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Yamaha DRIVE 2 2022 Owner's/Operator's Manual

Personal transport vehicle
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2022
MODEL YEAR
OWNER'S / OPERATOR'S MANUAL
PERSONAL TRANSPORT VEHICLE
Read this manual carefully before operating this vehicle.
DR2 PTV
POWERTECH AC IRS Li
LIT-19626-A2-17
J5C-F8199-10

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  • Page 1 2022 MODEL YEAR OWNER’S / OPERATOR’S MANUAL PERSONAL TRANSPORT VEHICLE Read this manual carefully before operating this vehicle. DR2 PTV POWERTECH AC IRS Li LIT-19626-A2-17 J5C-F8199-10...
  • Page 2 This product can expose you to chemicals 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...
  • Page 3 INTRODUCTION Congratulations on your purchase of a Yamaha Personal Transport Vehicle (PTV). This manual contains information you will need for proper operation, maintenance, and care of your 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

    Authorized Dealer or Distributor in the United States will be free from defects in material and workmanship for FOUR years from date of purchase, subject to the for the balance of the vehicle’s warranty period. All parts replaced under warranty become property of Yamaha Golf-Car Company.
  • Page 7 • THIS BATTERY IS INTENDED TO BE USED BY PERSONS WITH TRAINING AND EXPERIENCE WITH BATTERIES AND ONLY IN YAMAHA ELECTRIC VEHICLES. ANY OTHER USE RENDERS THE LIMITED WARRANTIES EXPRESSED HEREIN AND ALL IMPLIED WARRANTIES NULL AND VOID AND SAME ARE HEREBY EXCLUDED.

  • Page 8: Important Labels

    IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS Read the following labels carefully before operating your PTV. If any of these labels are damaged or missing, contact a Yamaha dealer for replacements.
  • Page 9 IMPORTANT LABELS WARNING AVERTISSEMENT WARNING AVERTISSEMENT Electrical shorts can result in Les courts-circuits électriques High voltage. Risk of shock. Haute tension. Risque d’électrochoc. burns. peuvent causer des brûlures. • Do not touch uninsulated • Ne touchez pas les bornes ou les fils •...
  • 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) WEIGHT (NO BATT): *** kg VEHICLE LOAD CAPACITY: *** kg PER SEAT, ** kg BAGWELL...
  • Page 11 The first three digits of the serial number are 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. 1. PTV serial number Serial number:...

  • 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 • Always drive slowly straight up 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.
  • 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 SAFETY INFORMATION SAFETY PRECAUTIONS DURING MAINTENANCE When performing maintenance, follow all safety in- structions contained in the manufacturer’s operation and service manuals, as well as the following safety procedures: • Properly immobilize PTV before beginning any maintenance to avoid any unexpected vehicle movement.
  • Page 17 SAFETY INFORMATION • If new nameplates, warnings or instructions are needed, contact your Yamaha dealer. STORAGE AND BATTERY CHARGING Take the following precautions to ensure maintenance worker safety: • Only use battery changing and charging facilities and procedures that are in accordance with appli-...

  • Page 18: Controls

    CONTROLS FEATURES 1. Main/light switch 2. Drive select switch 3. Steering wheel 4. Battery gauge 5. Brake pedal 6. Parking brake pedal 7. Horn switch 8. Accelerator pedal 9. USB ports 1. Reflector 2. Battery 1. Headlights 2. Front body 3.
  • Page 19 CONTROLS 1. Rear body 2. Taillights 3. Rear bumper 4. Rear tire 1. Tow switch...
  • Page 20 CONTROLS MAIN SWITCH The main switch controls the following items: “OFF” All electrical circuits are switched off (motor controller unit remains energized). The PTV cannot be operated. The key can be removed only in this position. Li-ion BATTERY “ON” Electrical circuits are switched on. The vehicle can be driven.
  • Page 21 CONTROLS 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 Li-ion BATTERY immediately.
  • Page 22 CONTROLS 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.
  • Page 23 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 24 CONTROLS HORN SWITCH The horn is located adjacent 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...

