Yamaha DR2A17 EFI PTV, Operator'S Manual

Page 1: ...E PERSONAL TRANSPORT VEHICLE DR2A17 EFI PTV OWNER S OPERATOR S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information Yamaha Motor Corporation USA 800 962 7926 J0D F8199 00 J0D F8199 00_cover qxp_LIT_19626_00_81 cover qxd 5 4 16 10 21 AM Page 1 ...

Page 2: ...J0D F8199 00_cover qxp_LIT_19626_00_81 cover qxd 5 4 16 10 21 AM Page 2 ...

Page 3: ... enjoyment from your new Yamaha If you have any questions about the operation or maintenance of your PTV please consult a Yamaha dealer Yamaha Motor Corporation USA DR2A17 EFI PTV Owner s Operator s Manual 2017 by Yamaha Motor Corporation USA 1st edition All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation USA is expressly prohibited Pri...

Page 4: ...rt of your PTV and should remain with the PTV when resold Particularly important information is distinguished in this manual by the following notations This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A WARNING indicates a potentially hazardous situation which if not avoid...

Page 5: ...ENTS 1 IMPORTANT LABELS 2 SAFETY CONSIDERATIONS 4 MAINTENANCE 8 STORAGE SPECIFICATIONS 9 WIRING 11 OPERATION 7 PRE OPERATION CHECKS 6 CONTROLS 5 OPERATOR SAFETY 3 10 J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 38 PM Page 3 ...

Page 6: ...covery and make the vehicle or charger available at that time for inspection and repairs by the dealer s authorized representative WARRANTY TRANSFER Any transfer of warranty must take place within the first three years of the original in service date of the vehicle The vehicle must be re registered by an authorized Yamaha Golf Car Dealer within 30 days of transfer A fee may be charged for the tran...

Page 7: ...aterials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in Yamaha Golf Car Company s application for certification The warranty period begins on the date the SORE vehicle is delivered to an ultimate purchaser or first placed into service The warranty period is two years Subject to certain conditions and exclusions as st...

Page 8: ...ranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if Yamaha Golf Car Company demonstrates that the SORE vehicle has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part That notwithstanding any adjustment of a component that has a facto...

Page 9: ...ng labels carefully before operating your PTV and promptly replace any labels which become damaged or removed Death or serious personal injury can result from failing to read and comply with the safety instruction labels IMPORTANT LABELS 2 1 J0D J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 7 ...

Page 10: ...IMPORTANT LABELS 1 2 3 4 5 6 7 8 9 10 11 2 2 J0D 2 5 4 Y 1606 3 J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 8 ...

Page 11: ...1 2 3 4 5 6 7 8 9 10 11 IMPORTANT LABELS 2 3 J0D 6 Y 1610 8 7 J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 9 ...

Page 12: ...the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha Golf Car Company dealer The engine serial number 1 is affixed in the location shown Y 2822 2 Engine Information 2 Y 2139 Y 851a THIS ENGINE MEETS CALIFORNIA EMISSION REGULATIONS FOR OFF ROAD ENGINES THIS ENGINE CONFORMS TO U S EPA REGULATIONS FOR SMALL NONROAD ENGINES 1 J0D F8199 00 qxp_LIT_19...

Page 13: ...ly and only in designated areas l Do not allow more than two occupants per seat This PTV is restricted to two occupants unless equipped with a rear seat l Do not operate the PTV while under the influence of alcohol or drugs their effect on vision and judgment make operating a PTV dangerous l Do not operate the PTV on public streets roads or highways unless allowed by law or the local regulating au...

Page 14: ...eds to avoid tipping or rolling the vehicle l Always drive slowly straight up or straight down slopes never at an angle to avoid tipping or rolling the vehicle l Do not run the engine indoors Exhaust gas is poisonous and could result in carbon monoxide poisoning l Do not make any modification or addition which affects capacity or safe operation or make any changes not in accordance with the owner ...

