Page 2 - WARNING
LIT-CALIF-65-01 The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birthdefects or other reproductive harm. YAMAHA WARNING G21A O_M IFC 8/8/00 7:56 AM Page 1
Page 3 - INTRODUCTION; TECHNICAL SERVICE DEPT
INTRODUCTION Congratulations on your purchase ofa Yamaha golf car. This manual con-tains information you will need forproper operation, maintenance, andcare of your golf car. A thoroughunderstanding of these simpleinstructions will help you to obtainmaximum enjoyment from your newYamaha. If you have...
Page 4 - IMPORTANT MANUAL; NOTE; CAUTION
ii G16A/E IMPORTANT MANUAL INFORMATION ● Yamaha continually seeks ad-vancements in product design andquality; therefore, while this manualcontains the most current productinformation available at the time ofprinting, there may be minor discrepancies between your golf car and this manual. If you have...
Page 5 - CONTENTS
iii G16A/E 1 WARRANTY CONTENTS 1 IMPORTANT LABELS 2 MAINTENANCE SAFETY PROGRAM 4 MAINTENANCE 8 STORAGE SPECIFICATIONS 9 WIRING 11 OPERATION 7 PRE-OPERATION CHECKS 6 CONTROLS 5 OPERATOR SAFETY 3 10 LIT_19626_16_00.qxd 7/13/01 8:42 AM Page 3
Page 6 - WARRANTY; YAMAHA MOTOR MANUFACTURING
1 2 3 4 5 6 7 8 9 10 11 1-1 G16A/E WARRANTY Yamaha Motor Manufacturing Corporation of Americahereby warrants that any new G16 (gas and electricmodels) Yamaha Golf Car purchased from an authorizedYamaha dealer in the United States will be free fromdefects in material and workmanship for the period of...
Page 9 - IMPORTANT LABELS; SAFETY AND
1 2 3 4 5 6 7 8 9 10 11 G16A/E 2-1 IMPORTANT LABELS Y-505 1 2 5 6 3 4 G16A G16E G16A G16E SAFETY AND INSTRUCTION LABELS Please read the followinglabels carefully beforeoperating your golf car,and promptly replace anylabels which become dam-aged or removed. WARNING Y-500 Y-502 1 2 3 5 6 4 LIT_19626_1...
Page 11 - OPERATOR SAFETY
1 2 3 4 5 6 7 8 9 10 11 G16A/E 3-1 OPERATOR SAFETY ! Y-67 Y-68 Y-8 Yamaha golf cars are designed to besimple to operate. However, be sureto observe the following: BEFORE OPERATINGTHE GOLF CAR ● Read this Owner’s/Operator’s man-ual and all safety and instructionlabels on the golf car before operat-in...
Page 13 - MAINTENANCE SAFETY PROGRAM; Steep Grades; Wet Areas
1 2 3 4 5 6 7 8 9 10 11 G16A/E 4-1 MAINTENANCE SAFETY PROGRAM ! Like all machines, golf cars cancause injury if improperly used ormaintained. This section containsbroad safety practices required forsafe golf car operation. Before golfcars are operated, golf course per-sonnel should establish any add...
Page 14 - Loose Terrain; Preventative Maintenance
1 2 3 4 5 6 7 8 9 10 11 G16A/E 4-2 MAINTENANCE SAFETY PROGRAM ● Loose Terrain . Loose terrain may cause a golf car to lose traction andmay affect stability. Repair loose ter-rain, chain or rope off these areas,or identify loose terrain with a suit-able warning. ● Golf Car and Pedestrian Interfer-enc...
Page 16 - CONTROLS; FEATURES
1 2 3 4 5 6 7 8 9 10 11 G16A/E 5-1 CONTROLS Y-506 18 7 10 Y-12 4 5 6 1 9 8 Y-507 16 17 15 14 3 Y-13 13 11 2 12 FEATURES 1 Steering wheel 2 Seat 3 Fuel cap (for G16A) 4 Brake pedal 5 Parking brake pedal 6 Accelerator pedal 7 Drive selector lever 8 Main switch 9 Oil warning light (for G16A) a Choke kn...
