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E-Z-GO 602080 Automobile User Manual

1. cce Dew De ii SAFETY le ee os vii WELCOME cA PIDE 1 BEFORE INITIAL 0 222 1 Fig T Initial Setvice Chart 3 o ee RE ERE EAE RETE Rd cae 1 CAPABILITIES TERRAIN VEHICLE CAPACITY MODIFICATIONS TO VEHICLE COMMON SENSE OPERATION CONTROLS amp INDICATORS 1 Leere eese een ee eene ans n essa san senes nasse sees nasa SERVICE BRAKE PEDAL Fig 2 Service Brake Pedal Fig 3 Park Brake and Indicator 3 3 3 3 3 Fig 4 Choke 4 IGNITION SWITCH iniret eere t sime Pee Een Pe E DE PEE 3 Fig 5 lghillom SWICK ierit tenente e ER E Bea eR LEN Ee cea Ade ER PR 4 DIRECTION SELECTOR 4 Fig 6 Direction Selector and Differential Locks 4 2WD 4WD SELECTOR 5 Fig 7 2WD 4WD Selector 5 DIFFERENTIAL LOCK 5 Fig 8 Differential Lock 5 ACCELERATOR ae eene Fig 9 Accelerator Pedal 6 Fig 10 Euel Tank and Gauge vce it rnt ect oe e R e e oen 7 LOW OIL PRESSURE INDICATOR LIGHT ae cis EA Low Pressureil Eightz i ep e eR Ere Re E ERR ER 7 MIGHT SWLIIGHES
2. Ref Lbs 2 Fig 15 Electric Lift Bed Switch WINCH An optional winch is available Read understand and fol low all following information on operation and use of winch before attempting to operate it WINCH APPLICATIONS To reduce possibility of IW severe injury or death the following must be observed Have all persons and pets leave area while operat ing winch Never allow anyone to remain in vehi cle Make sure object to which cable is attached can not be damaged or pulled over onto vehicle and it s occupants If attaching winch to a dead tree a section or limb could fall Page 9 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Do not pull at an angle Ref Fig 16 on page 10 This will cause cable to pile up on one end jam ming and damaging winch The winch cable could also break from being overstressed and strike someone Pulling vehicle at an angle can cause damage to front suspension and may cause vehi cle to overturn When pulling vehicle pull straight only If vehicle is being used as an anchor to winch a load it should have park brake set and wheels chocked Never use winch to lift people or other overhead loads The winch is not intended to be used in any hoisting operation Do not use winch to secure loads Use a tie down designed for the job
3. 25 SPARK ARRESTER 25 Fig 36 Cleaning Spark Arrester 0220 40 1200000000000060000000000 0 25 PROLONGED STORAGE m 25 FRONT AND REAR AXLES Eoo Ire E 26 CHECKING LUBRICANT LEVEL Decet e iden rg dee 26 Fig 37 Checking Axle Lubricant 22222220 00200000000000000000 26 54340 tlc 26 CHECKING LUBRICANT LEVEL ener tnen nne ee rne tnenrren retener etre e trennen enne nnn nns 26 Fig 38 Checking Transfer Case Lubricant sss 26 AIR INTAKE AND COOLING FINS 2 2242222 1111 26 Fig 39 Cleaning Air Intake and Cooling Fins 22242 4 4 1000200000000000 27 BRAKES ERR 27 PERIODIC BRAKE TEST FOR HYDRAULIC BRAKES sese 27 CAPACITIES mec EE 27 Fig 40 Capacilles RN d eU mb 27 HARDWARE e 28 Fig 41 Torque Specifications and Bolt Grades sssssssseeee eene 28 GENERAL SPECIFICATIONS rere ask cee doe 29 Fig 42 Vehicle Dimensions eo ee Lh ae dee eo e A o REM 31 Fig 43 Vehicle Incline Specification
4. 12 OPENING THE COWL HOOD 13 Fig 20 Unlatching COWL tete ertt etude i rl be tee e deg 13 DATA LABEL LOCATION 2 2 ERA aee 13 bans piece 14 PERIODIC SERVICE SCHEDULE 15 Fig 21 Periodic Service Schedule sss seen nnn 15 BASIC SERVICE PARTS 16 Fig 22 Basic Service Paris dee eua NR duties 16 LIFTING THE VEHICLE ree rient crinem rennen e rue Cue rem nc terree cu E ERR ncc e PER EET 17 Figs 23 LIMING the Vehicle 54 iere 17 s j Fig 24 Recommended Oil sss OIL LEVEL CHECK Fig 25 Fill and Level Check Ol ctm teet er IUE rid enema Eig 26 Oil Ghange et e e eet tk e eo tede eds OIE FIETER CHANGE eere E eie nb rne Dee E Rn fee Fig 27 Oil Filter Ghanja iem e e ete o re e Tea ede AREE PD Tue pee SPARK duci BELT ccn ADJUSTING BELT iot TERT seeds Fig 28 Adjusting Alternator Belt eese enitn tnn inniti nnn 20 AMR GLEANER eb LP ET CANIS
5. 2 ihe eem abe tem et rei et dette ita Fig 12 Light Switches 12 VOLT POWER OUTLET rnt occi tetti ay eite ee ea cett Ee t pon RP HE LIEU E TEC Fig 13 Power QUT sii tct ete cet RE o Pe or eer e STARTING AND DRIVING STARTING VEHICLE ON A HILL COASTING neenon een eed did ie E nette LOAD BED mcr DD E TAILGATE eee MANUAL LIFT BED eee Fig 14 Manual Lift Bed Release ELECTRIC LIFT BED OPERAT QN ct ir iet rti iiie erri ne e Fido tere He aiibi riidan Fig 15 Electric Lift Bed Switch rA SaR RR EnD ias EL WINCH APPLICATIONS Fig 16 Do Not Pull at Angle WINCH MOUNTING Fig 17 Mounting Winch WINCH OPERATION Fig 18 Use Nylon Sling and Install a Damper when Winching Fig 19 Winch Operation Owner s Manual and Service Guide Page iii TABLE CONTENTS TOP AND WINDSHIELD rouen e Deoa 12 25 12 gscm a 12 HAULING 12
6. Do not apply shock loads to winch Do not attempt to modify or weld winch Rolling load capacity of winch decreases with steepness of slope Winch is designed for intermittent duty only The electric motor should not be allowed to become excessively hot If motor becomes uncomfortably hot to touch stop and allow motor to cool Correct Incorrect Ref Wps 2 Fig 16 Do Not Pull at Angle Winch may be used for a number of purposes including pulling vehicle if it loses traction on unsuitable terrain or becomes stuck or hung up on an obstruction It is impossible to predict all conditions a winch could be used therefore the following warnings should not be Page 10 considered as complete Before operating winch con sider possible dangers and take precautions to protect yourself your passenger and any bystanders When pulling vehicle with winch pull straight only Do not permit cable to contact side of drum WINCH MOUNTING Winch can be mounted at front or rear if vehicle is equipped with optional rear hitch of vehicle to accommo date different situations At front winch is mounted in receiver of frame below cowl Ref Fig 17 on page 11 At rear winch is mounted in hitch receiver below load bed Unplug winch remote control before working on winch drum in order to prevent inadvertent operation Before moving winch unplug
7. North America Technical Assistance amp Warranty Phone 1 800 774 3946 FAX 1 800 448 8124 Service Parts Phone 1 888 GET EZGO 1 888 438 3946 FAX 1 800 752 6175 International Phone 010 1 706 798 4311 FAX 010 1 706 771 4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department Starting Model Year 2005 P N 602080 ISSUED April 2005
8. OWNER S MANUAL amp SERVICE GUIDE A Textron Company REVISED DATE JAN 2007 SAFETY For any questions on material contained in this manual contact an authorized representative for clarification Read and understand all labels located on the vehicle Always replace any damaged or missing labels See APPENDIX A On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface To pre vent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum speed on level ground See GENERAL SPECIFICATIONS Limit speed by applying the service brake Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessive speed may cause a loss of vehicle control is costly is considered abuse and will not be covered under warranty Be sure that this manual remains as part of the permanent service record should the vehicle be sold For towing transporting vehicle refer to TRANSPORTING VEHICLE NOTES CAUTIONS AND WARNINGS Throughout this guide NOTE CAUTION and WARNING will be used NOTE A NOTE indicates a condition that should be observed CAUTION A CAUTION indicates a condition that may result in damage to the vehicle A WARNING indicates a hazardous condition that could result in severe injury or death Observe
9. This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product To reduce the chance of personal injury or property damage the following must be carefully observed GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur No warnings can take the place of good common sense and prudent driving practices Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined The manufacturer strongly suggests that all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein If you have any questions regarding this vehicle contact your closest representative or write to the address on the back cover of this publication Attention Product Service Department The manufacturer reserves the right to make design changes without obligation to make these changes on units previ ously sold and the information contained in this manual is subject to change without notice The manufacturer is not liable for errors in this manual or for incidental or consequential damages that result
10. 85 ft Ibs 70 115 Nm torque in 20 ft Ibs 80 Nm increments Lower vehicle Cross Sequence Front of Vehicle 2 Ref Whi 4 Fig 34 Wheel Tightening Sequence Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings LIGHT BULB REPLACEMENT Inside of Cowl Headlight Bulb Ref Hdr 4 Fig 35 Headlight Replacement Replacement bulbs are available from a local Distributor an authorized Branch or the Service Parts Department Ref Fig 22 on page 16 Locate two screws on backside of cowl that secure head light Ref Fig 35 on page 25 Remove screws pull headlight out and disconnect wires Connect wires to new headlight install in cowl and secure with screws previously removed FUSE REPLACEMENT Fuses are available from a local Distributor an autho rized Branch or the Service Parts Department Ref Fig 22 on page 16 To replace fuses locate fuse block or individual water resistant fuses mounted to plate under cowl late produc tion Pull out failed fuse and replace with a fuse of same type and load rating SPARK ARRESTER To reduce possibility of INI severe injury or death allow muffler to cool before servicing and never operate vehicle without spark arrester in good condition and in place Raise load bed Remove s
11. GENERAL SPECIFICATIONS Owner s Manual and Service Guide Page 29 GENERAL SPECIFICATIONS STANDARD EQUIPMENT CHASSIS BODY Front BODY Rear BATTERY ENGINE TRANSFER CASE TRANSMISSION FUEL TANK BRAKES FRONT BRAKES REAR PARK BRAKE FRONT SUSPENSION REAR SUSPENSION STEERING SEATING SEATING CAPACITY TOTAL LOAD CAPACITY SPEED STANDARD COLOR DASH PANEL TIRE TIRE PRESSURE WEIGHT Without fuel BED OPERATING CONTROLS amp INSTRUMENTATION ST 4X4 Welded steel hot dip galvanized front hitch receiver Flexible Impact Resistant DuraShield Injection Molded Thermoplastic Elastomer with Base Coat Clear Coat Lightweight replaceable steel panels plastic rear fenders One 12 Volt Maintenance Free 340 CCA 38 Minute Reserve Honda 18 13 4 kW 37 5 614 cc Twin Oylinder Air Cooled Overhead Valve Replaceable Oil Filter Replaceable Dry Cartridge Air Filter with Remote Air Intake Transistorized Magneto Fixed Jet Bowl Carburetor Pulse Fuel Pump Helical geared with Forward Reverse and Ground Speed Governor Automatic Continuously Variable Transmission CVT 6 7 Gallon 25 4 Liters Tank Dual Front Wheel Hydraulic 8 208 mm Disc Brakes Dual Rear Wheel Hydraulic 6 3 160 mm Drum Brakes Hand Operated Lever with Indicator Light Independent with Hydraulic Struts Leaf Springs with Hydraulic Shock Absorbers Single Reduction Rack amp Pinion Cushion Foam Vinyl Cover Hip R
12. Notes Page 38 Owner s Manual and Service Guide LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner s Manual and Service Guide Appendix A 1 LABELS AND 5 Notes Appendix A 2 Owner s Manual and Service Guide LABELS AND PICTOGRAMS See Following See Following Pages Pages For For Explanation Of Explanation These Pictograms Of These 43 44 51 Pictograms 56 57 58 59 60 See Following Pages For Explanation Of This Pictogram 28 See Following Pages For Explanation Of These Pictograms 1 2 See Following Pages For Explanation Explanation Of These Of These 74821004 See Following Pictograms Pictograms Pages For 1 2 3 4 6 9 29 52 53 Explanation 36 37 54 55 A 2 Of These Pictograms 73769 001 1 2 12 10 11 50 7 5 To release cowl ae a a Be 72939601 72939001 74093901 See Following Pages For Explanation Of These Pictograms 1 23 27 18 20 22 17 15 See Following Pages For Explanation y e Of These VES C SS See Following Pictograms Eno Ern n 61 45 62 63 X i 73607G01 d Of These Pictograms 1 35 73605G01 73601G01 1569640 Peo See Following ie Pages For i E
13. the following Before working on the vehicle remove all jewelry rings watches necklaces etc Be sure that no loose clothing or hair can contact moving parts Use care not to touch hot objects Raise entire vehicle and support on jack stands before attempting to run or adjust powertrain Wear eye protection when working on or around vehicle In particular use care when working around batteries using solvents or compressed air Hydrogen gas is formed when charging batteries Do not charge batteries without adequate ventilation Do not permit open flame or anyone to smoke in an area that is being used for charging batteries A concentration of 4 hydrogen gas or more is explosive Engine exhaust gas carbon monoxide is deadly Carbon monoxide is an odorless colorless gas that is formed as a natural part of incomplete combustion of hydrocarbon fuels Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal The following are symptoms of carbon monoxide inhalation e Dizziness Vomiting Intense headache Muscular twitching Weakness and sleepiness Throbbing in temples If any of these symptoms are experienced get fresh air immediately Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area E Z GO Division Of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US
