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Summary of Contents for Yamaha DRIVE 2 2023
- Page 1 2023 MODEL YEAR OWNER’S / OPERATOR’S MANUAL PERSONAL TRANSPORT VEHICLE Read this manual carefully before operating this vehicle. DR2 PTV POWERTECH AC IRS LIT-19626-A2-34 J0E-F8199-16...
- 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.
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Page 4: Important Manual Information
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
Electric Personal Transporta purchased from Yamaha, or an 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 technician, dealer, or distributor will, free of ch , repair or replace, at Yamaha’s op... - Page 7 ONE YEAR FROM THE DATE OF PURCHASE. THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRAN- TY OR ANY IMPLIED WARRANTY. YAMAHA MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE, EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY.
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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 NOTICE Move switch to the “TOW” position before towing or storage. Failure to do so may lead to: • Drive system damage when towing. • Complete battery discharge and battery damage when storing long term. • After moving switch from “RUN” to “TOW”, wait 15 seconds minimum before switching again.
- 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 Keep a record of these numbers for SERIAL NO.: JXX-XXXXXX YAMAHA MOTOR POWERED PRODUCTS CO., LTD reference when ordering parts from a Yamaha Golf-Car Company dealer. 1. Vehicle serial number SERIAL NO.:...
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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.
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Page 14: Driver Qualifications
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.
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Page 16: Maintenance
SAFETY INFORMATION For electric powered PTVs, the amount of hydrogen gas emitted during charging depends on a number of factors, such as the condition of the batteries, the out- put rate of the battery charger and the amount of time the batteries are on charge. - Page 17 • Maintain in a legible condition all nameplates, warn- ings and instructions provided by the manufacturer. • 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: •...
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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. Batteries 1. Headlights 2. Front body 3. - Page 19 CONTROLS 1. Rear body 2. Taillights 3. Rear bumper 4. Rear tire 1. Tow switch...
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Page 20: Main Switch
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. BATTERY “ON” Electrical circuits are switched on. The vehicle can be driven. -
Page 21: Drive Select Switch
CONTROLS Use the table to determine the remaining battery ca- pacity. For example, if 7 of the 9 LED lights are lit, batteries still have approximately 47.4 volts left. When the batteries fall to 43.4 volts or less, 1 LED will blink on and off, meaning the batteries should be charged immediately. -
Page 22: Accelerator Pedal
CONTROLS ACCELERATOR PEDAL The accelerator pedal controls the PTV’s speed. Action Car Speed Depress pedal Increase Release pedal Decrease 1. Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the PTV. 1. Brake pedal PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the PTV. -
Page 23: Tow Switch
CONTROLS TOW SWITCH Before operating the car, make sure the tow switch is in the “RUN” position. NOTICE Ensure that the “Drive Select Switch” is in the “FWD” position and then move the “TOW Switch” to “TOW” before towing. 1. Tow switch After moving switch from “RUN”... -
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 car from moving while performing pre-op- eration checks: •... -
Page 25: Tire Condition
PRE-OPERATION CHECKS BATTERIES For Flooded Batteries Check that the batteries are held securely in place to prevent them from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the batteries. Check the battery terminals for corrosion and tight- ness. -
Page 26: Steering System
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 27: Body And Chassis
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 28: Operation
OPERATION STARTING With the parking brake applied, turn the drive select switch to “FWD” for forward, or “REV” for reverse. BATTERY NOTICE Do not shift from “FWD” (forward) to “REV” (re- verse) while the PTV is moving. Transmission dam- age can result. Turn the main switch to “ON.”... -
Page 29: Maintenance And Adjustment
Check steering operation * 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. ** Flooded Batteries only... - Page 30 * 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. ** Flooded Batteries only...
- Page 31 * 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. ** Flooded Batteries only *** Do no operate vehicle if discrepancy is found.
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Page 32: Battery Care
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 CARE For Flooded Batteries WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc. - Page 33 Using a hydrometer, check the specific gravity of the battery fluid in each cell against the readings on the chart below. Consult a Yamaha dealer if any low readings are found, or if readings vary more than one point between cells.
- Page 34 MAINTENANCE AND ADJUSTMENT For AGM Batteries (Optional) WARNING 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 veg- etable oil.
