Ezgo 605584-GB Owner`s manual

605584-GB
OWNER’S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED
TXT GOLF CARS & PERSONAL VEHICLES
REVISED NOVEMBER 2006
S AF E T Y
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.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent 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 drivetrain 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.
For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.
Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
BATTERIES
CONTAIN LEAD
AND RELATED PARTS
!
< 14˚ 25%
DO NOT
DRIVE ACROSS
SLOPES IN
EXCESS OF 14˚
WASH HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
Be sure that this manual remains as part of the permanent service record should the vehicle be sold.
Throughout this guide NOTE, CAUTION and WARNING
will be used.
A NOTE indicates a condition that should be observed.
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 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 product contains
chemicals known, in certain quantities, to
cause cancer, birth defects, or other reproductive harm.
The exhaust emissions of this vehicles’ engine complies with
regulations set forth by the Environmental 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.
Battery posts, terminals and related accessories contain lead and lead compounds. Wash
hands after handling.
This spark ignition system meets all requirements of the Canadian Interference-Causing
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
OWNER’S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED
TXT GOLF CARS & PERSONAL VEHICLES
TXT GOLF CAR (9 hp, CE, CARB)
FREEDOM™ (9 hp, CE, CARB, SE, LE, HP)
SHUTTLE 2 + 2 ( 9 hp, CE, CARB)
Starting Model Year 2007
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
information 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 & 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: 001-706-798-4311, FAX: 001-706-771-4609
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852
Owner’s Manual and Service Guide
Page i
GENERAL INFORMATION
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° F (-60° C).
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Owner’s Manual and Service Guide
TABLE OF CONTENTS
SAFETY ................................................................................................................Inside Covers
GENERAL INFORMATION ....................................................................................................... ii
SAFETY INFORMATION ........................................................................................................... v
BEFORE INITIAL USE .............................................................................................................. 1
Fig. 1 Initial Service Chart ...................................................................................................................... 1
CONTROLS AND INDICATORS ............................................................................................... 2
KEY/LIGHT SWITCH ........................................................................................................................................... 2
Fig. 2 Key / Light Switch ........................................................................................................................ 2
DIRECTION SELECTOR ..................................................................................................................................... 2
Fig. 3 Direction Selector ........................................................................................................................ 2
CHOKE ................................................................................................................................................................ 2
LOW OIL PRESSURE INDICATOR LIGHT ......................................................................................................... 2
Fig. 4 Choke .......................................................................................................................................... 2
FUEL GAUGE ...................................................................................................................................................... 2
ACCELERATOR PEDAL ..................................................................................................................................... 3
Fig. 5 Accelerator, Brake and Horn Controls ......................................................................................... 3
COMBINATION SERVICE AND PARK BRAKE PEDAL ..................................................................................... 3
HORN .................................................................................................................................................................. 3
Fig. 6 Horn Button .................................................................................................................................. 3
OPERATING THE VEHICLE ..................................................................................................... 4
RUN-IN ................................................................................................................................................................ 4
Fig. 7 Check Oil Level on Dipstick ......................................................................................................... 5
COLD STARTING ................................................................................................................................................5
STARTING AND DRIVING .................................................................................................................................. 5
STARTING THE VEHICLE ON A HILL ................................................................................................................ 5
COASTING .......................................................................................................................................................... 5
FUEL .................................................................................................................................................................... 5
Fig. 8 Fueling ......................................................................................................................................... 6
BATTERY ............................................................................................................................................................ 6
LABELS AND PICTOGRAMS .............................................................................................................................6
SUN TOP AND WINDSHIELD .............................................................................................................................6
VEHICLE CLEANING AND CARE ............................................................................................ 7
VEHICLE CLEANING .......................................................................................................................................... 7
REPAIR ...................................................................................................................................... 8
LIFTING THE VEHICLE ...................................................................................................................................... 8
Fig. 9 Lifting the Vehicle ........................................................................................................................ 8
WHEELS AND TIRES ......................................................................................................................................... 8
Tire Repair ..................................................................................................................................................... 8
Wheel Installation........................................................................................................................................... 9
Fig. 10 Wheel Installation ...................................................................................................................... 9
LIGHT BULB REPLACEMENT ............................................................................................................................ 9
Fig. 11 Headlight, Turn Signal & Marker Light Bulb Replacement ...................................................... 10
Fig. 12 Tail and brake light bulb replacement ...................................................................................... 10
FUSE REPLACEMENT ..................................................................................................................................... 10
VEHICLE WITH A DISCHARGED BATTERY ................................................................................................... 10
TRANSPORTING VEHICLE .................................................................................................... 10
TOWING ............................................................................................................................................................ 10
NEUTRAL LOCK ............................................................................................................................................... 11
On Rear Axle................................................................................................................................................11
Fig. 13 Neutral Lock on Rear Axle ....................................................................................................... 11
On Direction Selector ................................................................................................................................... 11