14. Engage drum by turning clutch knob 90 returning it to original position To wind cable use handsaver bar to keep tension on cable while activating remote When winding cable make sure it winds tightly and evenly onto drum leaving no gaps that could cause premature wear to cable When using winch under a load operate remote control as far Page 11 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings as possible from side of vehicle Do not operate winch while sitting in passenger seat Read Winch Applica tions section before attempting to operate winch Winch Remote Plug ENGAGED LOCKED OUT Pull o Qh Clutch Knob Turn 90 Minimum of 5 Turns Of Cable On Drum Ref Wop 1 Fig 19 Winch Operation TOP AND WINDSHIELD The sun top does not Ey IW provide protection from falling objects The windshield does not provide protection from tree limbs or flying objects Sun top and windshield can only be used with ROPS Roll Over Protection System equipped vehicles Sun top and windshield provide some protection from the elements however they will not keep operator and pas senger dry in a downpour An optional Cab provides pro tection from the weather utilizes an optional windshield wiper which is also available with the windshield equipped ROPS unit Page 12
15. Page 19 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings 3 8 1 cm Max Deflection for New Bel 1 2 1 3 cm Max Deflection for Existing Belt Ref Abt 3 Fig 28 Adjusting Alternator Belt AIR CLEANER CANISTER TYPE AIR CLEANER Air cleaner element is accessible by unsnapping two clips on air canister and removing cover and air filter ele ment Ref Fig 29 on page 20 Clean inside of cover and canister Install element and cover the same way they were removed Be sure positioning arrow on cover is pointing up and all clips are fastened securely CLEANING AIR FILTER ELEMENT Do not use compressed air to clean air CAUTION filter doing so will damage filter which may result in damage to engine If element is in acceptable condition loose dirt may be removed by tapping filter lightly Do not use oil on filter element or any part of unit Page 20 Air Cleaner Air Filter Air Cleaner Element Canister LIIL LIIIN LEE EEE H LE Li EEL ELLE LEE EL SPEI ETA OOOO POLES V1 577 07 92 25 ELE ROE 2 2222 Fig 29 Air Cleaner FUEL FILTER To reduce possibility of AWARNING A an explosion do not smoke near fuel tank or in an area where gasoline is being handled Do not perform procedures involving fuel system near open fire or electrical items which could produce a s
16. The sun top has been designed to provide roll over pro tection and requires the ROPS system to be installed In addition the sun top does not protect against falling objects nor does the windshield protect against flying objects and tree limbs Keep arms and legs inside of vehicle while it is moving TRANSPORTING VEHICLE TOWING This vehicle is not designed to be towed It is recommended that vehicle be moved by placing entire vehicle on a trailer flatbed truck or other suitable transport HAULING To reduce possibility of severe injury or death while transporting vehi cle Secure vehicle and contents Never ride on vehicle being transported Always remove windshield before transporting Maximum speed with sun top installed is 50 mph 80 kph If vehicle is to be transported at highway speeds the sun top must be removed When transporting vehicle below highway speeds check for tightness of hardware and cracks in sun top at mounting points It is recommended that the windshield be removed when transporting Always verify vehicle and contents are adequately secured before transporting Rated capacity of trailer or truck must exceed weight of vehicle see GENERAL SPECIFICATIONS for vehicle weight and load Lock park brake and secure vehicle using ratchet tie downs TOWING A TRAILER To reduce possibility of severe injury or death trailer weight is never to exceed 1500 I
17. all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings equipped is closed following vehicle manufacturer s rec ommended practice e Before disconnecting any part of the fuel system of LP CNG powered vehicles close the fuel cylinder valve and run the engine until fuel in the system is depleted the engine stops running and is allowed to cool f Disconnect battery s g Operation to check performance of the vehicle shall be conducted in an authorized area where suitable conditions exist free of vehicular and pedestrian traffic to cool h Before returning the vehicle to service follow the vehicle manufacturer s recommended procedures i Avoid fire hazards and have fire protection equip ment present in the work area Do not use an open flame to check level or leakage of fuel battery electrolyte or coolant j Properly ventilate the work area in accordance with applicable regulations or local ordinances k Handle fuel cylinders carefully Physical damage such as dents scrapes or gouges may dangerously weaken cylinders and make them unsafe for use I Brake mechanisms steering mechanisms speed and directional control mechanisms warning devices electrical systems governors guards exhaust system and safety devices shall be inspected regularly and maintained in accordance with the vehicle manufac turer s recommended procedures m
18. and not allowing the locking mech anism to release To avoid this simply turn vehicle as acceleration begins or accelerate in reverse ACCELERATOR With engine running push accelerator pedal to acceler ate in direction selected Ref Fig 9 on page 6 Release pedal to slow vehicle and engine will idle To stop vehicle quickly apply service brake FUEL To reduce possibility of N severe injury or death from improper fuel han dling Do not smoke near the fuel tank Do not refuel near open flame or electrical items including cellular phones which could produce a spark Never fill a gas can in the bed of a vehicle Static discharge could ignite gasoline vapor and cause an explosion Always handle gasoline in a well ventilated area Always wear eye protection to protect against splashed fuel and fuel vapors Always allow adequate space for the expansion of gasoline Leave at least 1 2 5 cm space below bottom of filler neck Inspect fuel cap tank and other components for leaks or deterioration that could cause a hazard ous condition Fuel cap is located on passenger side panel of vehicle beside seat Ref Fig 10 on page 7 Fuel tank is located Ref Acl 1 Fig 9 Accelerator Pedal under passenger side of seat Fill tank with fresh clean automotive grade gasoline High altitude or heavy use load applications may benefit from higher octane gaso line Do not use gasoline which contains Meth
19. engine may require use of choke To use pull choke knob out and hold while starting engine Ref Fig 4 on page 4 Once started and engine begins to warm release choke knob CAUTION Do not allow starter to operate continu ously for more than 10 seconds Allow 30 seconds between starting attempts If vehicle does not start on third attempt turn key switch off set park brake and deter mine cause of problem IGNITION SWITCH Ignition switch has three positions OFF ON and START Ref Fig 5 on page 4 Insert key into switch and turn clockwise to ON to enable starting system Continue to turn clockwise to START to activate starter Once engine starts release key allowing return to ON To prevent inadvertent operation of vehicle when left unattended turn key to OFF position and remove key Page 3 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Fig 4 Choke NOTE If vehicle is equipped with factory installed cus tom accessories some accessories remain operational with key switch in OFF position CAUTION To prevent draining the battery always place differential lock switches in the unlocked position turn the key switch to off and remove the key If one or both of the differential locks is engaged and the key left in the on position the differen
20. fre quent use with maximum load To reduce possibility of vehicle damage when servicing Do not lift vehicle by placing jack under front or rear aluminum differential cases See Lifting the Vehicle on page 17 Always place entire vehicle on jack stands select two 2 wheel drive and unlock both differentials when performing procedures requiring engine to run with vehicle in place and tires off ground Fail ure to do so will allow vehicle to pull itself off when supported by only two jack stands Do not operate engine with CVT drive belt removed since engine speed is governed by the transfer case Doing so allows engine to exceed its maximum revolutions per minute RPM To access powertrain for routine maintenance lift seat Additional access may be obtained by raising or remov ing load bed For major repair refer to appropriate Tech nician s Repair and Service Manual Some service procedures may require vehicle to be lifted For proper lifting procedure and safety information See LIFTING THE VEHICLE on page 17 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings PERIODIC SERVICE SCHEDULE BEFORE EVERY EVERY EVERY EVERY EVERY EVERY EACH 20 50 100 200 300 500
21. page 17 Front Differential 15 2 1 oz 450 ml of 80 90W GL5 Rear Axle 15 2 1 oz 450 ml of 80 90W GL5 Transfer Case 24 oz 700 ml MOBILFLUID 424 Fig 40 Capacities Fig 39 Cleaning Air Intake and Cooling Fins After every off road use allow to cool and then check for build up of dirt and debris in air intake and cooling fins Ref Fig 39 on page 27 Dirt and debris may clog the engine s air cooling system Clean areas shown to prevent engine damage Keep linkages springs and controls clean Keep area around muffler free of any combustible mate rial BRAKES PERIODIC BRAKE TEST FOR HYDRAULIC BRAKES To reduce possibility of INI severe injury or death always evaluate pedal travel before operating a vehicle to verify some brak ing function is present It is important to periodically check and maintain proper brake fluid level in master cylinder Ref BRAKES on page 27 Master cylinder is located under cowl When checking fluid wipe off any dirt from fill cap before removing it to reduce possibility of contamination Fluid level should be maintained at mark molded into reservoir If fluid must be added use only DOT 3 brake fluid and inspect system for fluid leaks Push brake pedal Pedal should have some free travel and then become hard A brake pedal that has no free travel excessive free travel or a spongy feel indicates that a brake inspection is required A brake ped
22. party shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accord ingly B 1 1 3 3 As required under B 1 1 3 1 or B 1 1 3 2 the vehicle manufacturer shall be contacted to secure new nameplates warnings or instructions which shall then be affixed in their proper place on the vehicle B 1 1 4 Fuel Handling B 1 1 4 1 The controlling party shall supervise the handling of liquid fuels when used to be certain that it is in accordance with appropriate sections of ANSI NFPA 505 and ANSI NFPA 30 or as required by local ordi nance Page xi SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings B 1 1 4 2 The controlling party shall supervise the handling of liquefied petroleum gas fuels when used to be certain it is in accordance with appropriate sections of ANSI NFPA 505 and ANSI NFPA 58 or as required by local ordinance B 1 1 5 Charging Storage Batteries B 1 1 5 1 The controlling party shall require battery charging procedures to be in accordance with appropri ate sections of ANSI NFPA 505 ISO 3691 or local ordi nance and meet any other requirements such as OSHA B 1 1 5 2 The controlling party shall periodically review procedures to be certain that appropriate sections of ANSI NFPA 505 or local ordinance and OSHA are strictly complied with and shall familiarize vehi
