2013-2016 Yamaha YDRA / YDRE (Gas & Electric) Golf Car OEM Service & Repair Manual

YDRA/E SERVICE MANUAL LIT-19616-29-12 0713

YDRA, YDRE GOLF CAR SERVICE MANUAL YDRA/E SERVICE MANUAL ©2013 by Yamaha Golf-Car Company 1st edition, July 2013 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-19616-29-12

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/E Service Manual YDRA, YDRE GOLF CAR SERVICE MANUAL 1 General Information Safety Precautions ................................................................................ 1-3 General Information......................................................................... 1-3 Prepare for Emergencies........................................................... 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 YDRA Chassis ........................................................................... 1-8 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 ...................................................................... 1-13 For Electrical Components ............................................................ 1-15 Vehicle Storage ................................................................................... 1-16 Gas-Powered Cars ........................................................................ 1-16 Preparation for Storage ........................................................... 1-16 Returning Car to Service ......................................................... 1-16 Electric-Powered Cars................................................................... 1-17 Preparation for Storage ........................................................... 1-17 Returning Car to Service ......................................................... 1-17 2 Specifications General Specifications .......................................................................... 2-2 General ............................................................................................ 2-2 Transmission ................................................................................... 2-2 Batteries .......................................................................................... 2-3 Chassis............................................................................................ 2-3 Paint Codes ..................................................................................... 2-3

ii YDRA/E Service Manual 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 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 Inspect Tires ............................................................................ 3-11 Check Tire Pressure ................................................................ 3-11 Inspect Wheels ........................................................................ 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 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 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 Check the Valve Clearance and Spark Plug ........................... 3-17 Adjust the Valve Clearance ..................................................... 3-19 Inspect the Shock Absorbers ........................................................ 3-20

YDRA/E Service Manual iii Yearly Service – Gas Cars .................................................................. 3-20 Change the Engine Oil .................................................................. 3-20 Replace the Fuel Filter – Carburetor Models ................................ 3-21 Adjust the Throttle Cables – Carburetor Models ........................... 3-21 Free Play Adjustment .............................................................. 3-23 Adjust the Throttle Cables – Fuel Injection Models ....................... 3-24 Introduction .............................................................................. 3-24 Adjustment Procedures ........................................................... 3-24 Starter Belt .................................................................................... 3-26 Inspect the Starter Belt ............................................................ 3-26 Adjust the Starter Belt.............................................................. 3-26 Check and Adjust the Speed Limiter ............................................. 3-27 Check the Speed Limiter ......................................................... 3-27 Adjust the Speed Limiter ......................................................... 3-27 Inspect the Wire Harness and Electrical Cables ........................... 3-28 Inspect the Rear Axle Bearing....................................................... 3-28 Radial Inspection ..................................................................... 3-28 Bearing Inspection ................................................................... 3-28 Inspect the Steering Knuckle......................................................... 3-28 Wheel Alignment ........................................................................... 3-29 Inspect the Front Wheel Bearing ................................................... 3-30 Check the Transaxle Oil Level ...................................................... 3-30 Adjust the Parking Brake ............................................................... 3-31 Adjust Brake Pedal Free Play ....................................................... 3-32 Two-Year Service – Gas Cars............................................................. 3-33 Inspect the Starter/Generator ........................................................ 3-33 Change the Transaxle Oil .............................................................. 3-33 Inspect the Brake Discs................................................................. 3-34 Daily Checks – Electric Cars ............................................................... 3-35 Operational Inspection .................................................................. 3-35 Inspect the Batteries...................................................................... 3-35 Inspect the Brakes......................................................................... 3-35 Inspect the Steering System ......................................................... 3-35 Inspect the Wheels and Tires ........................................................ 3-35 Inspect the Tires ...................................................................... 3-36 Check the Tire Pressure .......................................................... 3-36 Inspect the Wheels .................................................................. 3-36 Check the Body and Chassis for Damage .................................... 3-36 Check the Tightness of Bolts, Nuts, Screws and Rivets ............... 3-36 Check the Reverse Buzzer Operation ........................................... 3-36 Monthly Service – Electric Cars .......................................................... 3-37 Check the Battery Electrolyte Level .............................................. 3-37 Inspect the Charge Receptacle ........................................................... 3-37 Inspect the Electrical Connectors .................................................. 3-37 Check the Pedal Group ................................................................. 3-37 Six-Month Service – Electric Cars ....................................................... 3-38 Inspect the Wire Harness and Electrical Cables ........................... 3-38 Inspect the Shock Absorbers ........................................................ 3-38

iv YDRA/E Service Manual Yearly Service - Electric Cars ............................................................. 3-39 Perform the Discharge Test .......................................................... 3-39 Apply Battery Terminal Protectant ................................................. 3-39 Inspect the Controller Connector................................................... 3-39 Inspect the Rear Axle Bearing....................................................... 3-39 Radial Inspection ..................................................................... 3-39 Bearing Inspection................................................................... 3-39 Inspect the Steering Knuckle......................................................... 3-40 Wheel Alignment ........................................................................... 3-40 Inspect the Front Wheel Bearing ................................................... 3-41 Check the Transaxle Oil Level ...................................................... 3-41 Adjust the Parking Brake ............................................................... 3-42 Adjust Brake Pedal Free Play ....................................................... 3-43 Two-Year Service - Electric Cars ........................................................ 3-44 Change the Transaxle Oil.............................................................. 3-44 Inspect the Brake Discs................................................................. 3-45 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 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 Troubleshooting............................................................................. 4-15 Hardware System Faults ......................................................... 4-16 Charging (for All Markets Outside of the Western Hemisphere) ... 4-16

2013-2016 Yamaha YDRA / YDRE (Gas & Electric) Golf Car OEM Service & Repair Manual

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