Yamaha DRIVE 2 2022, Owner'S/Operator'S Manual

Page 1: ...OR S MANUAL Read this manual carefully before operating this vehicle PERSONAL TRANSPORT VEHICLE 2022 MODEL YEAR J5C F8199 10 LIT 19626 A2 17 DR2 PTV POWERTECH AC IRS Li 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 2: ...icals including phthalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm For more information go to www P65Warnings ca gov 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 3: ...ent from your new Yamaha If you have any questions about the operation or maintenance of your PTV please consult a Yamaha dealer Yamaha Golf Car Company DR2 PTV POWERTECH AC IRS Li OWNER S OPERATOR S MANUAL 2022 by Yamaha Golf Car Company 1st edition September 2021 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Golf Car Company is expressly prohibit...

Page 4: ... information to make procedures eas ier or clearer Yamaha continually seeks advancements in product design and quality therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your PTV and this manual If you have any questions concerning this manual please consult your Yamaha dealer Read and understand this...

Page 5: ...MPORTANT LABELS SAFETY INFORMATION CONTROLS PRE OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CONTENTS 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 6: ...e any failures caused by Accident or collision damage warranty The Customer s Responsibility under this warranty shall be to manual and EMISSION CONTROL SYSTEM WARRANTY USA only proper maintenance are not covered by this warranty Golf Car Company and excluded from this Warranty so the above exclusion may not apply to you This Warranty give yŽƵ ƐƉĞĐŝĮĐ ůĞgal rights and you may also have other right...

Page 7: ...CLUSIONS THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY IF BATTERIES ARE SUBJECTED TO ANY OF THE FOLLOWING CONDITIONS Lack of proper maintenance as outlined in the electric vehicle Owner s Operator s Manual For example improper charging procedures during long term storage half charge gathering devices lights radios or stereos or yardage measuring devices Less than one charger per car or i...

Page 8: ... labels carefully before operating your PTV If any of these labels are damaged or missing contact a Yamaha dealer for replacements 4 6 5 7 1 2 3 9 8 1 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 IMPORTANT LABELS 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 9: ... attendre un minimum de 15 seconds avant de le remettre K8298 K8297 Electricalshortscanresultin burns Donotmakeconnection betweenpositiveand negativebatteryterminals Lescourts circuitsélectriques peuventcauserdesbrûlures Nepasrelierlabornepositive etlabornenégatived unemême batterie AVERTISSEMENT WARNING Hautetension Risqued électrochoc Netouchezpaslesbornesoulesfils électriquesnonisolés N ouvrezpa...

Page 10: ...KAKEGAWA JAPAN MAX BATTERY WEIGHT kg MODEL NOMINAL SYSTEM VOLTAGE V MAX POWER hp kW WEIGHT NO BATT kg VEHICLE LOAD CAPACITY kg PER SEAT kg BAGWELL MY CAN ICES 2 NMB 2 H2377 6 7 8 9 8 5 IMPORTANT LABELS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 11: ...e for model identification the remain ing digits are the unit production num ber Keep a record of these numbers for reference when ordering parts from a Yamaha Golf Car Company dealer Serial number 1 1 PTV serial number TIP IMPORTANT LABELS 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 12: ...on public streets roads or highways unless allowed by law or local regulating authority Yamaha PTVs are designed to be simple to operate However be sure to observe the following to reduce the risk of serious injury or death due to loss of control and other hazards WHILE OPERATING THE PTV Keep your entire body inside the PTV remain seat ed and hold on when the car is in motion Do not start the PTV ...

Page 13: ...p or straight down slopes never at an angle to avoid tipping or rolling the vehicle Do not make any modification or addition which affects capacity or safe operation or make any changes not in accordance with the owner s oper ator s manual 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 14: ...ons in this manual WARNING 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 warni...

Page 15: ... Ventilation Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards Loose Terrain Avoid areas of loose terrain which may cause a PTV to lose traction and affect sta bility Take notice of conditions and reduce speed when driving on uneven or loose terrain Pedestrian Areas Avoid areas with pedestrian traffic or congested areas ...