23. pressure listed on sidewall of tire All four tires should have the same pressure for opti mum handling characteristics Use caution when inflating tires Due to low volume of small tires overinflation can occur in seconds Overinfla tion could cause tire to separate from wheel or cause tire to explode Be sure to install valve dust cap after checking REMOVAL AND INSTALLATION To reduce possibility of N severe injury caused by a broken socket when removing wheels use only sockets designed for impact wrench use Hardware involved 3 4 hex lug nut To remove loosen lug nuts If using an impact wrench use only impact sockets with it Regular sockets are not designed for impact pressures exerted by power tools Raise vehicle See LIFTING THE VEHICLE on page 17 Page 24 Remove lug nuts and wheel To reduce possibility of damage tight CAUTION en lug nuts to no more than 85 ft Ibs 115 Nm torque Use cross sequence pattern when tightening lug nuts to assure even seating of wheel NOTE against hub Special Tools Required Qty Torque wrench ft 2 2 1 To install place wheel onto studs with valve stem facing away from hub Ref Fig 34 on page 24 Be sure to position wheel on hub correctly with arrow on tire indicat ing direction of rotation when moving forward Add lug nuts and finger tighten Secure wheel by tightening lug nuts in a cross sequence pattern to 50
24. start vehicle do not use accessories excessively while engine is off Failure to promptly charge a discharged battery will shorten its life span Owner s Manual and Service Guide Slip Joints amp U Joint Yokes View From Underside of Vehicle Ref Lub 5 Fig 31 Lubrication Points Unless equipped with optional high output alternator the vehicle uses a charge coil to charge battery Battery is charged while engine is running Do not operate acces Sory items such as accessory lights radios winch etc excessively while engine is off The charge coil is capa ble of supplying 20 amps therefore operation of all accessories could result in discharge of battery even though engine is running Discharging and recharging a battery is known as deep cycling The battery is not a deep cycle model but is a starting battery that is intended to maintain a full charge from the charging circuit Multiple deep cycles will result in premature failure of battery If battery becomes discharged vehicle can be jump started See JUMP STARTING on page 22 After starting promptly charge battery using a 12 volt charger rated at 10 amps or less and in accordance with all instructions provided by the manufacturer of charger Page 21 OPERATION AND SERVICE INFORMATI
25. times They are intended to free or prevent vehicle from being stuck as terrain demands ideally for short runs at slow speeds Always disengage differential locks as ter rain and conditions allow Differential locks should only be used when NOTE additional traction is required Continued use of rear differential lock may cause excessive wear to tires Contin ued use of front differential lock may increase steering effort CAUTION Vehicle must be completely stopped before engaging or disengaging differ ential lock Failure to stop may damage differential Page 5 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings To prevent draining the battery always place differential lock switches in the unlocked position turn the key switch to off and remove the key To engage rear differential lock stop vehicle and push upper portion of rear differential lock switch To engage front and rear differential lock stop vehicle and push upper portion of both differential lock switches Indicator lights in gauge cluster illuminate to remind operator when locks are engaged To disengage differential locks stop vehicle and push lower portion of switches After unlocking the differential may remain locked if driving is resumed in a straight line This is a normal occurrence caused by pressure remain ing against the gears
26. wide temperature range P N 75500 G01 White Lithium Grease designed to provide lubrica tion protection in areas where staining or discolor ing is a problem or in areas of extreme temperature ranges P N 75502 G01 e Penetrant Lubricant a 4 in 1 product that pene trates seized parts lubricates leaving a light lubri cating film reduces corrosion by adhering to wet or dry surfaces and displaces moisture sealing against future moisture return P N 75503 G01 Multi purpose Cleaner and Degreaser that con tains natural environmentally safe solvents P N 75504 G01 Multi purpose Hand Cleaner is an industrial strength cleaner containing no harsh solvents yet gently lifts grease off hands May be used with or without water P N 75505 G01 Battery Cleaner that neutralizes battery acids and dissolves terminal corrosion and can be rinsed with water P N 75506 G01 Biodegradable Cleaner that breaks down grease to be easily wiped or rinsed away P N 75507 G01 Multi purpose Value Pack sampler includes 4 ounce 118 ml aerosol cans of Battery Protector Penetrant Lubricant White Lithium Grease and Carburetor and Choke Cleaner P N 75508 G01 LABELS AND PICTOGRAMS Vehicles are labeled with pictograms as a method of con veying information or warnings Appendix A illustrates and explains pictograms that appear on vehicle Not all pictograms shown in Appendix A will be used on vehicle Page 23 OPERATI
27. ANKING POSITION PULL HANDLE UP TO ENGAGE PARK BRAKE PULL HANDLE UP PUSH BUTTON IN PUSH HANDLE DOWN TO RELEASE PARK BRAKE e AR CMT RETE gt oun oun WARNING READ OWNER S MANUL BEFORE OPERATING VEHICLE IN FORWARD OR REVERSE WARNING READ OWNER S MANUAL BEFORE PARKING VEHICLE AND LEAVING IT UNATTENDED FORWARD NEUTRAL REVERSE WARNING READ OWNER S MANUAL BEFORE ENGAGING TWO OR FOUR WHEEL DRIVE PUSH TOP OF SWITCH TO LOCK DIFFERENTIAL PUSH BOTTOM OF SWITCH TO UNLOCK DIFFERENTIAL REAR DIFFERENTIAL LOCK SWITCH FRONT DIFFERENTIAL LOCK SWITCH WARNING READ OWNER S MANUAL BEFORE ENGAGING FRONT DIFFERENTIAL LOCK DO NOT ENGAGE LOCK WHILE FRONT WHEELS ARE TURNED AND VEHICLE IS AT SPEED PUSH TOP PART OF SWITCH TO RAISE LOAD BED PUSH BOTTOM PART OF SWITCH TO LOWER LOAD BED LABELS AND PICTOGRAMS AUXILIARY LIGHTS HORN BUTTON Fig 49 Pictogram Definitions Owner s Manual and Service Guide Appendix A 7 LABELS AND 5 Notes Appendix A 8 Owner s Manual and Service Guide Check area behind the AWARNING A vehicle before operating in reverse Make sure the direction selector is in correct position before attempting to start the vehicle Slow down before and during turns All turns should be executed at reduced speed Always bring vehicl
28. ATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Front of Vehicle Fig 27 Oil Filter Change Fill engine to upper hole on dipstick with appropriate oil Ref OIL CHANGE on page 18 Return oil fill cap and dipstick and lower seat Start engine and check for leaks Shut engine off check oil level and add if necessary to bring level to upper hole on dipstick SPARK PLUGS CAUTION To reduce possibility of engine damage Only use recommended spark plugs Tighten spark plugs as instructed Too loose can overheat engine and too tight can damage threads in cylinder head Inspect and replace spark plugs at intervals indicated in Periodic Service Schedule See PERIODIC SERVICE SCHEDULE on page 15 Remove plug wires and clean area around plugs to pre vent debris falling into cylinders Use a 13 16 spark plug wrench to remove plugs Owner s Manual and Service Guide Inspect electrodes for wear and insulator for cracks or chips Fouled spark plugs are indicated by a wet black appearance This could be caused by a dirty air filter ele ment or other restrictions in air intake system Incorrectly adjusted valves spark plug wires which are in poor con dition or poor quality fuel could also contribute If reusing spark plugs clean with wire brush Check gap Gap should measure 028 031 70 80 mm If necessary adjust gap bei
29. GET EZGO 1 888 438 3946 FAX 1 800 752 6175 INTERNATIONAL PHONE 010 1 706 798 4311 FAX 010 1 706 771 4609 E Z GO DIVISION OF TEXTRON INC 1451 MARVIN GRIFFIN ROAD AUGUSTA GEORGIA USA 30906 3852 Owner s Manual and Service Guide Pagei GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America USA as a World Vehicle The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated The use of non Original Equipment Manufacturer OEM approved parts may void the warranty Overfilling battery may void the warranty Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 60 ii Owner s Manual and Service Guide TABLE CONTENTS SAFETY gap inside covers GENERAL INFORMATION 2 2
30. ITEM USE WEEKLY HOURS HOURS HOURS HOURS HOURS HOURS Oe Check X Fluid Level Check x Pads amp Shoes Inspect X Rotors amp Drums Clean X Park Brake Clean X X Tires Check X X Overall Vehicle Condition Check X Wheels Check X Fuel Gauge Check X Alternator Belt Check X Engine Fan and Cooling Fins Clean X pe x Damage Accs X Wiring Check X Accelerator Check X Choke Check X Carburetor Linkage Check X Direction Selector Check X Engine Oil Check X Change xX X Engine Oil Filter Replace X Air Filter Check X Clean x Replace x Spark Plugs Check X Replace X Idle Speed Check Valve Clearance Check x X Fuel Filter Check X Replace X Combustion Chamber Clean X Steering Check X Fig 21 Periodic Service Schedule Owner s Manual and Service Guide Page 15 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings BEFORE EVERY EVERY EVERY EVERY EVERY EVERY EACH 20 50 100 300 500 ITEM USE WEEKLY HOURS HOURS HOURS HOURS HOURS HOURS Tie Rods Linkages Check X Rear Axle Check x Replace X Muffler Exhaust Check Spark Arrester Clean X Front Axle Check x Front Knuckles Check X Front Struts Check X Front Wheel Alignment Check X Rear Shock Absorbers Check X Fuel Tank Clean
31. N NO TAMPERING KEEP HANDS OUT WARNING CORROSIVE WARNING EXPLOSIVE Ju ares Fig 47 Pictogram Definitions Owner s Manual and Service Guide LABELS AND PICTOGRAMS WARNING LETHAL VOLTAGE DO NOT DISPOSE OF BATTERIES IN LANDFILL WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS BATTERIES ARE HEAVY USE CARE LIFTING USE INSULATED TOOLS WEAR EYE PROTECTION NO SMOKING HOT SURFACE Appendix A 5 AND PICTOGRAMS OPERATE FROM DRIVER S SIDE ONLY KEEP ARMS AND LEGS WITHIN VEHICLE TO OPERATE VEHICLE IN FORWARD TURN KEY TO ON MOVE DIRECTION SELECTOR TO FORWARD DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO OPERATE VEHICLE IN REVERSE TURN KEY TO ON MOVE DIRECTION SELECTOR TO REVERSE AN AUDIBLE DEVICE WILL SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO NEUTRAL Fig 48 Pictogram Definitions Appendix A 6 Owner s Manual and Service Guide KEEP CLEAR HAND OR FINGERS CAN BETRAPPED ON POSITION OFF POSITION HEADLIGHTS UNLOCKED LOCKED DIFFERENTIAL LOCKED WARNING KEEP ENTIRE BODY INSIDE CAR MAXIMUM TAILGATE LOAD ENGINE CR
32. ND CARE CLEANING To reduce possibility of INI severe injury or vehicle damage read and under stand all instructions supplied by manufacturer of pressure washer CAUTION To reduce possibility of damage do not use pressure in excess of 700 psi 4826 kPa when pressure washing exterior of vehicle and do not use any abrasive or reactive solvents to clean plastic parts It is important that proper techniques and cleaning mate rials be used Using excessive water pressure may cause severe injury to operator or bystander damage to seals plastics seat material body finish or electrical sys Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Front of Vehicle i Strong Battery Ref Jmp 1 Fig 33 Jump Starting tem Do not use pressure in excess of 700 psi 4800 kPa to wash exterior of vehicle Clean windshield with lots of water and a clean cloth Normal cleaning of vinyl seats and plastic or rubber trim requires use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish e
33. ON Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings BATTERY CLEANING CAUTION To reduce possibility of damage to vehicle or floor neutralize acid before rinsing battery To reduce possibility of damage to electrical components while cleaning do not use a pressure washer Cleaning should take place per PERIODIC SERVICE SCHEDULE See PERIODIC SERVICE SCHEDULE on page 15 When cleaning outside of battery and terminals first spray with a solution of sodium bicarbonate baking soda and water to neutralize any acid deposits before rinsing with clear water Use of a water hose without first neutralizing any acid will move acid from top of battery to other parts of vehicle or storage facility where it will attack metal concrete or asphalt Additionally a conductive residue will remain on battery and will contribute to its discharge To reduce possibility of battery explosion that could result in severe injury or death do not use metallic spray wand to clean battery and keep all smoking materials open flame or sparks away from battery Correct cleaning technique is to spray top and sides of battery with solution of sodium bicarbonate baking soda and clear water Ref Fig 32 on page 22 Solution should consist of amounts shown in diagram and is best applied with a garden type sprayer equipped with a non metallic spray wand or a plas