  • Page 25: 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 car from moving while performing pre-op- eration checks: •...
  • Page 26 PRE-OPERATION CHECKS 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. Battery hold-down 1. Battery terminal TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the PTV.
  • Page 27 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 switch to “REV” for reverse. The alarm should sound.
  • Page 28 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 29 OPERATION STARTING With the parking brake applied, turn the drive select switch to “FWD” for forward, or “REV” for reverse. Li-ion BATTERY NOTICE Do not shift from “FWD” (forward) to “REV” (re- verse) while the PTV is moving. Transmission dam- age can result.

  • Page 30: Operation

    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.
  • Page 31 Check wheel nut tightness, front wheel bearing play * 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.
  • 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.
  • Page 33 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). BATTERY CHARGING WARNING • Read and understand the owner’s manual pro- vided with your PTV’s battery charger before charging battery.
  • Page 34 • Always put the tow switch in the “TOW” position before charging battery or damage to the elec- trical system may result. • Use only the Yamaha provided Lithium-ion bat- tery charger that is rated for use with a Lithi- um-ion battery powered Yamaha Golf Car. Seri- ous battery damage can result.
  • Page 35 MAINTENANCE AND ADJUSTMENT With the charger properly connected and grounded (see charger’s owner’s manual), insert the DC output plug into the DC charger recep- tacle. WARNING Do not disconnect the DC output plug from the DC charger receptacle when the charger is on or an arc could occur that may cause an explosion.
  • Page 36 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 37 MAINTENANCE AND ADJUSTMENT Depress the locking tab of the fuse holder, and then remove the fuse holder cover. Pull the fuse out and inspect it. Replace the fuse if necessary. Install the fuse holder cover. Close the seat. 1. Fuse holder cover 2.
  • Page 38 MAINTENANCE AND ADJUSTMENT INSTALLATION WARNING RISK OF FIRE - Use this charger only on circuits with a 15-amp or higher branch circuit protection (circuit breaker or fuse) in accordance with the na- tional electrical code, ANSI/NFPA 70 and all appli- cable local codes and ordinances.
  • Page 39 MAINTENANCE AND ADJUSTMENT MOUNTING WARNING This charger is not designed for on-board use. Im- proper mounting or installation could result in a risk of fire or damage to the PTV. Mount the charger on a shelf or on the wall with ade- quate ventilation.
  • Page 40 Surfaces may be hot. To avoid risk of burns, do not touch. NOTICE Charge only Yamaha Lithium-ion battery systems manufactured by RoyPow Technology Co., Ltd. Damage to the charger and batteries may result if this charger is used on the wrong battery type.
  • Page 41 Whenever disconnecting a AC or DC cord set plug from receptacle, pull from the plug body and not from their respective cords. The instructions printed on the charger (shown below) are for daily reference. The charger is factory preset for use with Yamaha Lithium-ion golf car battery.
  • Page 42 MAINTENANCE AND ADJUSTMENT OPERATING INSTRUCTIONS PLUG AC CORD INTO A GROUNDED RECEPTACLE PLUG DC CORD INTO DC CHARGER RECEPTACLE CHARGE CYCLE WILL BEGIN AFTER A FEW SECONDS AND AMMETER WILL TURN ON CHARGER SHUTS OFF AUTOMATICALLY WHEN BATTERIES ARE CHARGED Connect battery charger’s AC cord set to AC pow- er.
  • Page 43 MAINTENANCE AND ADJUSTMENT Under normal charge circumstances, the LEDs operate as follows: Ammeter Displays approximate (Amber) scale of the output cur- rent during charging. Blinking: High internal charger temperature. Current output reduced. 80% Charge Charging, >80% charged. (Amber) Blinking: With no battery connect- ed, the number of flashes indicates the algorithm ID number.
  • Page 44 MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING LED Error Codes (For Battery Condition) WARNING Incorrect reassembly may result in a risk of electric shock or fire. The following procedures are intended only to determine if a malfunction may exist in the charger. WARNING To reduce 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.
  • Page 45 MAINTENANCE AND ADJUSTMENT If a fault occurs, count the number of red flashes between pauses and refer to the table below: Red Flashes Cause Solution Battery High Voltage Check battery size and condition and reset char- ger (i.e., remove the DC cord from the vehicle for 15 seconds).
  • Page 46 MAINTENANCE AND ADJUSTMENT Hardware System Faults Problem Description Cause Remedy Charger does not start. No AC power to charger. Ensure correct voltage No LEDs illuminate or at AC outlet. Check AC blink when AC cord is cord connections. connected. Replace AC cord if damaged.
  • Page 47 MAINTENANCE AND ADJUSTMENT TRANSMISSION OIL To check the transmission oil level: Place the PTV on a flat, level surface. Remove two bolts and remove the rear floor cov- Place an oil pan under the transmission case. 1. Bolt 2. Rear floor cover Clean the area around the transmission oil filler bolt, and then remove the bolt.
  • Page 48 MAINTENANCE AND ADJUSTMENT 10. Install the rear floor cover and secure with two bolts. 1. Bolt 2. Rear floor cover To replace the transmission oil: Place the PTV on a flat, level surface. Remove two bolts and remove the rear floor cov- 1.
  • Page 49 MAINTENANCE AND ADJUSTMENT Check the O-rings for damage, and replace them if necessary. Install the transmission oil drain bolt and its O-ring, and then tighten the bolt to the specified torque. Transmission oil drain bolt tightening torque: 4.3 N·m (0.43 kgf·m, 3.1 lb·ft) Refill the transmission case with the recom- 1.
  • Page 50 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 personal injury can result from failing to comply with the warning labels in this manual.
  • Page 51 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: 50-55 mm (1.97-2.17 in.) 1.
  • Page 52 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 53 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. Turning the screw clockwise will lower the beam and turning the screw counter-clockwise will raise the beam.
  • Page 54 MAINTENANCE AND ADJUSTMENT REPLACING A TAILLIGHT UNIT If a taillight does not come on, replace the tail- light unit removing the rubber grommet from the bezel assembly. Remove the wire connector, replace the taillight unit, and reinstall by fitting the rubber grommet over the taillight unit and bezel.