Page 16: ...lectrically powered PTVs or around batteries to avoid electrical shock or damage to the electrical system Do not open battery case The battery has no user serviceable parts Maintain all safety devices including brakes steer ing mechanisms warning devices and governors in a safe operating condition Do not modify these safety devices as supplied by the manufacturer After each maintenance or repair t...

Page 17: ...cordance with appli cable ordinances and regulations to avoid explo sions electrical shock or damage to the electrical system Periodically inspect charging facilities and proce dures to be certain that applicable safety codes regulations and procedures are being followed to avoid any fires or explosions If new nameplates warnings or instructions are needed contact your Yamaha dealer 2 0 2 2 Y a m a...

Page 18: ...ng brake pedal 7 Horn switch 8 Accelerator pedal 9 USB ports 1 9 2 8 6 5 4 3 7 9 1 Headlights 2 Front body 3 Seat 4 DC charger receptacle 5 Front tire 6 Front bumper 7 Fuses 6 5 4 1 2 3 7 1 Reflector 2 Battery 2 1 1 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CONTROLS 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 19: ...1 Tow switch 1 1 Rear body 2 Taillights 3 Rear bumper 4 Rear tire 4 2 3 1 2 CONTROLS 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 20: ...tor controller unit remains energized The PTV cannot be operated The key can be removed only in this position ON OFF Li ion BATTERY ON WITH LIGHTS The functions for this position are the same as for the ON position however this position will activate the headlights and taillights ON OFF Li ion BATTERY As the battery energy decreases the LEDs will move to the left toward the E When the LED light be...

Page 21: ...OFF Li ion BATTERY TIP BEEP Use the table to determine the remaining battery ca pacity For example if 7 of the 10 LED lights are lit the bat tery still has SOC state of charge 64 71 left When the battery falls to SOC 20 or less 1 LED will blink on and off meaning the battery should be charged immediately Li ion BATTERY BAR LEVEL 1 BLINK 2 3 4 5 6 7 8 9 10 SOC 0 20 20 29 29 37 37 46 46 54 54 64 64 ...

Page 22: ...l Increase Release pedal Decrease 1 Accelerator pedal 1 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 1 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CONTROLS 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 23: ...right to the second ON position This will activate the headlights and taillights ON OFF Li ion BATTERY TOW SWITCH Before operating the car make sure the tow switch is in the RUN position Ensure that the Drive Select Switch is in the FWD position and then move the TOW Switch to TOW before towing After moving switch from RUN to TOW wait 15 seconds minimum before switching again Failure to do so may ...

Page 24: ...to the brake pedal and is activated by depressing with your foot It is advisable to sound the horn when approaching blind corners 1 Horn Switch 1 TIP 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CONTROLS 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 25: ...e To keep car from moving while performing pre op eration checks Remove main switch key Apply parking brake WARNING PRE OPERATION CHECKS Refer to the Periodic Maintenance and adjustment charts on pages 25 and 27 SEAT Lift up the seat for checking and servicing 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PRE OPERATION CHECKS 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 26: ...jects When tire tread wears down to 1 mm 0 04 in replace the tire 1 Wear limit 1 BATTERY Check that the battery is held securely in place to pre vent it from being damaged from vibration or jarring Check the battery terminals for corrosion and tight ness 1 1 Battery hold down 1 1 Battery terminal 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PRE OPERATION CHECKS 2 0 2 2 Y a m a h a G o l f C a r C o m p a n...

Page 27: ...ds which may indicate loose steering components con sult a Yamaha dealer PEDAL OPERATION Check the following pedal controls for proper oper ation 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 pedal operates smoothly 1 Accelerator pedal 1 WARNING Brake Pedal Make sure the brake pedal feels firm when pres...

Page 28: ...GHTS Ensure the headlights and taillights are operational Never operate the PTV at night or during inclem ent weather without properly working headlights taillights WARNING HORN SWITCH Make sure the horn operates correctly 1 Horn Switch 1 BODY AND CHASSIS Before each use visually inspect the PTV body and chassis for damaged and or missing parts 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PRE OPERATION CHE...

Page 29: ...depress the accelerator pedal The PTV will start to move The parking brake automatically releases when the accelerator pedal is depressed ON OFF Li ion BATTERY NOTICE ON OFF Li ion BATTERY WARNING 1 Accelerator pedal 1 TIP STOPPING To stop the PTV gradually press down on the brake pedal Do not hold the PTV on an incline with the accel erator use the brake Transmission damage can result When the PT...