34. ON AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings WHEELS AND TIRES NOTE Tires are uni directional and should never be moved from one side of vehicle to the other This vehicle comes standard with low pressure tubeless uni directional tires mounted on one piece wheels Ref Fig 34 on page 24 Left side tires should always remain on left side of vehicle Right side tires should always remain on right side of vehicle Uni directional tires have an arrow on their sidewall indicating direction of rotation when moving forward TIRE INSPECTION AND INFLATION To reduce possibility of severe injury or death from tire separating from wheel or exploding use caution when inflating tires and never exceed maximum pressure rating on side wall of tire Overinflation can occur quickly Tire condition should be inspected per the PERIODIC SERVICE SCHEDULE See PERIODIC SERVICE SCHEDULE on page 15 Examine for cuts punctures and excessive wear Repair or replace as necessary Air pressure should be checked when tires are cool If air needs to be added see GENERAL SPECIFICATIONS section of this manual Standard and optional tires should be inflated to pressure designated If pressure is not des ignated inflate to pressure recommended on sidewall of tire Under no condition should inflation pressure be higher than maximum
35. TER TYPE AIR CLEANER eese CLEANING AIR FILTER ELEMENT Fig 29 Air Cleaner FUEL FILTER 22 T T E LUBRICATION POINTS 5 A A pe Ln Fig 37 Lubrication reca n a a dh 21 BATTERY 5 A MID LLL LM E M e ctt 21 BATTERY CLEANING GRE te eee ssa Hat I o DERI hak Soria te eds 22 FIGs 32 Cleaning Battery 3 vere pe mtn e eem erede e A 22 JUMP STARTING niece creer aene tuer Du oca VEHICLE CLEANING AND CARE 22 Cd Qn CBEANING eese LR o ser ii s e Ah CARE PRODUCTS LABELS AND PICTOGRAMS WHEELS AND TIRES E TIRE INSPECTION AND INFLATION E REMOVAL AND INSTALLATION Fig 34 Wheel Tightening Sequence Page iv Owner s Manual and Service Guide TABLE CONTENTS LIGHT BULB 5 2 EENEN ANARE ERNA 25 Fig 35 Headlight Replacement sss einen tnra 25 FUSE REPLACEMENT
36. Vehicles or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved oper ating features n Fuel systems shall be checked for leaks and condi tion of parts If a leak is found action shall be taken to prevent the use of the vehicle until the cause of the leak has been repaired The vehicle manufacturer s capacity operation and maintenance instruction plates tags and safety labels shall be maintained in legible condition p Batteries motors speed and directional control lers limit switches protective devices electrical conduc tors insulators and connections shall be inspected and maintained in accordance with vehicle manufacturer s recommended procedures q Vehicles shall be kept in a clean condition to mini mize fire hazards and facilitate the detection of compo nents needing service Page xiv r Hydraulic systems if so equipped shall be checked for leaks and condition of parts Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure Use paper or card board not hands to search for leaks s Modifications and additions which affect capacity and safe machine operation shall not be performed with out vehicle manufacturer s prior written authorization Where authorized modifications have been made the controlling party shall ensure that capacity operation warning and main
37. X Throttle Governor Linkage Check X Hardware And Fasteners Check X Tighten X Battery Clean X Drive Belt Check X Front Wheel Bearings Check X Drive shafts Lubricate X C V Joints and Boots Check X Fig 21 Periodic Service Schedule First occurrence only More frequently in dusty conditions To perform service that is listed in this schedule but not described in this manual contact a local Service Representative or see Repair and Service Manual for this vehicle NOTE BASIC SERVICE PARTS To order parts SERVICE PARTS Department contact information is as follows In USA Phone 1 800 241 5855 Fax 1 800 448 8124 Outside USA Phone 010 1 706 798 4311 Fax 010 1 706 771 4609 E Z GO Division of TEXTRON Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 Page 16 Air Filter Element Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions 72944 01 Oil Filter 15400 POH 305PE Spark Plugs ZGR5A J16CR U DENSO Optional Alternator Belt 73561 601 Belt 73965 G01 Fuse 15 amp P N 35212 G01 20 amp P N 35212 G02 7 5 amp P N 35212 G05 Headlight Bulb 20209 G3 Tail Light Bulb 1157 P N 21759 G1 Fig 22 Basic Service Parts Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thorou
38. al that offers little resistance after it is applied indicates a leak in system Owner s Manual and Service Guide Page 27 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings HARDWARE Generally three grades of hardware are used in vehicle Grade 5 hardware can be identified by three marks on Periodically vehicle should be inspected for loose fasten i the hexagonal bolt head and grade 8 by six marks ers Fasteners should be tightened in accordance with the Torque Specifications table Ref Fig 41 on page 28 Unmarked hardware is Grade 2 Use care when tightening fasteners and refer to Techni cian s Repair and Service Manual for specific torque val ues ALL TORQUE FIGURES ARE IN FT LBS Nm Unless otherwise noted in text tighten all hardware in accordance with this chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque required for dry fasteners BOLT SIZE 1 4 5 16 3 8 7 16 1 2 8 15 35 nox a 0 47 13 23 55 18 31 75 BOLT SIZE Class 5 8 Grade 2 Class 8 8 Grade 5 Class 10 9 Gog Grade 8 10 3 Ref Tsp 1 Fig 41 Torque Specifications and Bolt Grades Page 28 Owner s Manual and Service Guide GENERAL SPECIFICATIONS
39. anol Some fuels called oxygenated or reformu CAUTION lated gasoline are gasoline blended with alcohols or ethers Excessive amounts of these blends can damage the fuel system or cause performance problems If any undesirable operat ing symptoms occur use gasoline with a lower percentage of alcohol or ether Do not overfill the fuel tank Allow adequate space for the expan sion of gasoline Leave at least 1 2 5 cm space below bottom of filler neck FUEL GAUGE An electric fuel gauge is located left of steering wheel in gauge cluster Ref Fig 10 on page 7 It indicates amount of fuel in tank Owner s Manual and Service Guide Page 6 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings NS Ref Fill 4 Fig 10 Fuel Tank and Gauge LOW OIL PRESSURE INDICATOR LIGHT Low oil pressure indicator light is located in gauge cluster at left of dash panel Indicator light is activated if oil pres sure drops below 1 5 psi 11 kg cm Ref Fig 11 on page 7 Check oil level See OIL LEVEL CHECK on page 18 If oil level is between ADD and FULL mark on dipstick a mechanical problem exists within engine and vehicle must not be driven Contact a local Distributor or authorized Branch Fig 11 Low Pressure Oil Light CAUTION To reduce po
40. ated at 15 amps is located left of ignition switch Ref Fig 13 on page 7 It provides con stant power for accessories equipped with a 12 volt plug STARTING AND DRIVING To reduce possibility of PAU ENETINTE IW roll back which could result in severe injury or vehicle damage do not release service brake until engine has started To operate vehicle Apply service brake Place direction selector in neutral Insert key into ignition switch and turn it to ON position Apply choke if needed and turn key to START position just long enough for engine to start Release choke once engine runs smoothly Place direction selector in forward or reverse NOTE If equipped a warning signal will sound while direction selector is in reverse Release park brake Release service brake and apply accelerator When accelerator pedal is released engine will idle Apply service brake pedal to slow or stop vehicle Move direction selector only after vehicle has completely stopped STARTING VEHICLE ON A HILL To reduce possibility of P AASIN which could result in severe injury or vehicle damage do not release service brake until engine has started CAUTION Do not hold vehicle on hill by using accelerator and engine This will cause premature and excessive wear to drive train components To reduce the possibility of permanent damage to the drive system it is important to prevent excessi
41. ated on rubber bumpers secure with latches DATA LABEL LOCATION Serial number label is located on body just below air intake louvers near choke knob Manufacture date code and repeat of serial number are on data labels located on frame crossmember under bed See LOAD BED on page 8 Design changes take place on an ongoing basis In order to obtain correct components for vehicle manufacture date code serial number and vehicle model must be pro vided when ordering service parts Fig 20 Unlatching Cowl Owner s Manual and Service Guide Page 13 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings MAINTENANCE To reduce possibility of severe injury or death from improper servicing techniques Do not attempt any type of servicing operations before reading and understanding all notes cau tions and warnings in this manual Wear eye protection when working on 9 vehicle Use extra care when working Y around batteries or using solvents or compressed air Turn off all electrical loads from battery before removing battery wires Wrap wrenches with vinyl o tape to reduce possibility of a dropped wrench shorting out a battery which could result in an explosion Remove and ground spark plug wires and discon nect battery at negative terminal before servicing Treat all electrolyte spills to b
42. bs 680 kg To reduce possibility of vehicle dam CAUTION age do not exceed 1500 Ibs 680 kg trailer weight nor 150 Ibs 68 kg tongue weight Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Vehicle may be equipped with a receiver that accepts a standard 2 ball hitch Trailer range of motion is limited by the ball and hitch and should not be used on rough trails or over objects such as logs large rocks holes etc Never install non factory baskets or extensions in hitch receivers front or rear Such items change performance characteristics of vehicle and result in unsafe handling possible roll over or vehicle damage Remember a loaded trailer always reduces overall capacity of vehicle At no time should tongue weight be more than 150 Ibs 68 kg The maximum weight that can be towed on a trailer is 1500 Ibs 680 kg OPENING THE COWL HOOD To lift cowl Ref Fig 20 on page 13 Pull down and out on both latches to clear receiv ers mounted to frame Lift cowl up fully to allow catch to rest on cross member and release cowl To lower cowl Lift cowl up fully with one hand to remove weight from catch Pull catch away from crossmember with other hand Lower cowl until catch clears crossmember and continue lowering cowl with both hands Once se
43. cle at speeds that will permit it to be brought to a stop in a safe manner B 2 3 13 Use caution and slow down when approach ing or on wet or slippery surfaces loose or unfamiliar ter rain B 2 3 14 Avoid sudden starts stops turns or direction reversals so as not to shift the load endanger passen gers or lose control of the vehicle B 2 3 15 Do not operate vehicle in a dangerous man ner such as stunt driving or horseplay B 2 3 16 Avoid running over loose objects potholes and bumps B 2 4 Loading B 2 4 1 instructions Refer to operators manual for loading B 2 4 2 Transport only stable and safely arranged loads secured to prevent movement Avoid loads which cannot be centered B 2 4 3 Transport only loads within the gross vehicle weight capacity Owner s Manual and Service Guide B 2 4 4 Avoid material loads exceeding the physical dimensions of the vehicle or as specified by the vehicle manufacturer B 2 5 Operator Care of Light Utility Vehicles B 2 5 1 B 2 5 2 At the beginning of each operating period during which the vehicle will be used the operator shall check the vehicle condition and inspect the tires warning devices safety interlocks lights battery s fuel system speed and directional controllers brakes and steering mechanism If the vehicle is found to be in need of repair or in any way unsafe the matter shall be reported imme diately to the controlling party and the vehicle shall n
44. cle opera tors with it B 1 1 6 Lighting For Operating Areas B 1 1 6 1 The controlling party in accordance with his responsibility to survey the environment and operating conditions shall determine if the vehicle requires lights and if so shall equip the vehicle with appropriate lights in accordance with the vehicle manufacturer s recom mendations B 1 1 7 Warning Device s B 1 1 7 1 The controlling party shall make periodic inspections of the vehicle to be certain that the sound producing and visual device s if so equipped are main tained in good operating conditioning condition B 1 1 7 2 The controlling party shall determine if oper ating conditions require the vehicle to be equipped with additional sound producing and or visual devices com patible with the vehicle manufacturer s recommenda tions and be responsible for providing and maintaining such devices in accordance with the vehicle manufac turer s recommendations B 1 1 8 Safety Interlocks B 1 1 8 1 The controlling party shall make periodic inspections of the vehicle to be certain that the safety interlock system if so equipped is operating properly Page xii B 2 Operating Safety Rules and Practices B 2 1 Operator Qualifications B 2 1 1 Only persons who are trained in the proper operation of the vehicle shall be authorized to operate the vehicle Operators shall be qualified as to visual auditory physical and mental ability to safely operate