Fig. 14 Neutral Lock on Direction Selector .......................................................................................... 11
HAULING ........................................................................................................................................................... 12
SERVICE AND MAINTENANCE ............................................................................................. 12
Owner’s Manual and Service Guide
Page iii
TABLE OF CONTENTS
SERIAL NUMBER LABEL & LOCATION .......................................................................................................... 13
Fig. 15 Serial Number Plate & Location .............................................................................................. 13
PERIODIC SERVICE SCHEDULE ................................................................................................................... 14
Fig. 16 Periodic Service Schedule ...................................................................................................... 14
TIRE INSPECTION ........................................................................................................................................... 15
CHECKING THE OIL LEVEL ............................................................................................................................ 15
Fig. 17 Clean Entire Dipstick ............................................................................................................... 16
Fig. 18 Check Oil Level on Dipstick ..................................................................................................... 16
CHANGING THE OIL ........................................................................................................................................ 16
Fig. 19 Oil Viscocity Chart ................................................................................................................... 16
Fig. 20 Clean Top of Engine ................................................................................................................ 16
Fig. 21 Remove Oil Filter ..................................................................................................................... 17
Fig. 22 Clean Oil Filter ......................................................................................................................... 17
Fig. 23 Blowing Out Oil Filter ............................................................................................................... 17
Fig. 24 Add Engine Oil ........................................................................................................................ 17
STARTER/GENERATOR BELT TENSION ....................................................................................................... 18
Fig. 25 Checking Belt Tension with Gauge ......................................................................................... 18
Fig. 26 Checking Belt Tension Manually ............................................................................................. 18
Fig. 27 Adjusting Belt Tension ............................................................................................................. 18
BATTERY CLEANING ...................................................................................................................................... 18
Fig. 28 Preparing Acid Neutralizing Solution ....................................................................................... 19
BRAKES ............................................................................................................................................................ 19
Fig. 29 Typical Brake Performance Test ............................................................................................. 19
AIR INTAKE AND COOLING FINS ................................................................................................................... 20
Fig. 30 Cleaning Air Intake .................................................................................................................. 20
Fig. 31 Cleaning the Cooling Fins ....................................................................................................... 20
REAR AXLE ...................................................................................................................................................... 20
Fig. 32 Add, Check and Drain Rear Axle Lubricant ............................................................................. 20
AIR CLEANER INSPECTION AND REPLACEMENT ....................................................................................... 21
.......................................................................................................................................................................... 21
Fig. 33 Canister Type Air Cleaner ....................................................................................................... 21
LUBRICATION .................................................................................................................................................. 21
Fig. 34 Lubrication Points .................................................................................................................... 21
SPARK PLUGS ................................................................................................................................................. 21
DIRECTION SELECTOR (Dual Cable system) ................................................................................................. 22
Fig. 35 Shift Cable Adjustment ............................................................................................................ 22
PROLONGED STORAGE ................................................................................................................................. 22
HARDWARE ..................................................................................................................................................... 22
Fig. 36 Torque Specification ................................................................................................................ 23
CAPACITIES AND REPLACEMENT PARTS ................................................................................................... 23
Fig. 37 Capacities and Replacement Parts ......................................................................................... 23
GENERAL SPECIFICATIONS ................................................................................................ 25
TXT- GASOLINE ............................................................................................................................................... 26
TXT GASOLINE - FREEDOM™ SE .................................................................................................................. 27
TXT GASOLINE - FREEDOM™ LE .................................................................................................................. 28
TXT GASOLINE - FREEDOM™ HP SE ............................................................................................................ 29
TXT GASOLINE - FREEDOM™ HP LE ............................................................................................................ 30
TXT GASOLINE - SHUTTLE 2+2 ..................................................................................................................... 31
Fig. 36 Vehicle Dimensions ................................................................................................................. 32
VEHICLE WARRANTIES ........................................................................................................ 35
DOMESTIC WARRANTY .................................................................................................................................. 36
CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT ......................................... 39
LABELS AND PICTOGRAMS .............................................................................. Appendix A-1
DECLARATION OF CONFORMITY (EUROPE ONLY) ....................................... Appendix B-1
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Owner’s Manual and Service Guide
SA FE TY IN F O RM AT ION
SAFETY INFORMATION
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:
Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-ZGO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z-GO-manufactured
vehicle is modified an any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER
FERERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of
Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer
MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for
LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the
requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applicable in the
places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final
Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.
E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.
The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE OPERATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE
REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-ZGO, I am directing that E-Z-GO Branch personnel, Distributors and Dealers advise all customers to adhere to this
SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has reason to believe may be operated in personal transportation applications.
Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or
through the Internet at the website for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
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 previously 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 from the
Owner’s Manual and Service Guide
Page v
SAFETY IN FOR MATI O N
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 communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances.
