Yamaha DRIVE 2 EFI 2020 Owner's/Operator's Manual
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Yamaha DRIVE 2 EFI 2020 Owner's/Operator's Manual

Personal transport vehicle
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2020
MODEL YEAR
OWNER'S / OPERATOR'S MANUAL
PERSONAL TRANSPORT VEHICLE
Read this manual carefully before operating this vehicle.
DR2 PTV QUIETECH
LIT-19626-A0-33
J0D-F8199-12
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  • Page 1 2020 MODEL YEAR OWNER’S / OPERATOR’S MANUAL PERSONAL TRANSPORT VEHICLE Read this manual carefully before operating this vehicle. DR2 PTV QUIETECH LIT-19626-A0-33 J0D-F8199-12...
  • Page 2 Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your...
  • Page 3 INTRODUCTION Congratulations on your purchase of a Yamaha Electronic Fuel Injection (EFI) Per- sonal Transport Vehicle (PTV). This manual contains information you will need for proper operation, maintenance, and care of your EFI PTV. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha.
  • Page 4 PTV and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. WARNING Read and understand this manual completely before operating your PTV.

  • Page 5: Table Of Contents

    CONTENTS CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING...

  • Page 6: Warranty

    Any charges incurred in transporting a golf car or charger to and from an authorized Yamaha golf car dealer for service or in performing field service are also excluded from this warranty.
  • Page 7 EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser of each gas-powered golf car covered by this warranty that the product is designed, built, and equipped so as to conform at the time of sale with all U.S. emission standards...

  • Page 8: Important Labels

    IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS WARNING Please read the following labels carefully before operating your PTV, and promptly replace any labels which become damaged or removed. Death or se- rious personal injury can result from failing to read and comply with the safety instruction labels.
  • Page 9 IMPORTANT LABELS...
  • Page 10 IMPORTANT LABELS DATE OF CONSTRUCTION: *** **** MY**** YAMAHA MOTOR POWERED PRODUCTS CO., LTD 200-1 SAKAGAWA, KAKEGAWA, JAPAN MAX. BATTERY WEIGHT: ** kg MODEL: ****** NOMINAL SYSTEM VOLTAGE: **V MAX. POWER: *** hp (*** kW) FUEL TYPE: UNLEADED GASOLINE DRY WEIGHT: *** kg...
  • Page 11 Keep a record of these numbers for reference when ordering parts from a Yamaha Golf-Car Company dealer. 1. PTV serial number The engine serial number is affixed in the location shown.

  • Page 12: Safety Information

    SAFETY INFORMATION 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: BEFORE OPERATING THE PTV • Read this Owner’s/Operator’s manual and all safety and instruction labels on the PTV before operating.
  • Page 13 SAFETY INFORMATION • Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully. • Avoid starting or stopping abruptly. • Vary the speed of the PTV to match the terrain. • Avoid turning the steering wheel too sharply at higher speeds to avoid tipping or rolling the vehicle.
  • Page 14 SAFETY INFORMATION Like all machines, PTVs can cause injury if improperly used or maintained. Experience has shown that PTVs are safe when op- erated in accordance with the safety warnings affixed to every PTV. DRIVER QUALIFICATIONS Allow only authorized people to operate PTV. It is rec- ommended that only people who possess a valid mo- tor vehicle driver’s license be allowed to operate PTV.
  • Page 15 SAFETY INFORMATION • 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 whenever possible to prevent accidents.
  • Page 16 • Provide operator comment cards to assist in iden- tifying non-periodic maintenance needs for specific PTVs. • Maintain, in a legible condition all nameplates, warnings, and instructions provided by the manu- facturer. • If new nameplates, warnings or instructions are needed, contact your Yamaha Golf-Car Company dealer.
  • Page 17 SAFETY INFORMATION FUEL HANDLING/STORAGE Take the following precautions to ensure maintenance worker safety: • Supervise the storage and handling of liquid fuels in accordance with applicable fire and safety require- ments to avoid any fires or explosions.