45. considerations allow Consider the terrain and traffic conditions Consider environmental factors which effect the terrain and the ability to control the vehicle Avoid driving fast down hill Sudden stops or change of direction may result in a loss of control Use service brake to control speed when traveling down an incline Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc All travel should be directly up or down hills Use extra care when driving the vehicle across an incline Stay in designated areas and avoid steep slopes Use the parking brake whenever the vehicle is parked Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain NOTES CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER OWNER S MANUAL AND SERVICE GUIDE GASOLINE POWERED UTILITY VEHICLE ST 4x4 STARTING MODEL YEAR 2005 E Z GO Division of TEXTRON Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the infor mation contained in this manual is subject to change without notice E Z GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual TO CONTACT US NORTH AMERICA TECHNICAL ASSISTANCE amp WARRANTY PHONE 1 800 774 3946 FAX 1 800 448 8124 SERVICE PARTS PHONE 1 888
46. crew securing spark arrester and pull arrester from muffler Ref Fig 36 on page 25 Owner s Manual and Service Guide Brush off carbon deposits from arrester screen without damaging screen Screen must be intact Replace spark arrester if screen is breached Install arrester on muffler and secure with screw Ref Csa 1 Fig 36 Cleaning Spark Arrester PROLONGED STORAGE To reduce possibility of NI severe injury or death resulting from a possi ble explosion Do not handle fuel in an area that is not adequately ventilated Do not smoke near fuel tank or refuel near open flame or electrical items which could produce a spark Store vehicle in a clean dry area Do not store in same area as a stove furnace water heater or other appliance that uses a pilot light or has a device that can creale a spark When refueling inspect fuel cap for leaks or breaks that could result in fuel spillage Always wear safety glasses while refueling to prevent possible eye injury from gasoline or gasoline vapor Keep hands clothing and jewelry away from moving parts Use care not to contact hot objects Preparing vehicle for a prolonged storage period 30 days or more calls for a few simple steps to prevent a build up of varnish and gum in carburetor and corrosion in engine Clean body chassis and engine of debris mud chaff or grass Ref AIR INTAKE AND COOLING FINS on page 26 e Disconnect fuel hose at fu
47. ditional operating instructions provided by controlling party B 1 1 1 5 The controlling party shall survey specific operating conditions and environment establish safety practices and train vehicle operators to comply with these practices B 1 1 2 Operation Experience has shown that vehi cles which comply with the provisions stated in 7 8 are stable when properly operated in accordance with spe cific safety rules and practices established to meet actual operating terrain and conditions However improper operation faulty maintenance or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard Some conditions which could affect stability are failure of the operator to follow safety practices surface conditions grade speed loading braking turning improper loads towing attachments dynamic forces and the judgment exercised by the vehi cle operator B 1 1 3 ifications Nameplates Markings Capacity And Mod B 1 1 3 1 The controlling party shall maintain in a legi ble condition all nameplates warnings and instructions which are supplied by the vehicle manufacturer B 1 1 3 2 The controlling party shall not perform any modification or addition which affects capacity or safe operation or make any change not in accordance with the vehicle manual s without the vehicle manufacturer s prior written authorization Where authorized modifica tions have been made the controlling
48. e dis tributed in such a way that its center of gravity must not be higher than height noted on label and secured Failure to follow these instructions may result in severe injury and or vehicle damage resulting from rollover Use extra care when operating loaded vehicle Do not permit anyone to ride in load bed Do not drive vehicle with load bed raised or tailgate unsupported Avoid backing up to the edge of a drop off such as a loading dock or ravine A misjudgment of distance or an unstable surface could result in vehicle falling back wards Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Before operating verify no one is behind vehicle Always place a gas can on ground for filling Never fill a gas can in load bed of vehicle Built up static electricity could discharge during fueling process and ignite gaso line vapor TAILGATE To open tailgate Early Production Lift taillgate straight up with a sharp upward pull to lift out of closed position and swing out Maximum load is 100 Ibs 45 kg To open tailgate Late Production Pull latches out from recess in tailgate Slide both latch handles toward the center of the tailgate and pivot tailgate out to open posi tion Maximum load is 100 Ibs 45 kg To remove tailgate remove side cables from load bed and low
49. e oil fill cap and add oil until level reaches upper hole When finished return dipstick and oil fill cap and lower seat v e g Dip Stick YY NG N W N Ref Olc 1 Fig 25 Oil Fill and Level Check OIL CHANGE With engine warm park vehicle on level surface shut off engine remove key set park brake and wait a minute for oil to settle Lift seat wipe oil fill cap clean with a cloth and remove fill cap Ref Fig 25 on page 18 Page 18 Front of Vehicle uu Re Fig 26 Oil Change Place drain pan under engine Remove drain plug from base of engine Ref Fig 26 on page 18 Once oil has drained replace drain plug and if due change oil filter at this time Ref OIL CHANGE on page 18 Fill engine to upper hole on dipstick with appropriate oil Ref Fig 24 on page 17 Return oil fill cap and dipstick and lower seat OIL FILTER CHANGE Drain oil Ref OIL CHANGE on page 18 Clean oil filter and its mount Ref Fig 27 on page 19 Place drain pan under engine and being careful not to damage oil pressure switch remove oil filter Wipe sealing surface of filter mount clean Apply clean fresh oil to seal of new filter and screw filter on by hand until seal contacts filter mount Tighten 7 8 of a turn more Torque specification is 16 ft los 22 Nm Owner s Manual and Service Guide OPERATION AND SERVICE INFORM
50. e to a complete stop before shifting the direction selector See GENERAL SPECIFICATIONS for vehicle load and seating capacity Read and understand the following text and NOTE warnings before attempting to service vehicle In any product components will eventually fail to perform properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there fore should be considered potentially hazardous Use extreme care when working on any vehicle When diag nosing removing or replacing any components that are not operating correctly take time to consider the safety of yourself and others around you should the component move unexpectedly Some components are heavy spring loaded highly cor rosive explosive or may produce high amperage or reach high temperatures Gasoline carbon monoxide battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with the utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools listed in the tool list and wear approved safety equipment prevent personal AWARNINGA injury or death observe
51. el tank and plug hose With proper ventilation start engine and allow it to run until it stops due to lack of fuel Page 25 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings e Add fuel stabilizer to fuel tank following instruc tions on stabilizer container Attach fuel line to tank and drive vehicle for sev eral minutes to circulate fuel stabilizer through car buretor While engine is still warm change oil Ref OIL CHANGE on page 18 Remove spark plugs Ref SPARK PLUGS on page 19 and pour about 1 oz 30 ml of engine oil into each cylinder Replace spark plugs ground spark plug wires and use starter to turn engine over a few seconds to distribute oil FRONT AND REAR AXLES Rear axle is provided with a lubricant level check fill plug located on side of differential case Unless leakage is evi dent an annual lubricant check is sufficient CHECKING LUBRICANT LEVEL Hardware involved 7 16 hex head plug Clean check fill plug and area around it Ref Fig 37 on page 26 Remove plug Correct lubricant level is just below bottom of threaded hole If lubricant is to be added use a funnel and add correct type lubricant slowly until it starts to seep from hole See Checking Axle Lubricant on page 26 Install plug and tighten to 18 ft Ibs 25 Nm To replace lubricant a drain plug is pro
52. er tailgate until it is straight down lift tailgate straight up to remove from pins and remove from load bed Assemble in reverse order MANUAL LIFT BED To reduce possibility of AWARNING A severe injury exercise caution while manually lifting or lowering load bed Fingers or other body parts could be trapped under falling bed To raise manual lift bed locate latch handle at front left side of bed pull handle up with one hand to release and lift bed with other hand Ref Fig 14 on page 9 J Manual Load Bed br Latch Handle Pull Up Release And Lift Bed Ref Mbl 4 Fig 14 Manual Lift Bed Release A gas strut located underneath will assist in raising bed when empty and will keep it raised when empty Owner s Manual and Service Guide Over time the gas strut may allow the truck NOTE bed to slowly lower If this condition is evident replacement of gas strut is required To lower manual lift bed push down on bed until latch catches Be sure hands are not trapped by load bed ELECTRIC LIFT BED OPERATION To reduce possibility of IW severe injury exercise caution while lifting or lowering load bed Fingers or other body parts could be trapped under bed The electric lift toggle switch is located at left side of dash panel Ref Fig 15 on page 9 Push top part of switch to raise load bed and bottom part to lower
53. es should not be operated and to identify possible hazards a Steep Grade In areas where steep grades exist vehicle operation should be restricted to the designated vehicle s pathways where possible and shall be identi fied with a suitable warning giving the following informa tion Warning steep grade descend slowly b Wet Areas Wet areas could cause a vehicle to lose traction and could affect steering stability and braking c Sharp Turns Blind Corners Bridge Approaches Sharp turns blind spots bridge approaches and other potentially hazardous areas shall be identified with a suit able warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard d Loose Terrain Loose terrain could cause a vehicle to lose traction and could affect steering stability and braking B 1 1 1 3 Utility Vehicle Pedestrian X Interference Areas Areas where pedestrian and vehicle traffic could interfere should be avoided by rerouting the vehicle or the pedestrian traffic to eliminate the interference If elim ination of the interference is not possible or is highly impractical signs shall be erected warning pedestrians and vehicle operators of traffic conditions and to use cau tion Owner s Manual and Service Guide B 1 1 1 4 The controlling party shall train vehicle operators to adhere strictly to the operating instructions stated in vehicle operator s manual and those ad
54. estraint Hand Hold Operator amp 1 Passenger 1500 Ibs 545 kg Including Operator Passenger Accessories amp Cargo 25 mph 40 kph Recon Green Scuff Resistant Glass Fiber Reinforced Plastic Thermoplastic Olefin with 2 Drink Holders Carlisle AT489 25 x 11 12 Uni directional 16 20 psi 110 138 kPa 1250 Ibs 567 kg Rotomolded Load Bed Inside Dimensions 42 3 4 L X 54 W X 11 109 X 137 X 27 Removable Key Direction Selector Electric Fuel Gauge 4WD 2WD Selector with Indicator Lights Electric Front amp Rear Differential Locks with Indicator Lights Hour Meter Volt Meter MAXIMUM TRAILER WEIGHT 1500 Ibs 680 kg Page 30 Owner s Manual and Service Guide GENERAL SPECIFICATIONS 50 127 cm 54 137 cm 1181 4 11 1 2 29 cm 12 3 4 32 Front 43 3 8 110 cm 9 1 2 24 cm 7 77 8 3 8 21 3 Rear Clearance At Lowest Clearance At Lowest Point 43 3 4 111 cm Point On Frame Of Vehicle On Rear Axle Late 2005 Production Loadbed shown Early Production Similar Ref Dim 3 1 Indicates Late 2005 Production Dimension Fig 42 Vehicle Dimensions Ref Dim 3 2 Maximum Recommended Ramp Grade Maximum Recommended Side Tilt 25