Page 30: ...Opera tion 40 rounds 20 hours 100 miles 160 kms Every Month 250 rounds 125 hrs 600 mls 1000 kms Every 6 months 500 rounds 250 hrs 1200 mls 2000 kms Every Year 1000 rounds 500 hrs 2500 mls 4000 kms Every 2 years 2000 rounds 1000 hrs 5000 mls 8000 kms Every 4 years Page PRE OP Charge battery S S S S S S 12 28 Check for tight ness of hold down screws and terminals S S S S S S 21 Check brake pedal fre...

Page 31: ...y and resistor CS CS CS CS CS 50 EVERY 6 MONTHS Check all wire in sulation for cracks and or worn spots CS CS CS CS Check brake cable operation Inspect for abra sions and dam age and replace if necessary CS R CS R CS R CS R 45 Check shock absorbers for oil leaks and dam aged springs CS CS CS CS EVERY YEAR Apply battery Ter minal protectant S S S Check rear axle bearing play for roughness or freepl...

Page 32: ...00 kms Every 4 years Page EVERY YEAR Check transmis sion oil level and inspect for leakage CS CS CS 42 Adjust parking brake release CA CA CA 47 EVERY 4 YEARS Replace transmis sion oil R Inspect brake shoes and adjust or replace if nec essary CA Items without a page number reference should be serviced by a Yamaha dealer or other qualified me chanic This manual does not contain these procedures They ...

Page 33: ...ard TheLithium ionbatterychargingsystemisequipped with a resistor This resistor activates at the end of the charging cycle When the resistor is activated the resistor heat shield and resistor will become hot To charge the battery in your PTV follow the instruc tions contained in your battery charger s owner s man ual The following is a summary of the charging steps Do not attempt to recharge your ...

Page 34: ...amaha Golf Car Seri ous battery damage can result Thoroughly read and understand the user manual supplied with your charger for Yamaha Lithium ion battery system 3 Check the DC output plug and code for damage The location of the dummy pin is different between the flood battery and the Lithium ion battery NOTICE 1 DC output plug for Lithium ion battery 2 Identification wrap Green 3 Rib 1 3 2 1 Recept...

Page 35: ...age 28 5 Once the battery is fully charged the charge cy cle will stop automatically 6 After the end of the charge cycle a battery volt age leveling cycle begins The voltage leveling cycle turns on the resistor 7 After the battery charging and voltage leveling cycle has finished disconnect the DC output plug from the DC charger receptacle by grasping the plug body and pulling the plug straight out ...

Page 36: ...event accidental short circuiting and electrical system damage Put tow switch in the tow position The fuse holder is located under the seat next to the tow switch To access the fuse holder 1 Lift up the seat see page 20 2 Locate the fuse holder next to the tow switch WARNING NOTICE 1 Tow switch 2 Fuse holder 3 USB Mini fuse 5 0A 32V 4 Main Mini fuse 10 0A 58V 5 MCU Mini fuse 3 0A 58V 2 1 4 3 5 31 ...

Page 37: ...tinguisher Emergency phone numbers Read the text located on the case of the charger be fore operating or using the charger Features Switch Mode Design High efficiency operation with smooth ripple free DC output 10 LED Display Displays state of charge and charge error conditions Charge Protection Protects from improper connec tion overload and excessive temperatures Programmed safety features includ...

Page 38: ...ult in a risk of a fire or electric shock The output of chargers with greater than 48 volts may pose an energy and or shock hazard under normal use AVOID connecting a charger and another device to a single 15A 20A circuit or the circuit may become overloaded The AC line connected to the charger must be capa ble of supplying 12 Amperes to the charger Also maximum Ampere varies depending on AC volt a...

Page 39: ...the lower end of the charger Keep the charger free of oil dirt mud or dust to keep the cooling fins operating as efficiently as possible Mount the charger by the mounting plate using appro priate fasteners The charger s AC plug must be located at least 46 cm 18 in above the ground and the display visible to the user Chargers can ignite flammable materials and va pors Do not use near fuels grain dust ...

