
Check:
1. TPS
2. Stop Switch
3. Key Switch
4. MCU internal failure
F/R switch circuits open 06– start switch closed with no Momentary Fault, Auto Reset
direction picked
Check:
1. F/R Switch
Accel pedal down before key on 08– accelerator volts low at tow Momentary Fault, Auto Reset
switch closure, or before key
switch is closed
Check:
1. TPS
2. Stop Switch
3. Key Switch
F/R switch circuit both closed 09– forward and reverse switch Momentary Fault, Auto Reset
closed at the same time
Check:
1. F/R Switch
Y-1296
9
TROUBLESHOOTING Troubleshooting Using Genius

Stop switch closed before key 11– stop switch closed when Momentary Fault, Auto Reset
on close tow switch or key switch
Check:
1. Stop Switch
2. Key Switch
Battery voltage low 15– battery volts too low Momentary Fault, Auto Reset
Check:
1. Battery voltage
2. Power Terminal
Battery voltage high 16– battery volts too high Momentary Fault, Auto Reset
Check:
1. Charger
2. Excessive Regen
3. MCU internal error
TPS reading incorrect 21– TPS volts too high (lost wire Momentary Fault, Auto Reset
on TPS)
Check:
1. TPS
Y-1297


MCU internal error 23 23– field amplifier not calibrated Stored Fault, Tow Reset
correctly high reverse field
Check:
1. Motor field-C
2. Field to frame short
MCU internal error 24 24– field amplifier not calibrated Stored Fault, Tow Reset
correctly high forward field
Check:
1. Motor field-C
2. Field to frame short
MCU 12V PS or motor tach 27– 12 volt power supply is below Stored Fault, Tow Reset
9.6 volts
Check:
1. Speed Sensor short

2. TPS
MCU temperature high 41– controller over temperature Stored Fault (every 20 hours),
Tow Reset
Check:
1. Motor arm-C
2. Motor field-C
3. Power Terminal
4. Relay
5. Internal Motor short
Y-1298
9

MCU internal error 42 42– armature amplifier calibrated Stored Fault, Tow Reset
high
Check:
1. Armature circuit open

2. Motor arm-C
MCU internal error 43 43– armature amplifier calibrated Stored Fault, Tow Reset
low
Check:
1. Armature circuit short

2. Motor arm-C
MCU internal error 44 44– armature transistors did not Stored Fault, Tow Reset
turn off properly
Check:

2. Motor arm-C
MCU internal error 45 45– armature transistors did not Stored Fault, Tow Reset
turn on properly
Check:

2. Motor arm-C
Y-1299


MCU internal error 46 46– armature transistors are Stored Fault, Tow Reset
shorted
Check:

2. Motor arm-C
No field current 49– no field current flowing when Stored Fault, Tow Reset
armature current is on
Check:
1. Field current open

2. Motor field-C
MCU internal or miswiring 51– capacitors will not charge Stored Fault, Tow Reset
Check:
1. Miswiring: Something pow-

ered off switched side of re-
lay.
Relay open while motoring 57– control regening current dur- Stored Fault, Tow Reset
ing motoring, or line contactor is
open when control trying to motor
Check:
1. MCU (+) loose power wire

2. Relay
Y-1300
9

Relay coil shorted 65– line contactor coil driver is Stored Fault, Tow Reset
being shorted (coil driver over cur-
rent)
Check:
1. Relay
Field short circuit trip 66– controller field short circuit trip Stored Fault, Tow Reset
Check:
1. Motor field-C
2. Motor arm-C
Over voltage regen pedal-up 76– capacitor over-voltage during Stored Fault, Tow Reset
regen pedal up
Check:
1. Power Terminal
2. Hot battery
3. Excessive regen
Over voltage regen pedal-down 77– capacitor over-voltage during Stored Fault, Tow Reset
regen pedal down
Check:
1. Power Terminal
2. Hot battery
3. Excessive regen
Y-1301


Undescribed error Any fault other than those listed
Check:
Y-1302
9
TROUBLESHOOTING Golf Car Programming Mode
GOLF CAR PROGRAMMING • Enter your password. The generic password

is 28252.
MODE • Select “OK.” The Mode Select screen will
then appear.
PDA Operation Procedures
4 Mode Select
More 3
1 2 3 4 5
6 7 8 9 10
Regen 11 12 13 14 15
16 17 18 19 20
21 22 23 24 25
1
Less Speed More
G G
Diagnostic Program...
Read Mode Set Mode
SM-04-030
SM-04-028
Figure 9-36
Figure 9-34
1. Turn on power to PDA. (This will automatically
bring into view the Main Menu screen.)
2. Select the Genius icon (Figure 9-34, (1)) for
Programming.
YCMS
Yamaha Car Mode Selector
2
Password: ............. OK
1 2 3
4 5 6
7 8 9
0 Back Space
SM-04-029
Figure 9-35
3. Select Login. The YCMS (Yamaha Car Mode
Selector) Login screen (Figure 9-35, (2)) will
then appear.