55. free from stumps large rocks or holes crossing water no deeper than 8 inches 20 cm Slow down when traveling unfamiliar terrain cresting a hill Be aware of hazards such as steep slopes overhanging limbs danger of fire when vehicle is operated over dry combustible organic material On steep slopes do not turn vehicle or stop and turn around always travel straight up and down control speed with service brake when going downhill Vehicle stopping distance increases when driving on wet grass dirt roads or loose surfaces when crossing streams or bodies of water that soak the brakes Remember to lightly apply brakes and use friction to dry braking surfaces VEHICLE CAPACITY To reduce possibility of severe injury or death due to the variety of Page 1 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings ways the vehicle may be used it is important the operator consider any potential hazards before use to prevent serious injury or death See GENERAL SPECIFICATIONS section of this man ual for load and seating capacity Never carry passengers in load bed The weight of driver and passenger plus any options or accessories must be deducted from total payload rating to determine load bed capacity Stopping distance increases as vehicle load increases Load weight can be misleading Loads cons
56. from accumulating Never fuel a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane water heaters and furnaces Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal Owner s Manual and Service Guide Page ix SAFETY INFORMATION Notes Page x Owner s Manual and Service Guide SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings GENERAL The following text is provided as recommended by part II of SAE J2258 DEC 2003 E Z GO strongly endorses the contents of this specification B 1 PART Il FOR THE CONTROLLING PARTY B 1 1 Maintenance and Operations B 1 1 1 Introduction B 1 1 1 1 Like other machines light utility vehicles can cause injury if improperly used or maintained Part II contains broad safety practices applicable to vehicle operations Before operation the controlling party shall follow such additional specific safety practices as may reasonably be required for safe operation B 1 1 1 2 Safety Survey The controlling party shall perform a safety survey of their premises periodically and as conditions warrant identify areas where vehicl
57. from the use of the material in this manual This vehicle conforms to the current applicable standard s for safety and performance requirements These vehicles are designed and manufactured for off road use They do not conform to Federal Motor Vehicle Safety Standards of the United States of America USA and are not equipped for operation on public streets Some commu nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi nances Refer to GENERAL SPECIFICATIONS for vehicle seating capacity Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease its stability or increase the speed beyond the factory specification Such modifications can cause serious personal injury or death Modifications that increase the speed and or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehicle Do not make any such modifications or changes The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment Additionally speed should be further moderated by the environmental conditions terrain and common sense GENERAL OPERATION Always Use the vehicle in a respon
58. ghly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings LIFTING THE VEHICLE Tool List Qty Required FIQOF JACK 1 Jack Stands ets ee o 4 GHIOGKS 4 prevent possible inju PNIS IN ry or death resulting from vehicle falling off jack be sure vehicle is on a firm and level surface Never get under vehicle while it is supported by a jack Use jack stands and test vehicle stability on stands Always place chocks in front and behind the wheels not being raised Use extreme care since vehi cle is extremely unstable during lifting process prevent possible injury or death from operating engine while vehicle is raised disengage 4 wheel drive and unlock front and rear differentials To reduce possibil ity of vehicle damage Do not raise vehicle by placing jack under front or rear aluminum differential cases Do not operate engine with 4 wheel drive or either differential locks engaged Never operate engine with CVT drive belt removed View From Underside of Vehicle Some servicing operations may require entire vehicle to be raised Ref Fig 23 on page 17 Fig 23 Lifting the Vehicle Insta
59. gth to operate this or similar vehicles and should not be permit ted to do so Alcohol drugs and many over the counter medications reduce ability of driver to operate vehicle safely Always review side effects of any medication with a doctor or pharmacist before operating vehicle If the vehicle is to be used in areas where steep slopes overhanging limbs or other adverse conditions may be encountered protective clothing and an approved motor cycle helmet are recommended for both operator and passenger Plan carefully before using vehicle to go significant dis tances over questionable terrain Remember that a one hour drive may take many hours to walk out should vehi cle run out of fuel or be stranded by becoming stuck on unsuitable terrain Respect private property and comply with all local laws and regulations governing use of utility vehicles RUN IN Check for oil or fuel leaks that could have developed in shipment from factory Avoid full throttle starts and rapid acceleration until engine has achieved operating temper ature All engines consume more oil than normal during the first hours of operation As internal moving parts are run in oil consumption should gradually decrease until rate of consumption stabilizes Check oil level See OIL LEVEL CHECK on page 18 Add oil if level on dipstick is at lower hole Do not overfill engine Too much oil CAUTION may cause smoking or allow oil to enter the air filter enclo
60. isting of dry sand fertilizer sod etc will when wet grossly overload vehicle and increase potential for roll over and vehicle damage Towing a loaded trailer reduces capacity of vehicle load bed Ref TOWING A TRAILER on page 12 MODIFICATIONS TO VEHICLE Changes to weight distri bution or center of gravi ty may make vehicle unstable or prone to roll over which could result in injury or death to operator or passenger Do not modify vehicle in any manner that will change weight distribution Changes to weight distribution or center of gravity may make it unstable or prone to roll over which could result in injury or death to operator or passenger Do not tamper with governor It is set for maximum safe vehicle speed Do not tamper with exhaust system It is matched with engine for optimum performance Removal of muffler or other modifications to exhaust sys tem will annoy others not improve performance of vehi cle increase possibility of starting a fire COMMON SENSE OPERATION To reduce possibility of severe injury or death to operator passenger or bystanders do not operate vehicle improperly and or irresponsibly If vehicle is operated improperly and or irresponsibly severe injury or death to operator passenger or bystand ers can occur All operators should possess a valid driver s license Page 2 Children may not have the skill judgement or stren
61. le under the influence of drugs or alcohol B 2 3 3 Safeguard the pedestrians at all times Do not drive vehicle in a manner that could endanger other persons Owner s Manual and Service Guide SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings B 2 3 4 Riding on the vehicle by persons other than the operator is authorized only on seat s provided by the vehicle manufacturer All parts of each person s body shall remain within the plan view outline of the vehicle while the vehicle is in motion B 2 3 5 When a vehicle is to be left unattended stop vehicle apply the parking brake turn off the control or ignition circuit and remove the key if provided Block the wheels if vehicle is on an incline B 2 3 6 Maintain a safe distance from potential haz ards B 2 3 7 Use only approved vehicles in hazardous locations as defined in the appropriate safety standards B 2 3 8 Report all accidents involving personnel building structures and equipment B 2 3 9 Do not add to or modify the vehicle B 2 3 10 Slow down or stop as conditions dictate and activate a sound producing warning device if so equipped at intersections and when visibility is obstructed at other locations B 2 3 11 Ascend or descend grades slowly avoid turning if possible normally travel straight up and down B 2 3 12 Under all travel conditions operate vehi
62. ll chocks in front and behind each front wheel Cen ter jack under flange on long axle tube Raise vehicle and See chart for viscosity allowed in extreme temperatures locate a jack stand under outer ends of rear axle tubes Ref Fig 24 on page 17 Lower jack and test stability of vehicle on two jack stands Center jack under front of frame Raise vehicle and posi tion jack stands under frame as shown Lower jack and test stability of vehicle on four jack stands Lower vehicle by reversing lifting sequence OIL Use detergent motor oil designed for 4 stroke engines The oil must be of high quality and meet API SF SG standards 0 10 Ref Ove 3 Air Temperature For most conditions 10W30 oil is recommended Ref Fig 24 on page 17 Fig 24 Recommended Oil Owner s Manual and Service Guide Page 17 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings OIL LEVEL CHECK To reduce possibility of engine damage CAUTION do not run engine with oil level too low Park vehicle on level surface shut off engine and wait a minute for oil to settle Lift seat remove dipstick and wipe clean Ref Fig 25 on page 18 Replace dipstick and remove again Observe level indi cated and if itis between upper and lower holes oil level is correct if it is at or below the lower hole remov
63. ng careful not to dam age plug If replacing spark plugs use only recommended type Ref Fig 22 on page 16 New plugs must be properly gapped before installation Install plugs by hand to reduce chance of cross thread ing When plug seats against engine e Tighten used plugs an additional 1 8 to 1 4 turn e Tighten new plugs an additional 1 2 turn ALTERNATOR BELT Vehicle may be equipped with an optional hi output alter nator Ref Fig 28 on page 20 It provides power neces sary to run a variety of equipment such as electric powered tools hi intensity lighting radio and winch ADJUSTING BELT Hardware involved 1 2 and 9 16 hex Special Tools Required Qty Torque wrench ft IDS en 1 Belt tension gauge eeeeeeeeeeeeee 1 Inspect belt for cracking or wear Replace if required Loosen top nut Loosen bottom bolt By hand or using a pry bar pull alternator belt tight and hand tighten bottom bolt Check belt tension Tighten to Ref Fig 28 on page 20 75 80 Ibs 34 36 kg tension for an existing belt or 90 110 165 41 50 kg tension for a new belt when using belt tension gauge Apply gauge half way between the two pulleys Or a maximum deflection of 1 2 13 mm for an existing belt or 3 8 1 cm for a new belt when gauging by hand Tighten bolt to 9 11 ft Ibs 12 15 Nm torque and nut to 18 20 ft Ibs 25 27 Nm
64. nt of cable and secure Engage drum by rotating knob until it snaps in place Never operate winch unless clutch is engaged To prevent damage to wire cable never hook cable to itself Always use a nylon sling Ref Fig 18 on page 11 Stay clear of winch cable and cable hook Place a heavy cloth jacket or blanket over cable to act as a damper should cable break when operating winch Ref Fig 18 on page 11 Remember that winch operation with engine off Will drain battery and may leave insufficient power to start vehicle Always let engine idle while using winch When operating winch keep entire area in view Never release free spool clutch while cable is under load Never work around winch drum or cable under tension Owner s Manual and Service Guide Sling Ref Wca 3 Fig 18 Use Nylon Sling and Install a Damper when Winching Unplug winch remote control before working on winch drum in order to prevent inadvertent opera tion Take up slack in cable slowly Stop winch before cable becomes tight and inspect all attachments such as winch attachment hook attachment nylon sling if required and load attachment Plug winch remote control into receptacle located on dash panel Ref Fig 19 on page 12 To unwind cable locate clutch knob on winch Ref Fig 19 on page 12 Pull out knob and rotate 90 to lock out Using handsaver bar pull cable from winch drum Leave at least five turns of cable on drum