Page 15: ...s affixed to the PTV HAZARD PREVENTION Drivers should be mindful of road hazards and avoid dangerous situations that may include the following Steep Grades Where steep grades exist restrict PTV to designated roadway or path and descend slowly with foot on the brake Descend steep grades slowly with foot on brake Death or serious personal injury can result from failing to comply with the safety and ...

Page 16: ...ollowing to help ensure the safety of PTV occupants l Preventative Maintenance Per form all scheduled maintenance in accordance with manufacturer s recommendations to provide a safe properly operating PTV l Personnel Allow only qualified trained and authorized personnel to inspect adjust and maintain PTVs l Parts and Materials Use only replacement parts and materials recommended by the manufacture...

Page 17: ...e safety devices as supplied by the manufacturer l After each maintenance or repair the car must be driven by a qualified trained and authorized person in an area free of pedestrian traffic to ensure proper operation and adjustment l Record all maintenance performed in a maintenance record log by date name of person performing maintenance and type of maintenance Periodically inspect maintenance lo...

Page 18: ...SB ports 9 Reflector a Seat b Front body c Headlights d Front tire e Front bumper f Drive select lever g Battery h Rear body i Rear tire j Rear bumper k Taillights l Fuel tank m Fuel cap n E F I fuel pump o Fuel tank vent p Cover filler funnel Y 2748 9 9 Y 2747 1 2 8 8 5 4 3 6 7 Y 2750 18 20 19 17 16 20 14 13 12 11 15 10 Y 2749 Y 2751 24 22 23 21 25 J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39...

Page 19: ... The functions for this position are the same as for the ON position however this position will activate the headlights and taillights ENGINE OIL WARNING LIGHT When the engine oil level falls below an acceptable level this light comes on If the light comes on stop the engine check the engine oil level and add oil as necessary See page 6 3 NOTICE Y 2754 E F 1 2 ON OFF Y 2755 E F 1 2 ON OFF Y 2756 E...

Page 20: ...rate the vehicle Contact your Yamaha Service representative to have the vehicle serviced å Engine oil warning light DRIVE SELECT LEVER The drive select lever is used to shift the PTV into forward or reverse After coming to a complete stop move the lever to the desired position Lever Position Car Movement F FORWARD R REVERSE TIP The reverse alarm will sound when the drive select lever is turned to ...

Page 21: ...brake pedal whenever parking the PTV ç Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal The parking brake will automatically release when the accelerator pedal is depressed If the main switch is in the ON position depressing the accelerator may suddenly cause the PTV to move Death or serious personal injury can result from failing to comply with the safety inst...

Page 22: ...he hour meter to determine when scheduled maintenance is due å Hour meter USB PORTS A USB port is located inside the dash on the driver side and passenger side These can be used to power or charge USB devices or accessories The USB is only powered when the key is in the ON position 1 USB port HORN SWITCH The horn is located adjacent to the brake pedal and is activated by depressing with your foot ...

Page 23: ...nature To keep vehicle from moving while performing pre operation checks l Remove main switch key l Apply parking brake Death or serious personal injury can result from failing to comply with the safety instructions in this manual PRE OPERATION CHECKS Refer to the Periodic Maintenance charts on pages 8 1 and 8 2 SEAT Open the seat for checking and servicing J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7...

Page 24: ...er sources of ignition Refuel in a well ventilated area 2 Take care not to spill gasoline If gasoline spills wipe it up immediately with dry rags Always dispose of gasoline soaked rags properly 3 Tighten until a clicking sound is heard Gasoline is poisonous and can cause injury or death If you swallow gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical attent...

Page 25: ...d of the dipstick å Oil level dipstick Maximum oil level ç Safe operating range If the oil level is below the MIN mark on the dipstick add oil through the oil filler hole until the oil level is between the MIN and MAX marks å Oil filler hole l Use care not to fill past the MAX dipstick mark and be sure no foreign material enters the crankcase l Use care not to get oil on the starter belt TIP The d...