Page 40: ...st be grounded to reduce the risk of electric shock The charger is equipped with a 3 prong AC cord set The AC cord set must be con nected to an appropriate receptacle that is properly installed and grounded in accordance with the Nation al Electrical Code and all local codes and ordinances Improper connection of the equipment grounding conductor can result in a risk of an electric shock The conduc...

Page 41: ...ug cords charger or recepta cles are damaged or distressed in any way Using the charger with any of the above symptoms could result in a fire property damage or personal injury Do not disconnect the DC output plug from the DC charger 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 dis connect the charger DC output...

Page 42: ...ct the DC output plug to the vehicle charging receptacle by grasping the plug handle and pushing the plug straight into the DC charger recepta cle 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 charging is active 37 1 2 3 ...

Page 43: ...y connect ed the number of flashes indicates the algorithm ID number 100 Charge Green On Charging complete Charger in Storage Mode AC On Amber On The AC power is good Fault Red Blinking Charger error Refer to Troubleshooting on next page To reset charger after 100 charge Green LED disconnect the DC plug from battery for more than 30 seconds Then reconnect DC plug MAINTENANCE AND ADJUSTMENT 38 1 2 3...

Page 44: ...the risk of electric shock always disconnect the charger s AC cord set plug from AC power and its DC output plug from the vehicles DC charger receptacle before attempting any maintenance or cleaning Do not operate the charger if it is malfunctioning Personal injury or property damage could result WARNING WARNING WARNING 39 MAINTENANCE AND ADJUSTMENT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 0 2 2 Y a m a...

Page 45: ...as re duced due to high tem peratures Operate charger at a lower ambient temperature Unable to communicate with Battery Management System Check for shorted or dam aged cells Over Temperature Char ger shut down due to high internal temperature Ensure sufficient cooling air flow and reset charger i e remove the DC cord from the vehicle for 15 seconds Charger Internal Fault Reset charger i e remove the...

Page 46: ...es not start charging when DC cord set is plugged into char ger receptacle and the Amber AC On LED is illuminated Incorrect wiring or disconnection from DC cord charger receptacle and batteries Ensure polarity for wir ing is correct from DC cord charger receptacle and batteries Have qualified service technician inspect if problems persist WARNING 41 MAINTENANCE AND ADJUSTMENT 1 2 3 4 5 6 7 8 9 10 1...

Page 47: ...he level is low add sufficient oil of the recom mended type to raise it to the specified level Recommended oil brand Available viscosity index SAE 80W 90 or SAE 90 Transmission oil change quantity 475 cc 475 mL 0 50 US qt 7 Allow excess transmission oil to flow out of the hole until it stops 8 Check the O rings for damage and replace them if necessary 9 Install the transmission filler bolt Transmissio...

Page 48: ...he transmission case to collect the used oil 1 Bolt 2 Transmission cover 2 1 5 Clean the area around the transmission oil filler bolt and transmission oil drain bolt Remove the transmission oil filler bolt the trans mission oil drain bolt and their O rings to drain the oil Do not allow foreign material to enter transmis sion Serious transmission damage can result 1 Transmission oil drain bolt 2 O ri...

Page 49: ...e viscosity index SAE 80W 90 or SAE 90 Transmission oil change quantity 475 cc 475 mL 0 50 US qt 9 Install the transmission oil filler bolt and its O ring and then tighten the bolt to the specified torque Transmission oil filler bolt tightening torque 4 3 N m 0 43 kgf m 3 1 lb ft 10 Install the transmission cover and secure with four bolts and then install the rear floor cover and secure with two bolt...

Page 50: ...EMENT Before performing wheel or brake maintenance verify that the main switch is in the OFF position Accidental starting of the vehicle could cause the vehicle to move causing death or serious personal injury To remove and install a wheel on your PTV 1 With the wheels blocked to prevent the PTV from moving loosen the wheel nuts 2 Elevate the PTV with a suitable jack and remove the wheel nuts and ...

Page 51: ... the free play distance needs adjusting loos en the lock nut 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 tight ening will increase brake wear and affect overall performance of PTV Premature brake wear can result Death or serious personal injury can result from failing to comply with the wa...