65. ody and eyes with extended flushing with clear water Contact a phy sician immediately Any electrolyte spills should be neutralized with a solution of 2 teaspoons 10 ml sodium bicarbonate baking soda dissolved in 1 quart 1 liters of water and flushed with water Insulate metal aerosol containers of battery termi nal protectant to reduce chance of contacting bat tery terminals which could result in an explosion Always place entire vehicle on jack stands disen gage four 4 wheel drive and unlock front and rear differentials when performing a procedure requiring engine to run with vehicle in place and tires off ground Failure to do so will allow vehicle to itself off when supported by only two jack stands It is in the best interest of both vehicle owner and service technician to carefully follow procedures recommended in this manual Preventative maintenance applied at rec ommended intervals is the best guarantee for keeping vehicle both dependable and economical This vehicle will give years of satisfactory service provid ing it receives regular maintenance For appropriate ser vice intervals See PERIODIC SERVICE SCHEDULE on Page 14 page 15 For appropriate locations See LUBRICATION POINTS on page 21 CAUTION To prolong vehicle life some mainte nance items must be serviced more fre quently on vehicles used under severe driving conditions such as extreme temperatures extreme dust debris conditions
66. on for your vehicle provide vehicle model serial number and manufacture date code Ref Int 1 BEFORE INITIAL USE SERVICE OPERATION Remove protective plastic covering Check operation and brake fluid level Check air pressure see SPECIFICATIONS Fill tank with correct fuel Check oil level Record key number and store in a safe location Fig 1 Initial Service Chart Read understand and follow safety label on driver side fender well Ref Appendix A Be sure you understand how to safely operate vehicle and its equipment Owner s Manual and Service Guide Maintaining good performance depends to a large extent on owner operator To reduce possibility of INI severe injury or death do not use vehicle improperly such as engaging in horseplay or attempt ing to perform tasks for which it is not designed This vehicle is a utility vehicle It is NOT a toy or an all terrain vehicle ATV Before new vehicle is put into operation items shown in INITIAL SERVICE CHART must be performed Ref Fig 1 on page 1 CAPABILITIES TERRAIN To reduce possibility of severe injury or death while driving be aware of the following Environmental hazards such as steep slopes overhanging limbs etc Danger of fire when vehicle is operated over dry combustible organic material Vehicle is designed for improved roads not public high ways established trails open terrain
67. or 14 Max 25 or 14 Max Fig 43 Vehicle Incline Specifications Owner s Manual and Service Guide Page 31 GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER Approx 25 6 7 8 m Ref Dim 3 3 Fig 44 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance Page 32 Owner s Manual and Service Guide VEHICLE WARRANTIES VEHICLE WARRANTIES Owner s Manual and Service Guide Page 33 VEHICLE WARRANTIES Page 34 Owner s Manual and Service Guide VEHICLE WARRANTIES EMISSION CONTROL SYSTEM WARRANTY STATEMENT Owner s Defect Warranty Rights and Obligations Refer to the HONDA Emission Control System Warranty sheet provided with vehicle for information ENGINE OWNER WARRANTY POLICY Refer to the Warranty sheet provided with vehicle for Engine Warranty information INTERNATIONAL WARRANTY STATEMENT Refer to the International Warranty sheet provided with vehicle for information Owner s Manual and Service Guide Page 35 VEHICLE WARRANTIES Notes Page 36 Owner s Manual and Service Guide DECLARATION CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY Declaration of Conformity is packaged with vehicle For additional information contact Ransomes Jacobsen Limited West Road Ransomes Europark Ipswich England IP3 9TT Owner s Manual and Service Guide Page 37 DECLARATION CONFORMITY
68. ot be operated until it has been restored to safe operating con dition Follow Operator s Manual B 2 5 3 f during operation the vehicle becomes unsafe in any way the matter shall be reported immedi ately to the controlling party and the vehicle shall not be operated until it has been restored to safe operating con dition B 2 5 4 Repairs and adjustments shall only be per formed by specifically trained and authorized persons B 3 Maintenance Practices B 3 1 Maintenance Procedures B 3 1 1 Maintenance and inspection of all vehicles shall be performed in conformance with the vehicle man ufacturer s recommendations and the following practices if applicable Only trained and authorized personnel shall be permitted to maintain repair adjust and inspect vehi cles a A scheduled preventive maintenance lubrication and inspection system shall be followed b Before undertaking maintenance or repair follow the vehicle manufacturer s recommendations for immobi lizing the vehicle c Chock wheels and block chassis before working underneath it d Before disconnecting any part of the fuel system of a gasoline powered vehicle be sure shutoff valve if so equipped is closed and run engine until fuel system is depleted engine stops running and is allowed to cool Before disconnecting any part of the engine fuel system of a diesel powered vehicle be sure shutoff valve if so Page xiii SAFETY INFORMATION Read
69. park Do not handle gasoline in an area that is not ade quately ventilated Always wear safety glasses to prevent possible eye injury from gasoline or gasoline vapor Fuel filter is located at front of engine above fan cover Ref Fig 30 on page 21 Inspect it for dirt and or water Replace if significant amount is found To replace use a pair of pliers to move clamps off ends of filter Remove hose coming from fuel tank first and plug Remove filter from hose going to fuel pump and discard Orient direction of new fuel filter according to NOTE FLOW arrow on side of filter Install new fuel filter and reposition clamps over inlet and outlet Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Ref Ffi 1 Fig 30 Fuel Filter LUBRICATION POINTS Do not use more than three 3 pumps of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components Add no more than two or three pumps of grease to fit tings shown Ref Fig 31 on page 21 More than three pumps in a grease fitting could damage seals allowing contamination of grease sensitive components BATTERY CAUTION To reduce possibility of discharging battery and leaving insufficient reserve to
70. procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle Support the vehicle using wheel chocks and jack stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions Empty the fuel tank or plug fuel hoses to prevent fuel leakage Maintain the vehicle in an area away from exposed flame or persons who are smoking Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated Test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic Replace damaged or missing warning caution or information labels Keep complete records of the maintenance history of the vehicle The manufacturer cannot anticipate all situations therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic Page viii Owner s Manual and Service Guide SAFETY INFORMATION VENTILATION Always store gasoline vehicles in a well ventilated area Ventilation prevents gasoline fumes
71. s sss seen 31 Fig 44 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance 32 33 EMISSION CONTROL SYSTEM WARRANTY STATEMENT 35 ENGINE OWNER WARRANTY POLICY 4 4 0 nnne nnns 35 INTERNATIONAL WARRANTY STATEMENT nnmnnn 35 DECLARATION OF CONFORMITY EUROPE 37 LABELS 220 da egre 1 Fig 45 Label Locations anerian ina AA EEEE te Fa oen Appendix A 3 Fig 46 Pictogram Appendix A 4 Fig 47 Pictogram Definitlons one roce eee aee er dye ed Appendix A 5 Fig 48 Pictogram 0 00 00000000 seien senis Appendix A 6 Fig 49 Pictogram Definitions eese seii Appendix A 7 Owner s Manual and Service Guide Page v TABLE CONTENTS Notes Page vi Owner s Manual and Service Guide SAFETY INFORMATION
72. sible manner and maintain the vehicle in safe operating condition Read and observe all warnings and operation instruction labels affixed to the vehicle Follow all safety rules established in the area where the vehicle is being operated Reduce speed to compensate for poor terrain or conditions Owner s Manual and Service Guide Page vii SAFETY INFORMATION Apply service brake to control speed on steep grades Maintain adequate distance between vehicles Reduce speed in wet areas Use extreme caution when approaching sharp or blind turns Use extreme caution when driving over loose terrain Use extreme caution in areas where pedestrians are present MAINTENANCE Always Maintain the vehicle in accordance with the manufacturer s periodic service schedule Ensure that repairs are performed by those that are trained and qualified to do so Follow the manufacturer s maintenance procedures for the vehicle Be sure to disable the vehicle before performing any maintenance Disabling includes removing the key from the key switch and removal of a battery wire Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring Remove the battery or cover exposed terminals with an insulating material Use specified replacement parts Never use replacement parts of lesser quality Use recommended tools Determine that tools and
73. ssibility of engine damage do not operate engine until oil pressure is corrected Do not overfill engine Too much oil may cause smoking or allow oil to enter air filter enclosure Owner s Manual and Service Guide If oil level is below ADD mark on dipstick add oil to bring level to FULL mark Drive vehicle a short distance and check oil pressure If oil pressure light does not come on continue to use vehicle LIGHT SWITCHES Headlight switch is located to left of steering wheel on dash panel Ref Fig 12 on page 7 Headlights operate independently of ignition switch Headlight Accessory Ref Lsw 1 Switch Fig 12 Light Switches Accessory switch is located to right of headlight switch It may operate accessory items if equipped indepen dently of headlights and ignition switch 12 VOLT POWER OUTLET a lt E in N i SSS S KU ue MSN NN f b f 2 1 N 7 N N N N F KAN X S 22074 M NN Ref Pow 2 f Fig 13 Power Outlet Page 7 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Overuse of accessories may drain bat tery and leave insufficient reserve to start vehicle A 12 volt power outlet r
74. sure NOTE Both the oil dipstick and fill cap must be in place before operating the engine Failure to install the dipstick and fill cap will result in oil becoming contam inated and or being discharged into the engine compartment Oil should be changed while engine is warm at end of run in period Ref Periodic Service Schedule on page 15 Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings CONTROLS amp INDICATORS SERVICE BRAKE PEDAL Ref Sbp 1 Fig 2 Service Brake Pedal The service brake is a hydraulic front disc rear drum brake system Push foot operated service brake pedal to activate wheel brakes slowing or stopping vehicle Ref Fig 2 on page 3 PARKING BRAKE CAUTION Drive vehicle with park brake fully released Failure to do so will prema turely wear rear brakes The park brake is a mechanical system using rear drum service brakes To engage pull park brake handle up An indicator light will illuminate in gauge cluster reminding operator to release park brake before driving Ref Fig 3 on page 3 To disengage pull up slightly and push in release button at end of handle then fully lower park brake handle Owner s Manual and Service Guide Ref Pbh 2 Fig 3 Park Brake and Indicator CHOKE Starting a cold
75. tc will require use of a commercially available vinyl rubber cleaner Painted surfaces require frequent washing with luke warm or cold water and mild detergent Occasional cleaning and waxing with non abrasive prod ucts designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on underbody of vehicle These materials will cause corrosion of underbody parts unless flushed occa sionally with plain water Thoroughly clean any areas where mud or other debris can collect Sediment packed in closed areas should be loosened to ease it s removal taking care not to chip or otherwise damage paint Owner s Manual and Service Guide NOTE If engine does not start or runs improperly after washing remove spark plug wires by pulling the spark plug boots never the wires Dry all connections with forced air Reinstall wires CARE PRODUCTS To help maintain the vehicle there are several products available through local Distributors authorized Branches or the Service Parts Department e Touch up paint specially formulated to match vehi cle colors for use on both metal and molded plas tic bodies P N 28140 G and 28432 G for solid colors 75831 G for camouflage colors Battery Protectant formulated to form a long term flexible non tacky dry coating that will not crack peel or flake over a