Page 17 - MAIN SWITCH; If the light comes on, stop the
1 2 3 4 5 6 7 8 9 10 11 G16A/E 5-2 CONTROLS Y-15 OFF ON Y-16 OFF ON OFF OIL WARNING ON Y-17 A MAIN SWITCH The main switch controls the follow-ing items: OFFIgnition circuit is switched off.The key can be removed only in thisposition. ONElectrical circuits are switched on.The golf car can be driven. ...
Page 18 - DRIVE SELECT LEVER; ACCELERATOR PEDAL; BRAKE PEDAL
1 2 3 4 5 6 7 8 9 10 11 G16A/E 5-3 DRIVE SELECT LEVER The drive select lever is used to shiftthe golf car into forward or reverse.After coming to a complete stop,move the lever to the desired posi-tion. Lever Position Car Movement F FORWARD R REVERSE The back-up buzzer will beep whenthe drive select...
Page 20 - SEAT
1 2 3 4 5 6 7 8 9 10 11 G16A/E 6-1 PRE-OPERATION CHECKS Y-512 Pre-operation checks should bemade each time you use your golfcar. Get in the habit of performing thefollowing checks in the same way sothat they become second nature. ● Be sure the main switch key isremoved before performing thepre-opera...
Page 22 - MIN
1 2 3 4 5 6 7 8 9 10 11 G16A/E 6-3 ENGINE OIL (G16A) With the golf car parked on levelground, remove the dipstick andmake sure the engine oil is betweenthe MIN and MAX marks (the cross-hatched area on the end of the dip-stick). å Oil level dipstick ∫ Maximum oil level ç Safe operating range If the o...
Page 23 - Engine Cooling Inlet Duct; BATTERY
1 2 3 4 5 6 7 8 9 10 11 G16A/E 6-4 Engine Cooling Inlet Duct Check the engine cooling inlet duct fordebris. Remove any debris present. å Engine cooling inlet duct BATTERY Charge G16E batteries before eachuse. See charging steps in chapter 8, Maintenance. Check that the battery (G16A) or bat-teries (...
Page 25 - Parking Brake Pedal; Accelerator Pedal; BODY AND CHASSIS
1 2 3 4 5 6 7 8 9 10 11 G16A/E 6-6 PRE-OPERATION CHECKS Parking Brake Pedal Make sure the parking brake pedallocks in place with a positive click,and releases when the acceleratorpedal is pressed. å Parking brake pedal Release the parking brake bydepressing the accelerator pedal. Accelerator Pedal B...
Page 26 - OPERATION; STARTING
1 2 3 4 5 6 7 8 9 10 11 G16A/E 7-1 Y-16 OFF ON Y-18 Y-23 A CH OKE Y-20 A OPERATION STARTING 1. With the parking brake applied, turn the drive select lever to “F”for forward, or “R” for reverse. Do not shift from “F” forward to“R” reverse while the golf car ismoving. 2. Turn the main switch to “ON.” ...
Page 27 - STOPPING; Cause
1 2 3 4 5 6 7 8 9 10 11 G16A/E 7-2 OPERATION STOPPING To stop the golf car, gradually pressdown on the brake pedal. å Brake pedal When the car has come to a stop,apply the parking brake pedal andturn the main switch to “OFF.” ∫ Parking brake pedal Do not hold the golf car on anincline with the accel...
Page 28 - PERIODIC MAINTENANCE CHARTS; MAINTENANCE
1 2 3 4 5 6 7 8 9 10 11 G16A/E 8-1 PERIODIC MAINTENANCE CHARTS Regular maintenance is required for the best performance and safe operation of your golf car. Be sure to turn off the main switch and apply the parking brake when you perform maintenance unlessotherwise specified. If the owner is not fam...
Page 31 - Item
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE 8-4 EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS Item Acronym • CARB. ASSY., LH., JT., CARB (Carburetor) CARBURETOR 2 & JT.,CARBURETOR 1 • T.C.I. MAGNETO ASSY. & El (Electronic Ignition) PLUG, SPARK • CRANKCASE 1 & HEAD, PCV (Positive Crankcas...