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 responsible 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.
• 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.
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SA FE TY IN F O RM AT ION
• Use specified replacement parts. Never use replacement parts of lesser quality.
• Use recommended tools.
• Determine that tools and 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.
VENTILATION
Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes 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.
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SA FE TY IN F O RM AT ION
Notes:
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Owner’s Manual and Service Guide
SA FE TY IN F O RM AT ION
GENERAL
The following text is provided as recommended by part II of ANSI/ITSDF B56.8-2006. E-Z-GO strongly endorses the
contents of this specification.
PART II
FOR THE USER
4 GENERAL SAFETY PRACTICES
4.1
Introduction
4.1.1 Like other machines, carriers can cause injury if improperly used or maintained. Part II contains broad safety
practices applicable to carrier operations. Before operation, the user shall establish such additional specific safety
practices as may reasonably be required for safe operation.
4.2
Stability
4.2.1
Experience has shown that carriers which comply with the provisions stated in para. 7.3.9 are stable when
properly operated and when operated in accordance with specific 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 of the conditions which may affect stability
are failure of the user to follow safety practices; also, ground and floor conditions, grade, speed, loading, the operation
of the carrier with improper loads, battery weight, dynamic and static forces, and the judgement exercised by the carrier operator.
(a) The user shall train carrier operators to adhere strictly to the operating instructions stated in this Standard.
(b) The user shall survey specific operating conditions and environment, and establish and train carrier operators to
comply with additional, specific safety practices.
4.3
Nameplates, Markings, Capacity, and Modifications
4.3.1 The user shall maintain in a legible condition all nameplates, warnings, and instructions which are supplied
by the manufacturer.
4.3.2 The user shall not perform any modification or addition which affects capacity or safe operation, or make any
change not in accordance with the owner’s manual without the manufacturer’s prior written authorization. Where
authorized modifications have been made, the user shall ensure that capacity, operation, warning, and maintenance
instruction plates, tags, or decals are changed accordingly.
4.3.3 As required under paras. 4.3.1 or 4.3.2, the manufacturer shall be contacted to secure new nameplates,
warnings, or instructions which shall then be affixed in their proper place on the carrier.
4.4
Fuel Handling and Storage
4.4.1 The user shall supervise the storage and handling of liquid fuels (when used) to be certain that it is in accordance with appropriate paragraphs of ANSI/NFPA 505 and ANSI/NFPA 30.
4.4.2 Storage and handling of liquefied petroleum gas fuels shall be in accordance with appropriate paragraphs of
ANSI/NFPA 505 and ANSI/NFPA 58. If such storage or handling is not in compliance with these standards, the user
shall prevent the carrier from being used until such storage and handling is in compliance with these standards.
4.5
Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers
4.5.1 The user shall require battery changing and charging facilities and procedures to be in accordance with
appropriate paragraphs of ANSI/NFPA 505.
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SAFETY IN FOR MATI O N
4.5.2 The user shall periodically inspect facilities and review procedures to be certain that appropriate paragraphs
of ANSI/NFPA 505, are strictly complied with, and shall familiarize carrier operators with it.
4.6
Hazardous Locations
4.6.1 The user shall determine the hazard classification of the particular atmosphere or location in which the carrier is to be used in accordance with ANSI/NFPA 505.
4.6.2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI/
NFPA 505.
4.7
Lighting for Operating Areas
4.7.1 The user, in accordance with his responsibility to survey the environment and operating conditions, shall
determine if the carrier requires lights and, if so, shall equip the carrier with appropriate lights.
4.8
Control of Noxious Gases and Fumes
4.8.1 When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall
be maintained within limits specified in the American Conference of Governmental Industrial Hygienists publication,
“Threshold Limit Values for Chemical Substances and Physical Agents in the Workroom Environment”. This shall be
accomplished by ventilation provided by the user, and/or the installation, use, and proper maintenance of emission
control equipment recommended or provided by the manufacturer of the equipment.
4.9
Warning Device(s)
4.9.1 The user shall make periodic inspections of the carrier to be certain that the sound-producing and/or visual
device(s) are maintained in good operating condition.
4.9.2 The user shall determine if operating conditions require the carrier to be equipped with additional sound-producing and/or visual devices and be responsible for providing and maintaining such devices, in accordance with the
manufacturer’s recommendations.
5 OPERATING SAFETY RULES AND PRACTICES
5.1
Personnel and Burden Carrier Operator Qualifications
5.1.1 Only persons who are trained in the proper operation of the carrier shall be authorized to operate the carrier.
Operators shall be qualified as to visual, auditory, physical, and mental ability to safely operate the equipment according to Section 5 and all other applicable parts of this Standard.
5.2
Personnel and Burden Carrier Operators’ Training
5.2.1
The user shall conduct an operators’ training program.