76. tenance instruction plates tags and safety labels are changed accordingly t Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a specification at least equal to that provided in the original equipment End of SAE J2258 DEC 2003 Part Il Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings WELCOME Thank you for purchasing this utility vehicle Before driv ing vehicle we ask you to spend some time reading this Owner s Manual and Service Guide and the Owner s Manual provided by Honda Motor Co Ltd These manu als contain information to assist you in safe operation of vehicle They will also assist you in maintaining vehicle Some illustrations may show items that are optional Most service procedures in this guide can be accom plished using common automotive hand tools Other wise contact your service representative to schedule maintenance performed by a technician Any servicing must be done per the Periodic Service Schedule found in this manual and the Maintenance Schedule found in the engine manual Service Parts Manuals Technician s Repair and Service Manuals and engine Repair Manuals are available from a local Distributor an authorized Branch or the Service Parts Department When ordering parts or requesting informati
77. the vehicle according to Section 5 and all other applicable parts of this document and vehicle operator s manual B 2 2 Operator s Training B 2 2 1 The controlling party shall develop and con duct an operator training program B 2 2 2 Successful completion of the operator train ing program by the operator shall be required before operation of the vehicle The program shall be presented in its entirety to all new operators and not condensed for those claiming previous experience B 2 2 3 The controlling party should include as a minimum in the operator training program the following a Instructional material provided by the vehicle man ufacturer including vehicle operator s manual b Emphasis on safety of passengers vehicle opera tor and other persons c Safe loading practice including securing material loads d General safety rules contained within this docu ment and the additional specific rules determined by the controlling party in accordance with this document and why they were formulated e Introduction of equipment control locations and functions and explanation of how they work when used properly and the consequences of improper use expla nation of surface conditions grade and other conditions of the environment which could affect vehicle operation f Operator competency evaluations B 2 3 Operator Responsibility 2 3 1 Read and follow operator s manual B 2 3 2 Do not operate vehic
78. these NOTES CAUTIONS and WARNINGS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous Improper service or repair may damage the vehicle or render it unsafe Engine exhaust from this NUI NE product contains chemi cals known in certain quantities to cause cancer birth defects or other reproductive harm TE The exhaust emissions of this vehicles engine complies with regulations set forth by the Envi ronmental Protection Agency EPA of the United States of America USA at time of manufacture Significant fines could result from modifications or tampering with the engine fuel ignition or air intake systems 0 Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling NOTE This spark ignition system meets all require ments of the Canadian Interference Causing Equipment Regulations AWARNINGA Ce syst me d allumage par tincelle de v hicule respecte toutes les exigences du R glement sur le mat riel brouilleur du Canada Read and understand the following warnings before attempting to operate the vehicle To prevent personal AWARNING A injury or death observe the following When vehicle is to be left unattended engage parking brake move direction selector to F forward position turn key to OFF position and remove key NOTE Drive vehicle only as fast as terrain and safety
79. tial lock sole noid s will be activated Ref Fig 6 on page 4 and Ref Fig 8 on page 5 Over time the solenoids will drain the battery to a point where the vehicle will be unable to be started DIRECTION SELECTOR CAUTION To reduce possibility of drivetrain dam age vehicle must completely stop before moving direction selector Ref Fig 6 on page 4 Direction selector offers choice of three positions for ward neutral and reverse Ref Fig 6 on page 4 Selector must be in neutral to start engine Page 4 Fig 5 Ignition Switch Forward Engaged 73777G01 Reverse Neutral Disengaged Ref Dsl 5 Fig 6 Direction Selector and Differential Locks Always bring vehicle to a complete stop before changing selection Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Place direction selector in forward and set park brake when leaving vehicle unattended 2WD AWD SELECTOR CAUTION To reduce possibility of drivetrain dam age vehicle must completely stop before switching between two wheel and four wheel drive This lever allows choice of two wheel or four wheel drive Ref Fig 7 on page 5 Always bring vehicle to a complete stop before changing selection When four wheel drive is selected an indicator light in gauge cluster
80. tic spray bottle In addi tion special attention should be paid to metal compo nents adjacent to battery which should also be sprayed with solution Allow solution to sit for at least three min utes Use a soft bristle brush or cloth to wipe battery removing any residue that could contribute to self dis charge of battery Rinse entire area with clean water Do not use a pressure washer JUMP STARTING To reduce possibility of severe injury or death follow jump starting instructions explicitly To reduce possibility of permanent damage to battery promptly charge a discharged battery Turn key switch to OFF Page 22 1 1 2 gallons 6 liters Clear Water C 3 1 quart lt _ gt 1 liter Clear Water 2 Teaspoons 10 ce Sodium OR Baking Soda 5 1 4 Cup 60 ml Sodium Bicarbonate Baking Soda Bicarbonate Non Metallic Wand Plastic 2 Gallon Spray 7 5 liter Bottle Garden Sprayer Ref Pns 1 Fig 32 Cleaning Battery Place direction selector in neutral Attach one end of red positive cable to positive post of weak battery and other end to positive post of strong bat tery Ref Fig 33 on page 23 Attach one end of black negative cable to negative post of strong battery and other end to vehicle frame Start vehicle as usual Once started disconnect cables in reverse order Charge battery as soon as possible Ref BATTERY on page 21 VEHICLE CLEANING A
81. ve roll back when starting the vehicle on a hill Release park brake while depressing accelerator with right foot and release the service brake by lifting left foot Page 8 COASTING To reduce possibility of severe injury or death from coasting at above recommended speeds limit speed with service brake On steep hills it is possible for the vehicle to coast at greater than normal speeds encountered on a flat sur face To reduce possibility of drivetrain damage or loss of vehicle control speeds should be limited to no more than the maximum governed speed on level ground See GENERAL SPECIFICATIONS Limit speed by applying service brake LOAD BED A manual lift bed is standard An electric lift is optional To reduce possibility of severe injury or death read understand and fol low Warning label affixed inside load bed See Appen dix A Failure to follow label may result in vehicle tipping over Operate vehicle with awareness of load Do not permit anyone to ride in load bed Before operating verify no one is behind vehicle Never fill a gas can while it is in load bed Static dis charge could ignite gasoline vapor causing an explo sion A load bed warning label is affixed to inside front of bed See Appendix A For safe operation of vehicle this label must be understood See load bed warning label for maximum load Load must be positioned in bed as far forward as possibl
82. vided at bottom of differential case Check Fill Plug Drain Plug Fig 37 Checking Axle Lubricant Page 26 TRANSFER CASE The transfer case is provided with an oil level check fill plug located on passenger side at rear of case Unless leakage is evident an annual check is sufficient CHECKING LUBRICANT LEVEL Hardware involved 9 16 hex head plug Clean check fill plug and area around it Ref Fig 38 on page 26 Remove plug Correct lubricant level is just below bottom of threaded hole If lubricant is to be added use a funnel and add correct type lubricant slowly until it starts to seep from hole See Checking Transfer Case Lubricant on page 26 Install plug and tighten to 20 25 ft Ibs 27 34 Nm To replace lubricant a drain plug is provided at bottom of transfer case Ref Tcf 1 Fig 38 Checking Transfer Case Lubricant AIR INTAKE AND COOLING FINS To reduce possibility of FN Cy INE fire engine parts should be kept clean to reduce risk of overheating and ignition of accumulated debris Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings CAPACITIES Fuel Tank 6 7 gal 25 4 liters unleaded 87 octane or higher 1 59 quarts 1 5 liters crankcase only Engine Oil 1 90 quarts 1 8 liters crankcase and filter 10W30 usually See OIL on
83. will illuminate to verify engagement Vehicle should be left in two wheel drive when unat tended Two Wheel Drive VEN bot Four Wheel Drive 4 NOS D 1 5 AT HOURS n lt wa lt gt E z ND e 46 see d d Q o J J NN IH HIM aS Ref 4wd 1 Fig 7 2WD AWD Selector DIFFERENTIAL LOCK To reduce possibility of N severe injury or death from loss of control Owner s Manual and Service Guide Engaged Rear Differential Lock Switch Front Differential Lock Switch Disengaged IT ADT gt 6 48 a e pi Q J NN bi Ref Dif 1 uid Fig 8 Differential Lock while vehicle is in motion do not engage front differ ential lock while turning steering wheel Lock engage ment may abruptly force steering wheel to center causing loss of grip on wheel Front and rear differentials are equipped with electrically actuated locks Ref Fig 8 on page 5 With a differential unlocked if one tire looses traction the vehicle will likely become stuck With a differential locked power is dis tributed to both tires at all times and greatly increases traction Locks are not intended to be engaged at all
84. winch connector from wire harness To move winch from one end of vehicle to other remove spring pin pull out clevis pin and pull winch mount tube out of receiver Move to opposite end of vehi cle and install winch mount tube in receiver Secure by inserting clevis pin and securing with spring pin Plug winch connector into wire harness WINCH OPERATION To reduce possibility of severe injury or death the following warnings must be observed before attempting to operate winch Always wear thick leather gloves when handling wire cable Replace frayed wire cable with a direct factory replacement only Never operate winch with less than five 5 full turns of cable around drum Ref Fig 19 on page 12 If winch motor stalls from overloading do not continue applying power to winch The wire cable may become overstressed Do not attempt to pull loads exceeding 1500 Ibs 680 kg To pull out cable free spool clutch knob must be used Pull out and rotate knob If cable is under any load clutch may not release easily Jog out some cable to release tension and operate clutch Owner s Manual and Service Guide OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Winch shown mounted at front of vehicle Spring Pin Clevis Pin Ref Wmt 2 Fig 17 Mounting Winch Pull out desired amou
85. xplanation URNS Werte pee ee Of These PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY Pictograms 24880G1 See Following Pages 14 For Explanation Of These Pictograms 1 4099 601 74099901 Fig 45 Label Locations Owner s Manual and Service Guide Appendix A 3 LABELS AND 5 WARNING READ MANUAL FORMAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL READ MANUAL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAPACITY WARNING USE CAUTION IN INCLEMENT WEATHER DO NOT RIDEIN LOAD BED WARNING DO NOT OPERATE UNDERTHE INFLUENCE OF DRUGS ORALCOHOL DANGER OF MAXIMUM CROSS EXPLOSION HILL RAMP ANGLE 3 5 DONOTFILL ASSPECIFIED n GAS CAN gt IN LOAD BED WARNING MAXIMUM CROSS HILL RAMP ANGLE 5 SPECIFIED WARNING MAXIMUM LAOD amp CENTER OF GRAVITY KEEP LOAD AS FAR FORWARD AS POSSIBLE DO NOT RIDE IN LOAD BED LOAD WTH HIGH CENTER OF GRAVITY COULD RESULT IN TIP OVER LOAD CENTER OF GRAMTY MAXIMUM KEEP HANDS amp FINGERS AWAY FROM DUMP BED HEIGHT DO NOT STAND BEHIND DUMP BED Fig 46 Pictogram Definitions Appendix A 4 Owner s Manual and Service Guide CLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE UNLEAD GASOLINE DO NOT SPILL FUEL ONA HOT ENGINE GROUND FUEL PUMP LOW OIL PRESSURE NEGATIVE GROUND BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSIO

E-Z-GO 602080 Automobile User Manual

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