2010-2011 Yamaha Golf Cart YDRA YDRE Service & Repair Manual

YDRA/E SERVICE MANUAL LIT-19616-29-10 0909

YDRA, YDRE GOLF CAR SERVICE MANUAL YDRA/E SERVICE MANUAL ©2009 by Yamaha Golf-Car Company 3rd edition, August 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-19616-29-10

1 2 5 4 3 6 7 8 9 10 Chapter 1 – GENERAL INFORMATION Chapter 2 – SPECIFICATIONS Chapter 3 – PERIODIC MAINTENANCE Chapter 4 – BATTERIES Chapter 5 – ENGINE Chapter 6 – DRIVE TRAIN Chapter 7 – CHASSIS Chapter 8 – ELECTRICAL Chapter 9 – TROUBLESHOOTING Chapter 10 – PTV SPEED CODE KIT

YDRA/E Service Manual YDRA/E Service Manual

YDRA/E Service Manual i YDRA, YDRE GOLF CAR SERVICE MANUAL 1 General Information Safety Precautions ................................................................................ 1-3 General Information......................................................................... 1-3 Safety Lockout Procedure ............................................................... 1-6 Discharge the Motor Control Unit Capacitor .................................... 1-6 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 .......................................................................... 1-9 Gaskets, Oil Seals and O-rings ....................................................... 1-9 Lock Washers/Plates and Cotter Pins ............................................. 1-9 Bearings and Oil Seals .................................................................. 1-10 Retaining Rings ............................................................................. 1-11 Disassembly and Assembly Suggestions...................................... 1-11 Special Tools ....................................................................................... 1-11 For Tune-Up .................................................................................. 1-11 For Engine Service ........................................................................ 1-12 For Power Train............................................................................. 1-13 For Chassis Service ...................................................................... 1-13 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

ii YDRA/E Service Manual 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 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

YDRA/E Service Manual iii 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 Body and Chassis for Damage .................................... 3-34 Check the Tightness of Bolts, Nuts, Screws and Rivets ............... 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 Check the Pedal Group ................................................................. 3-35 Six-Month Service - Electric Cars........................................................ 3-36 Inspect the Wire Harness and Electrical Cables ........................... 3-36 Inspect the Shock Absorbers ........................................................ 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 Inspect the Rear Axle Bearing....................................................... 3-37 Inspect the Steering Knuckle......................................................... 3-38 Wheel Alignment ........................................................................... 3-38 Inspect the Front Wheel Bearing ................................................... 3-39 Check the Transaxle Oil Level ...................................................... 3-39 Adjust the Parking Brake ............................................................... 3-41 Adjust Brake Pedal Free Play ....................................................... 3-41 Adjust the Pedal Stop .................................................................... 3-42 Four-Year Service - Electric Cars........................................................ 3-43 Change the Transaxle Oil .............................................................. 3-43 Inspect the Brake Discs................................................................. 3-44 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 Battery Charging ................................................................................... 4-9 Charging Guidelines ...................................................................... 4-10 Charging Procedure ...................................................................... 4-10

iv YDRA/E Service Manual 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 Troubleshooting............................................................................. 4-19 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 Removal ........................................................................................ 5-11 Installation ..................................................................................... 5-12 Remove the Engine............................................................................. 5-13 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

YDRA/E Service Manual v 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 Inspect the Transaxle .................................................................... 6-38 Assemble the Transaxle ................................................................ 6-39

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2010-2011 Yamaha Golf Cart YDRA YDRE Service & Repair Manual

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