5.2.2 Successful completion of the operators’ training program shall be required by the user before operation of
the carrier. The program shall be presented in its entirety to all new operators and not condensed for those claiming
previous experience.
5.2.3
The user should include in the operators’ training program the following:
(a) instructional material provided by the manufacturer;
(b) emphasis on safety of passengers, material loads, carrier operator, and other employees;
(c) general safety rules contained within this Standard and the additional specific rules determined by the user in
accordance with this Standard, and why they were formulated;
(d) introduction of equipment, control locations and functions, and explanation of how they work when used properly
and when used improperly, and surface conditions, grade, and other conditions of the environment in which the carrier
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SA FE TY IN F O RM AT ION
is to be operated;
(e) operational performance tests and evaluations during, and at completion of, the program.
5.3
Personnel and Burden Carrier Operator Responsibility
5.3.1
5.4
Operators shall abide by the following safety rules and practices in paras. 5.4, 5.5, 5.6, and 5.7.
General
5.4.1
Safeguard the pedestrians at all times. Do not drive carrier in a manner that would endanger anyone.
5.4.2 Riding on the carrier by persons other than the operator is authorized only on personnel seat(s) provided by
the manufacturer. All parts of the body shall remain within the plan view outline of the carrier.
5.4.3 When a carrier is to be left unattended, stop carrier, apply the parking brake, stop the engine or turn off
power, turn off the control or ignition circuit, and remove the key if provided. Block the wheels if machine is on an
incline.
5.4.4 A carrier is considered unattended when the operator is 25 ft. (7.6 m) or more from the carrier which remains
in his view, or whenever the operator leaves the carrier and it is not within his view. When the operator is dismounted
and within 25 ft. (7.6 m) of the carrier still in his view, he still must have controls neutralized, and the parking brake(s)
set to prevent movement.
5.4.5
Maintain a safe distance from the edge of ramps and platforms.
5.4.6
Use only approved carriers in hazardous locations, as defined in the appropriate safety standards.
5.4.7
Report all accidents involving personnel, building structures, and equipment.
5.4.8
Operators shall not add to, or modify, the carrier.
5.4.9 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles, access to stairways, or fire equipment.
5.5
Traveling
5.5.1 Observe all traffic regulations, including authorized speed limits. Under normal traffic conditions keep to the
right. Maintain a safe distance, based on speed of travel, from a carrier or vehicle ahead; and keep the carrier under
control at all times.
5.5.2
uations.
Yield the right of way to pedestrians, ambulances, fire trucks, or other carriers or vehicles in emergency sit-
5.5.3 Do not pass another carrier or vehicle traveling in the same direction at intersections, blind spots, or at other
dangerous locations.
5.5.4
Keep a clear view of the path of travel, observe other traffic and personnel, and maintain a safe clearance.
5.5.5 Slow down or stop, as conditions dictate, and activate the sound-producing warning device at cross aisles
and when visibility is obstructed at other locations.
5.5.6
Ascend or descend grades slowly.
5.5.7 Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines; normally travel straight up
and down.
5.5.8 Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop in
a safe manner.
5.5.9 Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift the load, endanger
passengers, or overturn the carrier.
5.5.10 Do not indulge in dangerous activities, such as stunt driving or horseplay.
5.5.11 Slow down when approaching, or on, wet or slippery surfaces.
5.5.12 Do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly, and
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SAFETY IN FOR MATI O N
then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off
power, and set parking brakes. It is advisable that all other personnel leave the elevator before a carrier is allowed to
enter or exit.
5.5.13 Avoid running over loose objects, potholes, and bumps.
5.5.14 To negotiate turns, reduce speed to improve stability, then turn hand steering wheel or tiller in a smooth,
sweeping motion.
5.6
Loading
5.6.1 Handle only stable and safely arranged loads. When handling off-center loads which cannot be centered,
operate with extra caution.
5.6.2
Handle only loads within the capacity of the carrier as specified on the nameplate.
5.6.3 Handle loads exceeding the dimensions used to establish carrier capacity with extra caution. Stability and
maneuverability may be adversely affected.
5.7
Operator Care of Personnel and Burden Carriers
5.7.1 At the beginning of each shift during which the carrier will be used, the operator shall check the carrier condition and inspect the tires, warning devices, lights, battery(s), speed and directional controllers, brakes, and steering
mechanism. If the carrier is found to be in need of repair, or in any way unsafe, the matter shall be reported immediately to the designated authority and the carrier shall not be operated until it has been restored to safe operating condition.
5.7.2 If during operation the carrier becomes unsafe in any way, the matter shall be reported immediately to the
designated authority, and the carrier shall not be operated until it has been restored to safe operating condition.
5.7.3
Do not make repairs or adjustments unless specifically authorized to do so.
5.7.4
The engine shall be stopped and the operator shall leave the carrier while refueling.
5.7.5 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced
before starting engine.