Page 32 - Spark Plug Inspection
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16A 8-5 Spark Plug Inspection You should periodically remove andinspect the spark plug. Dirty or wornspark plugs can cause poor perfor-mance. å Spark plug ∫ Spark plug cap 1. Check for discoloration andremove carbon deposits with aspark plug cleaner or w...
Page 33 - Engine Oil Replacement
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16A 8-6 Engine Oil Replacement 1. Warm up the engine for several minutes, place the golf car on alevel surface, then stop theengine. Use caution not to touch hotengine oil or hot engine parts, dur-ing the following procedure. 2. Place an oil pan under th...
Page 34 - Air Filter
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16A 8-7 Y-515 A Y-518 A A A B Y-519 A B å Oil filler hole Use care not to fill past the MAXdipstick mark, and be sure no for-eign material enters the crank-case. After replacing engine oil,check for oil leaks around thedrain plug. If oil leaks are found,...
Page 35 - Drive Belt
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16A 8-8 Y-60 B A Y-508 Inspection and cleaning: 3. Wash the foam pre-filter in soapand water. Allow it to dry. å Soap and water ∫ Foam element 4. Check the filter element. If dam-aged or dirty, replace it. Do not wring out the foam pre-fil-ter, this coul...
Page 36 - Battery
1 2 3 4 5 6 7 8 9 10 11 G16A/E 8-9 MAINTENANCE - G16A B A Y-44 Inspection: To inspect the drive belt, check forfrayed edges or tears, and measuredrive belt against the following speci-fication. If the belt shows excessivewear or damage, replace the belt witha new one. å New: 1.22 in. (31.0 mm) ∫ Rep...
Page 37 - Fuse Replacement
1 2 3 4 5 6 7 8 9 10 11 G16A/E 8-10 MAINTENANCE - G16A Y-45 + + – – The 12-volt battery that provides start-ing power to your gas car normallydoesn’t require the addition of waterduring the one year period provided bythe battery manufacturer. If the bat-tery loses its charge, have an experi-enced me...
Page 38 - Battery Care
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16E 8-11 Battery Care Battery electrolyte is poisonousand dangerous, causing severeburns, etc. It contains sulfuric acid.Avoid contact with skin, eyes, orclothing.Antidote:EXTERNAL: Flush with water.INTERNAL: Drink large quantitiesof water or milk. Follo...
Page 39 - after
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16E 8-12 Y-47 Y-829 D A C B ● Before charging: only add distilled water if fluid is below the top of theplates, and then add just enough tocover plates. ● After charging: check that the fluid level is approximately 1/4 to 1/2inch above the plates and 1/4...
Page 40 - Battery Charging; Do not attempt to
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16E 8-13 Battery Charging Read and understand the owner’smanual provided with your golfcar’s battery charger before charg-ing batteries. Explosive hydrogen gas is pro-duced while batteries are beingcharged. Only charge batteries inwell ventilated areas (...
Page 41 - Battery Installation
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16E 8-14 Do not disconnect the DC outputcord from the battery receptaclewhen the charger is on or an arccould occur that may cause anexplosion. 4. The charger will turn off automat- ically when the batteries reachfull charge. 5. After the charger has tur...
Page 42 - When installing batteries:
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16E 8-15 Y-51 C A B D D D Y-52 Y-653 B A 2. Connect the wire leads as shown. å Forward ∫ To relay ç To controller ∂ Between batteries When installing batteries: ● Carefully place battery cablesand holddowns making sure thatcables don’t lie across vent ca...
Page 43 - Gear Box Oil
1 2 3 4 5 6 7 8 9 10 11 G16A/E 95% MAINTENANCE - G16A & G16E 8-16 Gear Box Oil To check gear box oil level: 1. Place the golf car on a level sur- face. 2. Remove the access panel by removing the screws in the twolower corners of the panel andpulling the panel from the car. 3. For G16A and G16E ●...