Page 26: ...nuts Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the PTV Tire pressure 124 kPa 1 26 kgf cm2 18 psi ...

Page 27: ...unds which may indicate loose steering components consult a Yamaha dealer REVERSE ALARM Check the reverse alarm by moving the drive select lever to R for reverse The alarm should sound PEDAL OPERATION Check the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha dealer Accelerator Pedal With the main switch in the OFF position make sure the accelerator ...

Page 28: ...ng brake pedal TIP Release the parking brake by depressing the accelerator pedal Headlights Taillights Ensure the headlights and taillights are operational Never operate the PTV at night or during inclement weather without properly working headlights taillights Death or serious personal injury can result from failing to comply with the safety instructions in this manual Horn Switch Make sure the h...

Page 29: ...urn the main switch to ON Do not depress the accelerator pedal when turning on the main switch or the PTV may suddenly start moving Death or serious personal injury can result from failing to comply with the safety instructions in this manual 3 Check that your path is clear in the direction you plan to go and slowly depress the accelerator pedal The PTV will start to move å Accelerator pedal TIP T...

Page 30: ... å Brake pedal When the PTV has come to a stop apply the parking brake pedal and turn the main switch to OFF Parking brake pedal Do not hold the PTV on an incline with the accelerator use the brake Transmission damage can result NOTICE Y 65b A B C J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 28 ...

Page 31: ...ck operation of 7 1 Forward Reverse shifting Clean Lube pedal control area CL EVERY 6 Wash pre filter check air S S S S 8 6 8 7 MONTHS cleaner element Check spark plug and plug cap 8 4 condition Check compression Check shock absorbers for oil leaks and damaged springs Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contai...

Page 32: ...sary CL CL CL Check steering knuckle bushing free play Adjust wheel alignment CA CA CA Check wheel nut tightness front wheel bearing play Check operation and adjust CA CA CA Adjust parking brake release CA CA CA pedal stop if necessary EVERY 2 YEARS Check starter brushes for wear and commutator for dirt S EVERY 4 YEARS Replace fuel hoses R Check tightness of cylinder CA head Adjust valves Inspect ...

Page 33: ...bbreviations conform to the latest version of the SAE s recommended practice document J1930 Diagnostic Acronyms Terms and Definitions For Electrical Electronic System It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic TROUBLESHOOTING If the vehicle s engine will not start use the following chart Cause Remedy Fuel System No fuel in tank Fill fuel tank Fuel...

Page 34: ...mage the insulator A damaged insulator could allow external sparks which could lead to explosion or fire Death or serious personal injury can result from failing to comply with the safety instructions in this manual å Spark plug Spark plug cap 1 Check for discoloration and remove carbon deposits with a spark plug cleaner or wire brush The normal electrode color will be tan 2 Check the spark plug t...

Page 35: ...il or hot engine parts during the following procedure Death or serious personal injury can result from failing to comply with the safety instructions in this manual To remove the oil from the engine an oil extraction tool can be used to extract the oil via the dipstick feed hole instead of draining out the drain plug 2 Block rear tires and lift front end of car Secure car with car stands 3 Release...

Page 36: ...Dispose of used oil in an environmentally safe way such as taking oil to an oil collection station 8 Install the drain plug along with a new drain plug gasket finger tight before tightening to the following torque Drain plug torque 31 Nm 3 1 m kg 23 ft lb 9 Add the correct quantity of oil through the oil filler hole Recommended oil Yamalube SAE 10W30 4 cycle oil Engine oil capacity 1 0 L 1000 cc 1...

Page 37: ...drain plug If oil leaks are found consult a Yamaha dealer 10 Reinstall exhaust duct and secure by using a new tie strap 11 Install panel and mount with four bolts 12 Secure rubber tabs of exhaust duct to panel Air Filter To remove the air filter elements 1 Unlatch the air filter cover clips and remove cover å Air filter cover clips Air filter cover 2 Lift the air filter and pre filter out of the a...