5.7.6
Do not operate a carrier with a leak in the fuel system or battery(s).
5.7.7
Do not use open flames for checking electrolyte level in storage battery(s) or liquid level in fuel tanks.
6 MAINTENANCE PRACTICES
6.1
Introduction
6.1.1 Carriers may become hazardous if maintenance is neglected. Therefore, maintenance facilities, trained personnel, and procedures shall be provided. Such facilities may be on or off the premises.
6.2
Maintenance Procedures
6.2.1 Maintenance and inspection of all carriers shall be performed in conformance with the manufacturer’s recommendations and the following practices.
(a) A scheduled preventive maintenance, lubrication, and inspection system shall be followed.
(b) Only qualified and authorized personnel shall be permitted to maintain, repair, adjust, and inspect carriers.
(c) Before undertaking maintenance or repair, follow the manufacturer’s recommendations for immobilizing the carrier.
(d) Block chassis before working underneath it.
(e) Before disconnecting any part of the engine fuel system of a gasoline or diesel powered carrier with gravity feed
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SA FE TY IN F O RM AT ION
fuel systems, be sure shutoff valve is closed, and run engine until fuel system is depleted and engine stops running.
(f) Before disconnecting any part of the engine fuel system of LP gas powered carriers, close the LP gas cylinder
valve and run the engine until fuel in the system is depleted and the engine stops running.
(g) Operation to check performance of the carrier shall be conducted in an authorized area where safe clearance
exists.
(h) Before commencing operation of the carrier, follow the manufacturer’s instructions and recommended procedures.
(i) Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to
check level or leakage of fuel, battery electrolyte, or coolant. Do not use open pans of fuel or flammable cleaning fluids
for cleaning parts.
(j) Properly ventilate the work area.
(k) Handle LP gas cylinders with care. Physical damage, such as dents, scrapes, or gouges, may dangerously
weaken the tank and make it unsafe for use.
(l) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors,
guards, and safety devices shall be inspected regularly and maintained in a safe operating condition.
(m) Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure
that maintenance preserves the original approved safe operating features.
(n) Fuel systems shall be checked for leaks and condition of parts. If a leak is found, action shall be taken to prevent
the use of the carrier until the leak has been eliminated.
(o) The carrier manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals shall be
maintained in legible condition.
(p) Batteries, motors, speed and directional controllers, limit switches, protective devices, electrical conductors, and
connections shall be inspected and maintained.
(q) Carriers shall be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective
parts.
(r) Modifications and additions which affect capacity and safe machine operation shall not be performed by the customer or user without manufacturer’s prior written authorization; where authorized modifications have been made, the
user shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or decals are changed
accordingly.
(s) Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment.
END OF ANSI/ITSDF56.8-2006 TEXT
Owner’s Manual and Service Guide
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SA FE TY IN F O RM AT ION
Notes:
Page xiv
Owner’s Manual and Service Guide
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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 ANSI / NGCMA Z130.1 - 2004. E-Z-GO, as a member of the
National Golf Car Manufacturers Association (NGCMA), strongly endorses the contents of this specification.
PART II
MAINTENANCE AND OPERATIONS
5.
GENERAL SAFETY PRACTICES
5.1.
Introduction
Like other vehicles, golf cars can cause injury if improperly used or maintained. Part II contains broad safety practices
recommended for safe golf car operations. Before operation, the controlling party should establish such additional specific safety practices as may be reasonably required for safe operations.
Experience has shown that golf cars that comply with the provisions stated in Part III of this standard are safe when
properly operated in accordance with the safety and operation warnings affixed to every golf car. Safe operation is
enhanced when the golf cars are operated within a specific set of operation instructions, safety rules and practices
established to meet actual operating terrain and conditions.
The safety information contained in Part II is intended to enable the controlling party to implement a golf car safety program.
It is suggested and recommended that Part II be reprinted in the golf car manufacturer’s operation and service manuals
to encourage safe operations and practices at the controlling party’s facility.
5.2.
Safety Survey
The controlling party shall perform a safety survey of its premises periodically, and as conditions warrant, identify areas
where golf cars should not be operated and possible hazards exist. See, for example, 5.2.1. See also NGCMA Golf
Course Safety Guidelines and NGCMA Golf Car Storage Facility Safety Guidelines.
5.2.1. Grades
All grades shall be descended at a reduced speed. Excessive speed while descending grades adversely affects the stability of the golf car and its ability to stop. In areas where steep grades exist, golf car operations should be restricted to
designated golf car paths and roads where possible. Steep grades shall be identified with a suitable warning giving the
following information: "Warning, steep hill, apply brake to limit speed." Avoid parking on steep hills. Avoid sharp
turns on grades. Provide flat surface parking areas adjacent to golf car paths on steep grades.