  • Page 55: Storage

    Perform the following preparations when storing your PTV for extended periods of time. NOTICE Yamaha Golf-Car Company does not approve the use of high-pressure washers to clean the prod- ucts they manufacture. Doing so may damage the finish on the body or result in doing other damage not covered by warranty.

  • Page 56: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Items DR2 PTV POWERTECH AC IRS Li 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) 1795 mm (70.7 in.) Height of floor 325 mm (12.8 in.) Wheelbase...
  • Page 57 Lubricant/capacity SAE 80W-90 or SAE 90 gear oil/475 cc (475 mL, 0.50 US qt) BATTERY Items DR2 PTV POWERTECH AC IRS Li Lithium-ion battery: Yamaha Lithium-ion battery manufuctured by RoyPow 51-volt 5.3kwh BATTERY AMBIENT TEMPERATURES Lithium Battery Condition Temperature Operation -20 –...
  • Page 58 SPECIFICATIONS Items DR2 PTV POWERTECH AC IRS Li Brakes: Brake system Mechanical drum brake on each rear wheel with self-adjusters Type of brake Dual internal expanding shoe Leading/trailing shoes (self-adjusting) Brake pedal freeplay linkage 50-55 mm (1.97-2.17 in.) adjustment Parking brake Type Foot type;...
  • Page 59 SPECIFICATIONS GENERAL SPECIFICATIONS (BATTERY CHARGER) DC Output – see Operating Instructions Voltage - nom (V) Voltage - max (V) 67.2 Current - max (A) Battery Type Specific to selected algorithm Reverse Polarity Electronic protection – auto-reset Short Circuit Electronic current limit AC Input Voltage - max (Vrms) 85-265...
  • Page 60 SPECIFICATIONS MECHANICAL DRAWINGS (BATTERY CHARGER) 278 ±3 mm 196 ±3 mm 260 ±3 mm 3 ±1 mm M4(4 mm) Grounding Stud(Ref.)

  • Page 61: Wiring

    WIRING DR2 PTV POWERTECH AC IRS Li WIRING DIAGRAM...
  • Page 64 CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING PRINTED IN USA 2021.11-0.3×1 CR...

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