Page 52: ...ent adjust brake pedal free play 1 Apply pressure to the parking brake pedal until the brake nail catches the first latch position on the sector 2 Loosen the locknut and turn the bolt counter clockwise until it contacts the sector 3 Turn the bolt clockwise 1 3 of a turn 120 de grees then tighten locknut NOTICE 1 Parking brake pedal 2 Bolt 3 Locknut 4 Brake nail 5 Sector 1 2 3 4 5 47 1 2 3 4 5 6 7 8...

Page 53: ...ire connector to the headlight as sembly 1 Screws three 2 Screws four 1 2 ADJUSTING A HEADLIGHT It is recommended to have the headlight adjust ment performed by a Yamaha dealer The screw can be accessed from under the fender 1 Using a Phillips head screwdriver turn the ad justing screw 2 Turning the screw clockwise will lower the beam and turning the screw counter clockwise will raise the beam NOT...

Page 54: ...om the bezel assembly 2 Remove the wire connector replace the taillight unit and reinstall by fitting the rubber grommet over the taillight unit and bezel 1 Bulb assembly 2 Rubber grommet 3 Bezel assembly 1 3 2 49 1 2 3 4 5 6 7 8 9 10 11 12 13 14 MAINTENANCE AND ADJUSTMENT 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 55: ...urn main switch key to OFF position lift seat and put the tow switch in the TOW position Remove key from main key switch and store key in a safe place NOTICE TIP BATTERY PREPARATION 1 Leave the battery in the golf car during storage Do not charge it before storage The charger should not be left connected to the car during storage 1 month or less in storage Storage temperature 20 45 C 4 113 F More ...

Page 56: ...ad Front 885 mm 34 8 in Rear 990 mm 39 0 in Ground clearance 140 mm 5 5 in Weight Curb weight With Lithium ion battery 338 kg 745 lb Curb weight With Sun top W S Lithium ion battery 368 kg 811 lb Performance Factory speed setting 31 4 km h 19 5 mph Maximum speed 31 4 km h 19 5 mph Minimum turning radius 2 9 m 9 5 ft Seating capacity Two occupants per seat Hill climbing capacity 15 51 1 2 3 4 5 6 7...

Page 57: ...ry manufuctured by RoyPow 51 volt 5 3kwh BATTERY AMBIENT TEMPERATURES Lithium Battery Condition Temperature Operation 20 55 C 4 131 F Charging 5 49 C 42 121 F Storage 1 month or less 20 45 C 4 113 F More than 1 month 0 35 C 32 95 F CHASSIS Items DR2 PTV POWERTECH AC IRS Li Suspension Front Independent Coil over strut type Rear Independent Coil over strut type Steering system Type Rack and Pinion S...

Page 58: ...adjustment 50 55 mm 1 97 2 17 in Parking brake Type Foot type parking brake with automatic release Wheel Tire size Width mm Aspect ratio Rim size in Ply rating Front 205 65 10 4 PR Rear 205 65 10 4 PR Rim size Dia in Width in Offset mm 10 6 0 6 Tire pressure 151 kPa 1 55 kgf cm2 22 psi Lights Headlight LED Taillight 12 V BULB 53 SPECIFICATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 0 2 2 Y a m a h a G...

Page 59: ...5 1A 240VAC Current nom Arms 10A 120VAC 6A 200VAC 5 5A 220VAC AC Power Factor 0 98 at nominal input current Mechanical Dimensions 28 0 24 5 14 0 cm 11 9 7 5 5 in Weight 5 kg 11 lbs w standard cord Environmental Enclosure IP66 except to AC connection pins IP20 Operating Temperature 30 C to 50 C 22 F to 122 F derated above 30 C below 0 C Storage Temperature 40 C to 70 C 40 F to 158 F AC Input Connec...

Page 60: ...S BATTERY CHARGER 278 3 mm 196 3 mm 260 3 mm 176 3 mm 125 mm 246 3 mm 3 1 mm M4 4 mm Grounding Stud Ref 139 3 mm 111 3 mm 55 SPECIFICATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

Page 61: ...DR2 PTV POWERTECH AC IRS Li WIRING DIAGRAM 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 WIRING 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...

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Page 64: ... 1 CR E CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING 1 2 3 4 5 6 7 8 9 10 2 0 2 2 Y a m a h a G o l f C a r C o m p a n y ...