5.2.2. Wet areas or icy terrain
Extreme caution should be used when driving on wet or icy terrain. Wet grassy areas or ice may cause a golf car to lose
traction and may affect operator control. Wet or icy areas should be chained or roped off to prevent golf car operations
or be identified by a suitable warning to operators not to operate golf cars in that area.
Owner’s Manual and Service Guide
Page xv
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
5.2.3. Sharp Turns, Blind Corners, Bridge Approaches
All turns shall be negotiated at a reduced speed. Negotiating a turn can affect the stability and control of a golf car, causing loads and passengers to shift. Sharp turns, blind spots, bridge approaches, and other potentially hazardous areas
shall be closed off to prevent golf car operation or shall be identified with a suitable warning to the operator of the nature
of the hazard, stating the proper precautions to be taken to avoid the hazard.
5.2.4. Loose Terrain
Extreme caution shall be used when driving in areas of loose terrain. Loose terrain, for example, sand or gravel, can
cause a golf car to lose traction and may affect stability. Areas of loose terrain should be repaired if possible, or closed
off to prevent golf car operation, or identified by a suitable warning to operators not to operate golf cars in those areas.
5.2.5. Golf Car/Pedestrian Interaction Areas
Areas where pedestrians and golf cars could interact should be avoided by rerouting the golf car traffic or the pedestrian
traffic. If avoidance of the interaction is not possible or is highly impractical, signs shall be erected warning pedestrians
of the golf car traffic. Signs shall also be erected warning golf car operators of the pedestrian traffic and to drive slowly
and with caution.
6.
MAINTENANCE
6.1. Introduction
Golf cars may become hazardous if maintenance is neglected or improperly performed. Proper maintenance facilities,
trained personnel and maintenance procedures, in accordance with the manufacturer’s recommendations, shall be provided by the controlling party.
6.2.
Preventive Maintenance
A regularly scheduled inspection and preventive maintenance program in accordance with the manufacturer’s recommendations should be established. Such a program will be a valuable tool in providing the golfing patron with a safe,
properly operating golf car.
6.2.1. Personnel
Only qualified, trained and authorized personnel shall be permitted to inspect, adjust and maintain golf cars.
6.2.2. Parts and Materials
Manufacturer’s recommended replacement parts and materials should be used.
6.2.3. Maintenance and repair safety procedures
All maintenance shall be performed in accordance with the manufacturer’s recommended maintenance and safety procedures as outlined in the manufacturer’s operation and service manuals. For example:
a) Follow manufacturer’s instructions for immobilizing golf car before beginning any maintenance;
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Owner’s Manual and Service Guide
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b) Block chassis before working underneath golf car;
c) Before disconnecting any part of the fuel system, drain the system and turn all valves, if so equipped, to the "off" position to prevent leakage or accumulation of flammable fuels;
d) Avoid fire hazards and have fire protection equipment available;
e) Before performing any maintenance on an electric golf car, disconnect the electrical system in accordance with the
manufacturer’s instructions;
f) Use only properly insulated tools when performing maintenance;
g) Periodically inspect and maintain brakes, steering mechanisms, warning devices, governors, safety decals and all
other safety devices and maintain them in a safe operating condition. Do not modify these devices unless instructed to
do so by the manufacturer;
h) After each maintenance or repair, have the golf car driven by qualified and trained personnel to ensure proper operation and adjustment; perform validation checks in an area that is free of vehicular and pedestrian traffic;
i) Record all maintenance performed in a maintenance record log by date, name of person performing maintenance and
type of maintenance. Controlling Party should periodically inspect maintenance log to ensure currency and completeness of entries.
6.2.4.
The controlling party shall maintain all Danger, Warning and Caution labels, (collectively and individually “safety labels”);
nameplates; serial numbers; and instructions, when supplied by the manufacturer, in a legible condition.
6.2.5.
The controlling party shall not perform or allow to be performed, any modification or addition to the vehicle that affects
capacity or safe operation, or make any change not in accordance with the manufacturer’s operations and service manuals, without the manufacturer's prior written authorization. Where authorized modifications have been made, the controlling party shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or decals are
changed accordingly.
6.2.6.
As required in 6.2.4, the manufacturer shall be contacted to secure new nameplates, warnings, or safety labels, as necessary, which shall be affixed in their proper place on the golf car if and as designated in the owner’s manual.
7.
FUELS HANDLING AND STORAGE/BATTERY CHARGING
7.1. Ventilation
Maintenance and storage areas shall be properly ventilated to avoid fire hazards in accordance with applicable fire
codes and ordinances.
Ventilation for internal combustion engine golf cars shall be provided to remove flammable vapors, fumes and other
flammable materials. Consult applicable fire codes for specific levels of ventilation.