Page 38: ...he elements reverse the above steps The pre filter has a notch on one side It will only fit in the case one way Serious engine damage can result from improperly positioned filter Drive Belt To remove the drive belt 1 Set the drive select lever halfway between forward and reverse 2 Pull up on the drive belt and push it outward over the edge of the secondary sheave 3 Turn the secondary sheave clockw...

Page 39: ...year for proper drive operation Refer to the Periodic Maintenance chart in this owner s manual Air Duct Check for debris in intake air duct tubing and connections 1 Park the PTV on a flat level surface and apply the parking brake 2 Remove the floor mat 3 Remove the seat 4 Remove the drive select lever 1 Drive select lever 5 Unscrew and remove the 8 retaining pins and remove the front panel 2 Retai...

Page 40: ...hanic charge it Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteri...

Page 41: ...ort circuiting and electrical system damage 1 Locate the in line fuse box in the battery compartment 2 Pull fuse holder cover off 3 Pull fuse out inspect and replace if necessary å Fuse box Fuse Type 1 DC Outlet Fuse 10A Blade Style 2 Light Fuse 15A Blade Style 3 Fuse 10A Blade Style 4 25 Amp Blade Style MAIN Fuse location off of negative battery terminal 15 cm 6 in NOTICE A Y 2288 R RW R R B MAIN...

Page 42: ... Block rear tires and lift front end of PTV Secure PTV with car stands 4 Remove the two panel retaining bolts for the lower panel 3 Panel bolts 5 Tip the front of the lower panel down and unhook the front of the panel to remove the panel 4 Lower panel 6 Place an oil pan under the transmission Y 2739 1 2 Y 2817 3 Y 2818 4 J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 40 ...

Page 43: ...8 Install the drain plug 9 Remove the oil fill plug on top of the transmission 6 Oil fill plug 10 Fill the transmission with 16 06 oz 475 cc and replace the oil fill plug 11 Install the lower panel and exhaust duct tabs 12 Install the bag holder insert 2 and secure with two bolts 1 Recommended oil YAMALUBE SAE 80W 90 Gear Oil Transmission oil capacity 475 cc 16 06 oz Transmission oil change quanti...

Page 44: ... remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 88 Nm 8 8 m kg 65 ft lb Brake Adjustment The brakes on your PTV are self adjusting Before you operate the PTV press down on the brake pedal several times to make sure the brakes are functioning properly Consult your Yamaha dealer before using your PTV if you suspect brake problems...

Page 45: ... the floor of the PTV 2 If the free play distance needs adjusting loosen the lock nut å and turn the adjusting nut in or out until the free play specification is met Then tighten the lock nut in place Do not over tighten the brake cables Over tightening will increase brake wear and affect overall performance of PTV Premature brake wear can result Death or serious personal injury can result from fa...

Page 46: ...ake pedal until the brake nail catches the first latch position on the sector 2 Loosen the locknut and turn the bolt counterclockwise until it contacts the sector 3 Turn the bolt clockwise 3 8 120 degrees then tighten locknut 1 Parking brake pedal 2 Bolt 3 Locknut 4 Brake nail 5 Sector NOTICE MAINTENANCE Y 2823 1 2 3 4 5 J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 44 ...

Page 47: ...hree screws 2 and remove the light control unit 3 Remove the four screws 3 to remove the headlight assembly from the holder 4 Remove the headlight assembly from the holder 5 Install new headlight assembly into holder and secure with the four screws 6 Install the light control unit and fasten with three screws 7 Connect the wire connector to the headlight assembly J0D F8199 00 qxp_LIT_19626_00_81 q...