Golf Car Programming Mode TROUBLESHOOTING

Mode Select Screen About Application
From the Mode Select screen (Figure 9-36, (3)) The About Application screen will appear with the
you can select the Read Mode or Set Mode tab. following information:
• This application can set the regen and speed
of the car.
NOTE:
• Expiration date of software
For Help on the Read Mode or Set Mode tabs,
read the following information. • Yamaha copyright
Select “OK” and you will return to the Mode
Select screen.
5 Mode Select
Options
NOTE:
Help....
About Application.... 5 The PDA device must be held within 1 foot of
the IR data port for successful communications.
6 7 8 9 10 If one beep is heard, communication was
successful; if not, the PDA will beep twice
Regen 11 12 13 14 15 indicating a communication error.
16 17 18 19 20
21 22 23 24 25 Mode Select
Less Speed More More

1 2 3 4 5
Read Mode Set Mode
6 7 8 9 10
SM-04-031
Regen Communicating...
11 12 13 14 15
Figure 9-37 16 17 18 19 20
If the Mode Select tab (Figure 9-36, (4)) is 21 22 23 24 25
pushed, you then have an Options tab
(Figure 9-37, (5)) with the following options: Less Speed More
• Help
Read Mode Set Mode
• About Application 1 2
Help SM-04-032
The Help-Mode Select screen will appear with the

following four topics: Figure 9-38
• This screen is used to change the regen Read Mode

braking and the governed speed of the car. 1. Make sure that the golf car’s tow/run switch is
• The Read Mode, Date Book and Address set in the RUN position.
Book buttons read the car mode. 2. Aim and hold the PDA within 1 foot of the IR
• The Set Mode and Memo Pad buttons set the data port.
highlighted mode. 3. Select the Read Mode tab (Figure 9-38, (1)).
• The Scroll buttons highlight the next mode up (The cursor will be blinking.)
or down. • A text message “Communicating” will appear
Select “OK” and you will return to the Mode on screen.
Select screen.
9
TROUBLESHOOTING Golf Car Programming Mode
• If one “Beep” is heard, Communication was 2. Select the intended number for Regen and
successful and the Speed/Regen setting for Speed. (The cursor will be blinking.)
the MCU will be displayed (the cursor will be 3. Aim and hold the PDA within one foot of the
solid). IR data port.
4. Select the Set Mode tab.
Communication Error... • A text message “Communicating” will appear
on screen.
Make sure PDA and data successful and the Speed/Regen setting for
port are less than one the MCU will be displayed. (The cursor will be
foot apart. solid.)
was unsuccessful and the above steps 1
through 4 must be taken. You will see a
Communication Error screen. Select “OK” to
return to Mode Select screen (Figure 9-39).
To return to the Main Menu screen, select the
“Home” icon.
OK
NOTE:
SM-04-019
If a Communication error is persistent, even
Figure 9-39 though operation is within 1 foot and aimed
directly at the data port, cycle the Tow Switch.
was unsuccessful and the above steps 1, 2
and 3 must be taken. You will see a
Communication Error screen, select “OK” to
return to Mode Select screen (Figure 9-39).
Mode Select
More
1 2 3 4 5
6 7 8 9 10
Regen Communicating...
11 12 13 14 15
16 17 18 19 20
21 22 23 24 25
Less Speed More
Read Mode Set Mode

1 2
SM-04-032
Figure 9-40
Set Mode (Figure 9-40, (2)).
1. Make sure that the golf car’s tow/run switch is

YDRA/ YDRA 2009: Service Manual

Uploaded by

Copyright:

Available Formats

YDRA/ YDRA 2009: Service Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

YDRA/ YDRA 2009: Service Manual

Uploaded by

Copyright:

Available Formats

YDRA/ YDRA 2009

YDRA/E SERVICE MANUAL

Chapter 1 – GENERAL INFORMATION 1

YDRA/E Service Manual

0 YDRA/E Service Manual

YDRA/E Service Manual i

ii YDRA/E Service Manual

Daily Checks - Electric Cars................................................................ 3-33

YDRA/E Service Manual iii

Battery Charging ................................................................................... 4-9

iv YDRA/E Service Manual

Inspect the Engine Components ......................................................... 5-23

YDRA/E Service Manual v

vi YDRA/E Service Manual

Rear Suspension Components ........................................................... 7-51

— Electrical Test and Repair —

— Repair - YDRA (Gas Car) —

YDRA/E Service Manual vii

Start Solenoid Relay ........................................................................... 8-23

— Repair - YDRE (Electric Car) —

viii YDRA/E Service Manual

Speed Sensor...................................................................................... 8-41

YDRA/E Service Manual ix

— Troubleshooting - YDRE (Electric Car) —

— Z-2 Diagnostic Tester —

— Genius Diagnostic System —

x YDRA/E Service Manual

YDRA/E Service Manual 1-1

1-2 YDRA/E Service Manual

Safety Precautions GENERAL INFORMATION

YDRA/E Service Manual 1-3

GENERAL INFORMATION Safety Precautions

1-4 YDRA/E Service Manual

Safety Precautions GENERAL INFORMATION

YDRA/E Service Manual 1-5

GENERAL INFORMATION Safety Precautions

1-6 YDRA/E Service Manual

Safety Precautions GENERAL INFORMATION

Discharge the Motor Control Unit

YDRA/E Service Manual 1-7

GENERAL INFORMATION General Service Information

1-8 YDRA/E Service Manual

General Service Information GENERAL INFORMATION

Before servicing, thoroughly clean the exterior of

YDRA/E Service Manual 1-9

GENERAL INFORMATION General Service Information

Replacement Parts Bearings and Oil Seals

Gaskets, Oil Seals and O-rings

Lock Washers/Plates and Cotter

1-10 YDRA/E Service Manual

General Service Information GENERAL INFORMATION

YDRA/E Service Manual 1-11

GENERAL INFORMATION Special Tools

SPECIAL TOOLS For Engine Service

1-12 YDRA/E Service Manual

Special Tools GENERAL INFORMATION

YDRA/E Service Manual 1-13

GENERAL INFORMATION Special Tools

Y-1322 P/N YM-04064-A