Owner’s Manual and Service Guide
Page xvii
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Ventilation for electric-powered golf cars shall be provided, to remove the accumulation of flammable hydrogen gas
emitted during the charging process. Because of the highly volatile nature of hydrogen gas and its propensity to rise and
accumulate at the ceiling in pockets, a minimum of 5 air changes per hour is recommended for multiple vehicles and
one air change per hour may be adequate for one vehicle. The controlling party shall consult applicable fire and safety
codes for the specific ventilation levels required. See NGCMA Golf Car Safety Storage Guidelines and SAE J1718.
7.2.
The controlling party shall require battery changing and charging facilities and procedures to be in accordance
with applicable ordinances or regulations.
7.3.
The controlling party shall supervise the storage and handling of liquid fuels in accordance with ANSI/NFPA 30.
7.4.
Storage and handling of liquefied petroleum gas fuels shall be in accordance with ANSI/NFPA 58.
7.5.
TThe controlling party shall periodically inspect charging and storage areas or facilities and review procedures to
be certain that the procedures in 7.1 through 7.4, inclusive, are being followed.
8.
OPERATING SAFETY RULES AND PRACTICES
8.1. Operator Qualifications
8.1.1. It is recommended that only persons qualified under the rules of the regulatory authority be allowed to operate a
golf car. Qualifications may include proof of insurance, minimum age requirement or other appropriate requirements.
8.1.2. The controlling party shall display the operation and safety instructions as recommended by the golf car manufacturers and the golf course safety rules in a conspicuous place near the golf car rental area or golf car pick-up area, or
on each golf car, or both. It is also recommended that the warning "Do not operate golf car when under the influence of
intoxicating or mind altering substances," be posted in a conspicuous location..
Page xviii
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OPERATION AND SERVICE INFORMATION
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Thank you for purchasing this vehicle. Before driving the
vehicle, we ask you to spend some time reading this
Owner’s Manual and Service Guide. This guide contains
the information that will assist you in maintaining this
highly reliable vehicle. Some illustrations may show
items that are optional for your vehicle. This guide covers
the operation of several vehicles; therefore, some pictorial views may not represent your vehicle. Physical differences in controls will be illustrated.
This vehicle has been designed and manufactured as a
‘World Vehicle’. Some countries have individual requirements to comply with their specifications; therefore,
some sections may not apply in your country.
Most of the service procedures in this guide can be
accomplished using common automotive hand tools.
Contact your service representative on servicing the
vehicle in accordance with the Periodic Service Schedule.
Service Parts Manuals and Technician’s Repair and Service Manuals are available from a local Distributor, an
authorized Branch or the Service Parts Department.
When ordering parts or requesting information for your
vehicle, provide vehicle model, serial number and manufacture code.
Vehicle battery must be fully charged before initial use.
Check for correct tire inflation. See GENERAL SPECIFICATIONS.
Check for oil or fuel leaks that could have developed in
shipment from the factory.
Determine and record braking distance required to stop
vehicle for future brake performance tests.
Remove the protective clear plastic, that protect the seat
bottom and back rest during shipping, before placing the
vehicle in service.
ITEM
SERVICE OPERATION
Battery
Charge battery
Seats
Remove protective plastic covering
Brakes
Check operation and adjust if necessary
Establish acceptable stopping distance
Tires
Check air pressure (see SPECIFICATIONS)
Fuel
Fill tank with correct fuel
Engine
Check oil level
Ref Isc 16
Fig. 1 Initial Service Chart
BEFORE INITIAL USE
Read, understand and follow the safety label on the
instrument panel. Be sure you understand how to operate the vehicle, its equipment and how to use it safely.
Maintaining good performance depends to a large extent
on the operator.
Hydrogen gas is generated as a natural part of
the lead acid battery charging process. A 4%
concentration of hydrogen gas is explosive and
could cause severe injury or death. Charging
must take place in an area that is adequately
ventilated (minimum of 5 air exchanges per
hour).
To reduce the chance of battery explosion that
could result in severe injury or death, never
smoke around or charge batteries in an area
that has open flame or electrical equipment that
could cause an electrical arc.
Before a new vehicle is put into operation, the items
shown in the INITIAL SERVICE CHART must be performed (Ref Fig. 1 on page 1).
Owner’s Manual and Service Guide
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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 AND INDICATORS
Vehicle controls and indicators consist of:
•
•
•
•
•
•
•
•
Located on the seat support panel, this lever permits the
selection of either ‘F’ (forward) or ‘R’ (reverse) (Ref Fig. 3
on page 2). Vehicle should be left in ‘F’ when unattended.
key/light switch
Reverse
direction selector
Forward
choke
fuel gauge
low oil pressure indicator light
Ref Dsl 2
accelerator pedal
Fig. 3 Direction Selector
combination service and park brake pedal
horn
CHOKE
KEY/LIGHT SWITCH
Located on the dash panel, this switch enables the basic
electrical system of the vehicle to be turned on and off by
turning the key. To prevent inadvertent operation of the
vehicle when left unattended, the key should be turned to
the ‘OFF’ position and removed (Ref Fig. 2 on page 2).