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Page 35: Battery Charging
Lift up the seat and move the tow switch to the TOW position. NOTICE Use only battery chargers that are rated for use with 48-volt Yamaha PTVs. Serious battery dam- age can result. Thoroughly read and understand the user manual supplied with your 48-volt char- ger. - Page 36 MAINTENANCE AND ADJUSTMENT Check the DC output code and plug for damage. The location of the dummy pin is different between the flood battery and the AGM battery (Optional). 1. DC output plug for Flooded batteries 1. Receptacle for Flooded batteries 2.
- Page 37 MAINTENANCE AND ADJUSTMENT With the charger properly connected and grounded (see charger’s owner’s manual), insert the DC output into the DC charger receptacle. WARNING Do not disconnect the DC output cord from the DC charger receptacle when the charger is on or an arc could occur that may cause an explosion.
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Page 38: Battery Installation
MAINTENANCE AND ADJUSTMENT BATTERY INSTALLATION WARNING When working with batteries, do not put wrench- es or other metal objects across the battery ter- minals. An arc can occur causing explosion of the battery. For Flooded Batteries Install the battery hold-down plates and torque to 7-9 N·m (0.7-0.9 kgf·m, 5.2-6.6 lb·ft) as shown. - Page 39 MAINTENANCE AND ADJUSTMENT For AGM Batteries (Optional) Install the battery hold-down plates and torque to 7-9 N·m (0.7-0.9 kgf·m, 5.2-6.6 lb·ft) as shown. Install the temperature sensor between the wire terminal and flat washer in correct place and then tighten the terminal connecting bolts to 9-10 N·m (0.9-1.0 kgf·m, 6.6-7.4 lb·ft) as shown.
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Page 40: Fuse Replacement
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 41: Battery Charger
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 42: Installation
MAINTENANCE AND ADJUSTMENT Step 3: Constant Voltage Step: Regulated voltage “equalizes” individual battery cells, resulting in full charge delivered to the battery. Step 4: Topping Off Step: Battery pack is brought slowly to full charge without excess gassing. Step 5: Storage: Every 14th day and if voltage be- comes less than 48V, charger restarts cycle to re- fresh batteries in storage. - Page 43 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 44 MAINTENANCE AND ADJUSTMENT GROUNDING The battery charger must 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.
- Page 45 MAINTENANCE AND ADJUSTMENT WARNING Visually and manually inspect to verify that the DC output cord, plug and battery charging receptacle are in good working condition before each and ev- ery use. Do not use the charger under any of the following conditions: •...
- Page 46 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 charger’s AC cord set to AC power.
- Page 47 MAINTENANCE AND ADJUSTMENT Under normal charge circumstances, the LEDs operate as follows: Ammeter Displays approximate (Amber) scale of current output during Step 2. Blinking: High internal charger temperature. Current output reduced. 80% Charge 80% charged, Step 2 (Amber) complete. Begin Step 3. Blinking: With no battery connect- ed, indicates algorithm...
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Page 48: Troubleshooting
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 cord set plug from batteries before at- tempting any maintenance or cleaning. - Page 49 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 (interrupt DC connec- tion for 15 seconds).
- Page 50 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.
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Page 51: Transmission Oil
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 52 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 53 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.
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Page 54: Wheel Replacement
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 55: Brake Pedal Free Play Adjustment
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 56 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 57 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 58 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.
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Page 59: Chassis Preparation
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 60: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS Items DR2 PTV POWERTECH AC IRS 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 1635 mm (64.4 in.) - Page 61 SPECIFICATIONS TRANSMISSION Items DR2 PTV POWERTECH AC IRS Differential/reduction gear Secondary reduction system helical gear Secondary reduction ratio: Forward/Reverse 12.44:1 Differential type bevel gear Lubricant/capacity SAE 80W-90 or SAE 90 gear oil/475 cc (475 mL, 0.50 US qt) BATTERIES Items DR2 PTV POWERTECH AC IRS Flooded battery: Trojan - T-875 (6x8-volt)
- Page 62 SPECIFICATIONS Items DR2 PTV POWERTECH AC IRS 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: 10 × 6.0 +6 (Dia.
- Page 63 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 64 SPECIFICATIONS MECHANICAL DRAWINGS (BATTERY CHARGER) 278 ±3 mm 196 ±3 mm 260 ±3 mm 3 ±1 mm M4(4 mm) Grounding Stud(Ref.)
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Page 65: Wiring
WIRING DR2 PTV POWERTECH AC IRS WIRING DIAGRAM... - Page 68 CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING *J0EF8199160080* PRINTED IN USA 2022.11-0.3×1 CR...
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Does this PTV have a Tow switch
Yes, the Yamaha DRIVE 2 2023 PTV has a tow switch.
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