  • Page 18: Controls

    CONTROLS FEATURES 1. Engine/oil warning light/fuel gauge/ hour meter 2. Main/Light switch 3. Brake pedal 4. Parking brake pedal 5. Accelerator pedal 6. Steering wheel 7. Horn switch 8. USB ports 1. Reflector 1. Seat 2. Front body 3. Headlights 4.
  • Page 19 CONTROLS 1. Battery 2. Rear body 3. Rear tire 4. Rear bumper 5. Taillights 6. Fuel tank 1. Fuel tank 2. Fuel cap 3. E.F.I. fuel pump 4. Fuel tank vent 5. Cover filler funnel...
  • Page 20 CONTROLS MAIN SWITCH The main switch controls the following items: “OFF” The electrical power circuit is switched off. The key can be removed only in this position. 1/ 2 “ON” The electrical power circuit is switched on. The PTV can be driven. 1/ 2 “ON”...
  • Page 21 CONTROLS NOTICE If the light is flashing, do not operate the vehicle. Contact your Yamaha Service representative to have the vehicle serviced. 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.
  • Page 22 CONTROLS PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the PTV. Release the parking brake by depressing the acceler- ator pedal. 1. Parking brake pedal WARNING The parking brake will automatically release when the accelerator pedal is depressed. If the main switch is in the “ON”...
  • Page 23 CONTROLS HOUR METER The hour meter displays the total number of hours the PTV has been run. Use the hour meter to determine 1/ 2 when scheduled maintenance is due. 1. Hour meter USB PORTS A USB port is located inside the dash on the driver side and passenger side.

  • Page 24: Pre-Operation Checks

    PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your PTV. Get in the habit of performing the fol- lowing checks in the same way so that they become second nature. WARNING To keep vehicle from moving while performing pre-operation checks: •...
  • Page 25 PRE-OPERATION CHECKS Stop engine and allow it to cool for several min- utes before refueling. Do not smoke when refueling and keep away from sparks, flames or other sources of ignition. Refuel in a well-ventilated area. Take care not to spill gasoline. If gasoline spills, wipe it up immediately with dry rags.
  • Page 26 PRE-OPERATION CHECKS ENGINE OIL With the golf car parked on level ground, remove the dipstick and make sure the engine oil is between the MIN and MAX marks (the crosshatched area on the end of the dipstick). 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.
  • Page 27 PRE-OPERATION CHECKS BATTERY Check that the battery is held securely in place to pre- vent the battery from being damaged from vibration or jarring. Tighten the battery hold-down nuts if loose. Also check that the battery cap is not missing to pre- vent battery acid from spilling from the battery.
  • Page 28 If you feel excessive free play, or hear rattling sounds which may indicate loose steering components, con- sult a Yamaha dealer. REVERSE ALARM Check the reverse alarm by moving the drive select lever to “R” for reverse. The alarm should sound.
  • Page 29 PRE-OPERATION CHECKS Parking Brake Pedal Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed. Release the parking brake by depressing the acceler- ator pedal. 1. Parking brake pedal HEADLIGHTS/TAILLIGHTS Ensure the headlights and taillights are operational.

  • Page 30: Operation

    OPERATION STARTING With the parking brake applied, turn the drive select lever to “F” for forward, or “R” for reverse. NOTICE Do not shift from “F” (forward) to “R” (reverse) while the PTV is moving. Transmission damage can result. Turn the main switch to “ON.” WARNING Do not depress the accelerator pedal when turning 1/ 2...

