Yamaha ADVENTURER SPORT 2+2 2023 Owner's/Operator's Manual

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OWNER'S / OPERATOR'S MANUAL

Read this manual carefully before operating this vehicle.

ADVENTURER

SPORT 2+2

POWERTECH AC IRS

LIT-19626-A2-95

MODEL YEAR

UTILITY VEHICLE

DR2 CAMP

2023

J2H-F8199-15

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Summary of Contents for Yamaha ADVENTURER SPORT 2+2 2023

Page 1 2023 MODEL YEAR OWNER’S / OPERATOR’S MANUAL UTILITY VEHICLE Read this manual carefully before operating this vehicle. ADVENTURER SPORT 2+2 DR2 CAMP POWERTECH AC IRS LIT-19626-A2-95 J2H-F8199-15...
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 Adventurer Sport 2+2 Vehicle. This manual contains information you will need for proper operation, maintenance, and care of your sport vehicle. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha.
Page 4 A TIP provides key 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 vehicle and this manual.
Page 5 CONTENTS CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING...
Page 6 • • WARRANTY TRANSFER: EMISSION CONTROL SYSTEM WARRANTY: or workmanship which arise solely as a result of owner abuse and/ or lack of proper maintenance are not covered by this warranty. YAMAHA GOLF-CAR COMPANY, KENNESAW, GEORGIA 30144 EFFECTIVE DATE: 07/01/20...
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.
Page 8 IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS Read the following labels carefully before operating your utility vehicle. If any of these labels are damaged or missing, contact a Yamaha dealer for replace- ments. BATTERY...
Page 9 IMPORTANT LABELS YEAR OF CONSTRUCTION: **** MY**** YAMAHA MOTOR POWERED PRODUCTS CO., LTD 200-1 SAKAGAWA, KAKEGAWA, JAPAN MODEL: ****** **** *** MAX. BATTERY WEIGHT: *** kg NOMINAL SYSTEM VOLTAGE: **V MAX. POWER: *** hp (*** kW) CURB WEIGHT (****): *****kg (**** lb) G.V.W.R.: ***** kg (***** lb)
Page 10 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 11 Keep a record of these numbers for SERIAL NO.: reference when ordering parts from a JXX-XXXXXX YAMAHA MOTOR POWERED PRODUCTS CO., LTD Yamaha Golf-Car Company dealer. 1. Vehicle serial number SERIAL NO.: JXX-XXXXXX Serial number: YAMAHA MOTOR POWERED PRODUCTS CO., LTD...
Page 12 SAFETY INFORMATION Yamaha sport vehicles 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 SPORT VEHICLE •...
Page 13 SAFETY INFORMATION WHILE OPERATING THE SPORT VEHICLE • Keep your entire body inside the sport vehicle, remain seated and hold on when the vehicle is in motion. • Do not start the sport vehicle until all occupants are seated. • Always keep both hands on the steering wheel when driving.
Page 14 • Choose only accessories designed for your sport vehicle. Your Yamaha dealer has a variety of gen- uine Yamaha accessories. Other accessories may also be available on the market. However, it is not...
Page 15 SAFETY INFORMATION Loading Cargo can change the stability and handling of a sport vehicle. You must use common sense and good judg- ment when carrying cargo. Keep the following points in mind: • Never exceed the weight limits shown on page 58.
Page 16 SAFETY INFORMATION • Parts and Materials. Use only replacement parts and materials recommended by the manufacturer. • Ventilation. Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards. Ven- tilation is also required to remove hydrogen gas from the vehicle storage areas during the battery charging process.
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: •...
Page 18 CONTROLS FEATURES 1. Drive select switch 2. Main/Light switch 2 1 6 3. Brake pedal 4. Parking brake pedal 5. Accelerator pedal 6. Battery gauge BATTERY 7. Horn switch 8. USB ports 1. Reflector 2. Sun roof 3. Rear seat 4.
Page 19 CONTROLS 1. Rear body 2. Rear tire 3. Rear bumper 4. Taillights 5. Side handrail 1. Batteries 2. Tow switch 3. DC charger receptacle...
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 sport vehicle cannot be operated. The key can be removed only in this posi- BATTERY tion. “ON” The electrical power circuit is switched on.
Page 21 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 CONTROLS ACCELERATOR PEDAL The accelerator pedal controls the sport vehicle’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 sport ve- hicle. 1. Brake pedal PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the sport vehicle.
Page 23 CONTROLS TOW SWITCH Before operating the vehicle, 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 CONTROLS REAR SEAT The rear seat is designed to carry a maximum of two passengers. All passengers should remain inside the sport vehicle, remain seated with their feet on the rear footrest and hold onto the handrails while the vehicle is in motion.
Page 25 PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your sport vehicle. Get in the habit of performing the following checks in the same way so that they be- come second nature. WARNING To keep vehicle from moving while performing pre-operation checks: •...