Page 44 - Wheel Replacement; Brake Adjustment
1 2 3 4 5 6 7 8 9 10 11 G16A/E MAINTENANCE - G16A & G16E 8-17 Wheel Replacement To remove and install a wheel on yourgolf car: 1. With the wheels blocked to pre- vent the golf car from moving,loosen the wheel nuts. 2. Elevate the golf car with a jack and remove the wheel nuts andthe wheel. 3. Re...
Page 46 - STORAGE; DRAINING FUEL
STORAGE Perform the following preparationswhen storing your golf car for extend-ed periods of time: Turn main switch key to “OFF” posi-tion, remove key, and store key in asafe place. DRAINING FUEL (G16A GAS CAR) Gasoline and its vapors are highlyflammable and explosive. ● Do not smoke when refueling...
Page 47 - ENGINE PREPARATION
1 2 3 4 5 6 7 8 9 10 11 95% 9-2 G16A/E STORAGE ENGINE PREPARATION (G16A GAS CAR) With the key removed and the sparkplug lead disconnected, tur n theclutch by hand until compression isfelt. This puts the valves in the closedposition. CHASSIS PREPARATION 1. Increase the tire pressure to 20 psi (137 kP...
Page 48 - SPECIFICATIONS; GENERAL SPECIFICATIONS
SPECIFICATIONS GENERAL SPECIFICATIONS Items G16A G16E Dimensions: Overall length 93.9 in. (2385 mm) Overall width 47.2 in. (1200 mm) Overall height (steering height) 46.8 in. (1190 mm) Height of floor 11.8 in. (300 mm) Wheelbase 64.0 in. (1629 mm) Tread: Front 34.3 in. (870 mm) Rear 38.6 in. (980 mm...
Page 49 - ENGINE; TRANSMISSION; BATTERIES
95% 1 2 3 4 5 6 7 8 9 10 11 10-2 G16A/E SPECIFICATIONS ENGINE Items G16A Description: Engine type 4-stroke, Gasoline, OHV Number of cylinders Single Displacement 301 cm 3 Bore x stroke 3.07 x 2.48 in. (78 x 63 mm) Compression ratio 8.1:1 Rated output 9.5 hp (7.1 kw)/4000 rpm Cooling system Forced ai...
Page 50 - CHASSIS
1 2 3 4 5 6 7 8 9 10 11 G16A/E 10-3 SPECIFICATIONS CHASSIS Items G16A and G16E Steering system: Type Worm and pin Steering angle (L.H.) 1.5 turn Steering angle (R.H.) 1.5 turn Lubricant/capacity Grease/3.0 US oz (0.09 L, 3.17 Imp oz) Brakes: Brake system Mechanical drum brake on each rear wheel with...
Page 51 - WIRING; G16A WIRING DIAGRAM
1 2 3 4 5 6 7 8 9 10 11 G16A/E WIRING 11-1 G16A WIRING DIAGRAM R B R B P B R REV FWD R P B B P P B P Br R/W Br R/W Br A1 F2 B B RW RW R R R R R/W R/W G B RW G G G G G B Br B B R/W Br R/W OFF ON Br R/Y L BB L G Br B R/W R/W L L L BB B B B – + Y-509 GG Br Br B RW R Br R RY Br Br 16 1 2 3 4 5 6 7 8 9 1...
Page 52 - G16E WIRING DIAGRAM
1 2 3 4 5 6 7 8 9 10 11 G16A/E WIRING 11-2 G16E WIRING DIAGRAM Br B/R OFF START CHECK B Br Br Br Br R R R R R/Y R/Y R/Y R/Y R/Y B B B R/W R/W R/W R R/W Br Br OFF ON B B P P R/W R/W Br R/W Br R/W R R B R/W B RR R/W BP R OFF ON P OFF ON Y/B FORWARD BACKWARD SF 2 F 1 R + – – – + – – + + – – + + G G G W...
Page 54 - GOLF CAR
OWNER’S/OPERATORSMANUAL YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA GOLF CAR G16A G16E Printed in U.S.A. KCC Yamaha Motor Corp., USA Cypress, California made in 07/12/0 1 LIT196261600 USA *LIT196261600* 1PC - G16A/E O/M LIT-19626-16-00 JN6-F8199-13