  • Page 31: Maintenance And Adjustment

    Check body and chassis for dam- * 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 are contained in the Service Manual. ** Related to emission control system.
  • Page 32 * 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 are contained in the Service Manual. ** Related to emission control system.
  • Page 33 - Replace if nec- essary * 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 are contained in the Service Manual. ** Related to emission control system.
  • Page 34 * 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 are contained in the Service Manual. ** Related to emission control system.
  • Page 35 The abbreviations conform to the latest version of the SAE’s recommended prac- tice 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 qual- ified mechanic. TROUBLESHOOTING If the vehicle’s engine will not start, use the following chart:...
  • Page 36 MAINTENANCE AND ADJUSTMENT REAR LIFTING POINT If the rear of the car needs to be lifted for a mainte- nance procedure, make sure it is lifted at the correct rear lifting point (see arrow). SPARK PLUG INSPECTION You should periodically remove and inspect the spark plug.
  • Page 37 MAINTENANCE AND ADJUSTMENT ENGINE OIL REPLACEMENT Warm up the engine for several minutes, place the golf car on a level surface, then stop the en- gine. WARNING Use caution not to touch hot engine oil or hot en- gine parts, during the following procedure. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.
  • Page 38 MAINTENANCE AND ADJUSTMENT Remove the tie strap, and then remove the ex- haust duct. 1. Tie strap 2. Exhaust duct Place an oil pan under the engine drain plug. Remove the oil drain plug and let the oil drain completely. Dispose of used oil in an environmentally safe way, such as taking oil to an oil collection station.
  • Page 39 Use care not to fill past the MAX dipstick mark, and be sure no foreign material enters the crankcase. After replacing engine oil, check for oil leaks around the drain plug. If oil leaks are found, consult a Yamaha dealer. 10. Install the exhaust duct, and then install the tie strap.
  • Page 40 MAINTENANCE AND ADJUSTMENT AIR FILTER To remove the air filter elements: Unlatch the air filter cover clips and remove cov- 1. Air filter cover clips 2. Air filter cover Lift the air filter and pre-filter out of the air filter case.
  • Page 41 MAINTENANCE AND ADJUSTMENT DRIVE BELT To remove the drive belt: Set the drive select lever halfway between for- ward and reverse. Pull up on the drive belt and push it outward over the edge of the secondary sheave. Turn the secondary sheave clockwise and the drive belt will roll off the sheave.
  • Page 42 MAINTENANCE AND ADJUSTMENT AIR DUCT Check for debris in intake air duct, tubing and con- nections: Park the PTV on a flat, level surface and apply the parking brake. Remove the floor mat. Remove the seat. Remove the drive select lever. Unscrew and remove the 8 retaining pins and re- move the front panel.
  • Page 43 MAINTENANCE AND ADJUSTMENT BATTERY The 12-volt battery that provides starting power to your gas car normally does not require the addition of water. If the battery loses its charge, have an experi- enced mechanic charge it. WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc.
  • Page 44 MAINTENANCE AND ADJUSTMENT FUSE REPLACEMENT WARNING Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and cre- ate a fire hazard. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.
  • Page 45 MAINTENANCE AND ADJUSTMENT Pull the fuse out and inspect it. Replace the fuse if necessary. Install the fuse holder cover. Close the seat. To access the USB fuse Remove the ornament, and then remove the bolt. 1. Ornament 2. Bolt Remove the cup holder.
  • Page 46 MAINTENANCE AND ADJUSTMENT TRANSMISSION OIL To replace transmission oil: Place the PTV on a flat, level surface. Remove two bolts and the bag holder insert. Block rear tires and lift front end of PTV. Secure PTV with car stands. 1. Bolt 2.
  • Page 47 MAINTENANCE AND ADJUSTMENT Install the drain plug. Remove the oil fill plug on top of the transmis- sion. 10. Fill the transmission with 16.06 oz (475 cc) and replace the oil fill plug. 1. Oil fill plug 11. Install the lower panel and exhaust duct tabs. 12.
  • Page 48 WARNING Consult your Yamaha dealer before using your PTV if you suspect brake problems. Brake failure could result in a serious accident. Death or serious per- sonal injury can result from failing to comply with...
  • Page 49 MAINTENANCE AND ADJUSTMENT BRAKE PEDAL FREE PLAY ADJUSTMENT Check the brake pedal free play by pressing against the pedal with two fingers (using light force) and mea- suring the distance the pedal travels before resistance is felt. Brake pedal free play: 1.
  • Page 50 MAINTENANCE AND ADJUSTMENT PARKING BRAKE RELEASE ADJUSTMENT NOTICE Before performing parking brake release adjust- ment, adjust brake pedal free play. Apply pressure to the parking brake pedal until the brake nail catches the first latch position on the sector. Loosen the locknut and turn the bolt counter- clockwise until it contacts the sector.
  • Page 51 MAINTENANCE AND ADJUSTMENT REPLACING A HEADLIGHT UNIT This model is equipped with LED-type headlights. If a headlight does not come on, replace it as follows: Disconnect the wire connector from the head- light assembly. Remove the three screws and remove the light control unit.
  • Page 52 MAINTENANCE AND ADJUSTMENT ADJUSTING A HEADLIGHT NOTICE It is recommended to have the headlight adjust- ment performed by a Yamaha dealer. The screw can be accessed from under the fender. Using a Phillips head screwdriver, turn the ad- justing screw.