Page 26 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 27 • turning the steering wheel slightly to the right and left. 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”...
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. BATTERY NOTICE Do not shift from “FWD” (forward) to “REV” (re- verse) while the sport vehicle is moving. Transmis- sion damage can result. Turn the main switch to “ON.”...
Page 30 OPERATION STOPPING To stop the sport vehicle, gradually press down on the brake pedal. NOTICE Do not hold the sport vehicle on an incline with the accelerator – use the brake. Transmission damage can result. 1. Brake pedal 2. Parking brake pedal When the sport vehicle has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.”...
Page 31 OPERATION • Avoid making sharp turns unless at very slow speeds to avoid tipping or rolling the vehicle. • Avoid hills and rough terrain. Choose terrain care- fully. Added weight affects the stability and han- dling of the vehicle. WARNING Uncontrolled Movement Hazard •...
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. ** Flooded Batteries only...
Page 33 * 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 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. ** Flooded Batteries only *** Do no operate vehicle if discrepancy is found.
Page 35 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 36 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 37 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.
Page 38 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 vehicles. Serious battery damage can result. Thoroughly read and under- stand the user manual supplied with your 48-volt charger.
Page 39 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 40 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.
Page 41 MAINTENANCE AND ADJUSTMENT BATTERY INSTALLATION WARNING When working with batteries, do not put wrenches or other metal objects across the battery termi- nals. An arc can occur causing an 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 42 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.
Page 43 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 44 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 45 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 46 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 vehicle. Mount the charger on a shelf or on the wall with ade- quate ventilation.
Page 47 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 48 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 49 MAINTENANCE AND ADJUSTMENT The instructions printed on the charger (shown below) are for daily reference. The charger is factory preset for use with Trojan 48-volt golf car batteries. 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...
Page 50 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...
Page 51 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 52 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 53 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 54 MAINTENANCE AND ADJUSTMENT TRANSMISSION OIL To check the transmission oil level: Place the sport vehicle 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 55 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 sport vehicle on a flat, level surface. Remove two bolts and remove the rear floor cov- 1.
Page 56 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 57 WARNING Consult your Yamaha dealer before using your sport vehicle 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 safety instructions in this manual.
Page 58 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 59 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 60 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. 1. Wire connector Remove the three screws and remove the light control unit.
Page 61 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 62 Perform the following preparations when storing your vehicle 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 63 SPECIFICATIONS GENERAL SPECIFICATIONS Items DR2 CAMP POWERTECH AC IRS Dimensions: Overall length 2750 mm (108.3 in.) Overall width 1290 mm (50.8 in.) Overall height (steering height) 1275 mm (50.2 in.) Overall height (sun top height) 1860 mm (73.2 in.) Height of floor 375 mm (14.8 in.) Wheelbase 1645 mm (64.8 in.)
Page 64 SPECIFICATIONS TRANSMISSION Items DR2 CAMP 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 CAMP POWERTECH AC IRS Flooded battery: Trojan - T-875 (6x8-volt)
Page 65 SPECIFICATIONS Items DR2 CAMP POWERTECH AC IRS Wheel Tire size: (Dia. [in]) × (Width [in]) - (Rim size [in]) / Ply rating) Front 20 × 10–8 4PR Rear 20 × 10–8 4PR Rim size: 8 × 7.2 +23 (Dia. [in]) × (Width [in]) (Offset [mm]) Tire pressure: Front...
Page 66 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 67 SPECIFICATIONS MECHANICAL DRAWINGS (BATTERY CHARGER) 278 ±3 mm 196 ±3 mm 260 ±3 mm 3 ±1 mm M4(4 mm) Grounding Stud(Ref.)
Page 68 WIRING WIRING DIAGRAM...
Page 70 CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING *J2HF8199150080* PRINTED IN USA 2022.11-0.3×1 CR...

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