Page 48: ...rning the screw clockwise will lower the beam and turning the screw counter clockwise will raise the beam Replacing a Taillight Bulb 1 If a taillight bulb burns out replace the bulb assembly 1 by removing the rubber grommet 2 from the bezel assembly 3 2 Remove the wire connector replace the bulb and reinstall by fitting the rubber grommet 2 over the bulb assembly 1 and bezel 3 NOTICE Y 2771 1 3 2 ...

Page 49: ...r Change clothing if gasoline spills on it to avoid potential fire hazard Fill up the fuel tank with new fuel and add recommended Yamalube Fuel Stabilizer and Conditioner per the instructions listed on the container Operate the vehicle for at least 5 minutes to distribute the treated fuel through the fuel system Specified amount 7 5 cc of stabilizer for each liter of fuel 1 oz of stabilizer for ea...

Page 50: ...e battery from your PTV and store it in a cool dry place that stays between 0 C 32 F and 30 C 90 F 2 Have the battery recharged every 60 90 days to keep it fully charged The battery must be kept fully charged to avoid damage 3 Batteries like the one supplied with your car normally do not require you to check the water level inside the battery for the one year warranty period provided by the manufa...

Page 51: ...640 mm 64 6 in Tread Front 870 mm 34 3 in Rear 980 mm 38 6 in Minimum ground clearance 110 mm 4 3 in Weight Dry weight with suntop without battery 341 kg 751 lb Performance Factory speed setting 31 38 km h 19 5 mph Maximum speed 31 5 km h 19 5 mph Minimum turning radius 2 8 m 110 2 in Seating capacity Two occupants per seat four occupants maximum Fuel Tank Capacity 22 0 L 5 8 U S Gallons J0D F8199...

Page 52: ...lube SAE 10W30 4 cycle oil Engine oil capacity 1 0 L 1000 cc 1 0 US qt Oil change quantity 1 0 L 1000 cc 1 0 US qt TRANSMISSION Items DR2A17 PTV Transmission Type V belt automatic centrifugal engagement V belt width and outer line length 31 0 x 1010 mm 1 20 x 39 76 in V belt wear limit 27 0 mm 1 06 in Governor Type Oil bath flyweight Factory speed setting 31 38 km h 19 5 mph Differential reduction...

Page 53: ...pe of brake Dual internal expanding shoe Leading trailing shoes self adjusting Brake pedal freeplay linkage adjustment 20 25 mm 0 79 0 98 in Brake cable end play 0 004 0 02 in 0 1 0 5 mm Parking brake Type Foot type parking brake with automatic release Wheel Tire size Front 20 5 x 8 0 6PR Rear 20 5 x 8 0 6PR Rim size 10 x 6 Tire pressure 124 kPa 1 26 kgf cm2 18 psi Lights Bulb voltage wattage x qu...

Page 54: ...1 2 3 4 5 6 7 8 9 10 11 J0D 11 1 J0D SCHEMATIC WIRING DR2A17 PTV WIRING DIAGRAM J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 52 ...

Page 55: ...1 2 3 4 5 6 7 8 9 10 11 J0D 11 2 WIRING DR2A17 PTV WIRING DIAGRAM J0D WIRE DIA J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 53 ...

Page 56: ...1 2 3 4 5 6 7 8 9 10 11 J0D NOTES J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 54 ...

Page 57: ...1 2 3 4 5 6 7 8 9 10 11 J0D NOTES J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 55 ...

Page 58: ...1 2 3 4 5 6 7 8 9 10 11 J0D NOTES J0D F8199 00 qxp_LIT_19626_00_81 qxd 6 7 16 3 39 PM Page 56 ...

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Page 60: ...E PERSONAL TRANSPORT VEHICLE DR2A17 EFI PTV OWNER S OPERATOR S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information Yamaha Motor Corporation USA 800 879 0078 J0D F8199 00 J0D F8199 00_cover qxp_LIT_19626_00_81 cover qxd 5 5 16 9 45 AM Page 1 ...