  • Page 53: Storage

    Use of fuel stabilizer and conditioner eliminates the need to drain the fuel system. Consult a Yamaha deal- er if the fuel system needs to be drained instead. Perform the following preparations when storing your...
  • Page 54 STORAGE DRAINING FUEL WARNING Gasoline and its vapors are highly flammable and explosive. Death or serious personal injury can re- sult from failing to comply with the safety instruc- tions in this manual. • Do not smoke when draining fuel and keep away from sparks, flames, or other sources of ignition.
  • Page 55 STORAGE BATTERY PREPARATION Remove the battery from your PTV and store it in a cool, dry place that stays between 0°C (32°F) and 30°C (90°F). Have the battery recharged every 60-90 days to keep it fully charged. The battery must be kept fully charged to avoid damage.

  • Page 56: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Items DR2 PTV QUIETECH Dimensions: Overall length 2380 mm (93.7 in.) Overall width 1200 mm (47.2 in.) Overall height (steering height) 1230 mm (48.4 in.) Overall height (sun top height) 1825 mm (71.9 in.) Height of floor 325 mm (12.8 in.) Wheelbase 1635 mm (64.4 in.)
  • Page 57 SPECIFICATIONS ENGINE Items DR2 PTV QUIETECH Description: Engine type 4-stroke, Gasoline, OHV Number of cylinders Single Displacement 357 cm Bore × stroke 85 × 63 mm (3.30 × 2.48 in.) Compression ratio 8.1:1 Output / Gross 9.17 kw (12.29 hp) / 3600 rpm Output / Net 6.71 kw (9.00 hp) / 3600 rpm Cooling system...
  • Page 58 SPECIFICATIONS TRANSMISSION Items DR2 PTV QUIETECH Transmission: Type V-belt automatic centrifugal engagement V-belt width and outer line length 31.0 × 1010 mm (1.20 × 39.76 in.) V-belt wear limit 27.0 mm (1.06 in.) Governor: Type Oil bath flyweight Differential/reduction gear: Secondary reduction system helical gear Secondary reduction ratio: Forward 9.789 / Reverse 14.358...
  • Page 59 SPECIFICATIONS Items DR2 PTV QUIETECH Parking brake Type Foot type; parking brake with automatic release. Wheel Tire size: Front 20.5 × 8.0 4PR Rear 20.5 × 8.0 4PR Rim size: 10 × 6 Tire pressure: 152 kPa, 1.55 kgf/cm (22 psi) Lights: Bulb voltage, wattage x quantity: Headlight...

  • Page 60: Wiring

    WIRING DR2 PTV QUIETECH WIRING DIAGRAM...
  • Page 62 CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING PRINTED IN USA 2019.05-3.0×1 CR...

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