Key/Light Switch
Fuel
Gauge
OFF
ON
E
The choke is used to aid cold starting (Ref. Fig. 4 on
page 2). See COLD STARTING section for operating
instructions.
LOW OIL PRESSURE INDICATOR LIGHT
A low oil pressure indicator light is located on the dash
panel (Ref Fig. 2 on page 2). The light illuminates when
the oil pressure is low. Check oil level. If oil level is
between ADD and FULL mark on dipstick, a mechanical
problem exists within the engine and the vehicle must no
be driven. Contact a local distributor or authorized
branch.
F
FUE
Ref Kes 2
L
Low Oil Pressure
Indicator Light
Fig. 2 Key / Light Switch
If the vehicle is equipped with lights, the key switch has
a position to operate them, indicated by the light icon.
If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch
in the ‘OFF’ position.
Ref Chk 1
DIRECTION SELECTOR
Choke
Fig. 4 Choke
FUEL GAUGE
To reduce the possibility of component damage, the
vehicle must be completely stopped before moving the
direction selector.
Page 2
The fuel gauge (if equipped) will either be located on the
dash panel (electric) (Ref Fig. 2 on page 2) or directly on
the fuel tank (mechanical).
Owner’s Manual and Service Guide
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Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
To prevent engine damage, do not operate engine until
oil pressure is corrected. Do not over fill engine. Too
much oil may cause smoking or allow oil to enter the filter
enclosure.
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 light does not come on, continue
to use vehicle.
ACCELERATOR PEDAL
Depressing the lower section of the brake pedal is the preferred method of releasing the park brake to assure the longest
service life of brake components.
COMBINATION SERVICE AND PARK BRAKE
PEDAL
The brake pedal incorporates a park brake feature (Ref
Fig. 5 on page 3). To engage, push down on the upper
section of the pedal until it locks in place. The park brake
will release when the service brake pedal is depressed.
Use the lower section of the brake pedal to operate the
service brake system.
HORN
Unintentional movement of the accelerator pedal will release the park brake and may cause
the vehicle to move which could result in
severe injury or death.
The horn is operated by pushing the horn button located
on the floor to the left of the brake pedal (Ref Fig. 5 on
page 3)
Horn
Horn
Horn
Park
Brake
Service
Brake
H
With the key switch ‘ON’, depressing the accelerator
pedal starts the engine. When the pedal is released, the
engine will stop (Ref Fig. 5 on page 3). To stop the vehicle more quickly, depress the service brake.
PPAARRKK
ORN
Ref
Ref Hor
Hor11
Fig. 6 Horn Button
PARK
Accelerator
Ref Abc 1
Fig. 5 Accelerator, Brake and Horn Controls
If key switch is ‘ON’ and park brake is set, depressing the
accelerator inadvertently will release the park brake and
will cause the vehicle to move which could cause severe
injury or death.
Depressing the accelerator pedal will release the park
brake if it is engaged. This is a feature to assure the vehicle is not driven with the park brake engaged. Depressing the accelerator pedal is not the preferred method of
releasing the park brake.
Owner’s Manual and Service Guide
Page 3
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OPERATING THE VEHICLE
vehicle is to be left unattended, engage the
park brake, move direction selector to forward position, turn key to ‘OFF’ position and
remove key.
Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance.
Read and understand the following warnings before
attempting to operate the vehicle.
To reduce the possibility of severe injury or
death resulting from loss of vehicle control, the
following warnings must be observed:
When driving vehicle, consider the terrain,
traffic conditions and the environmental factors which effect the terrain and the ability to
control the vehicle.
Use extra care and reduced speed when
driving on poor surfaces, such as loose dirt,
wet grass, gravel, etc.
Stay in designated areas and avoid
extremely rough terrain.
Maintain a safe speed when driving down
hill. Use service brake to control speed
when traveling down an incline. A sudden
stop or change of direction may result in
loss of control.
Slow down before and during turns. All turns
should be made at reduced speed.
Never drive vehicle up, down, or across an
incline that exceeds 14° (25% grade).
To reduce the possibility of severe injury or
death resulting from improper vehicle operation, the following warnings must be observed:
Refer to GENERAL SPECIFICATIONS for
seating capacity.
Depressing accelerator pedal will release
foot operated park brake and may cause
inadvertent vehicle movement. Turn the key
to the ‘OFF’ position whenever the vehicle is
parked.
To prevent inadvertent movement when the
Page 4
Make sure that the direction selector is in
correct position before attempting to start
the vehicle.
Always bring the vehicle to a complete stop
before shifting the direction selector.
Do not take vehicle out of ‘gear’ while in
motion (coast).
Check the area behind the vehicle before
operating in reverse.
All occupants must be seated. Keep entire
body inside vehicle and hold on while vehicle is in motion.
RUN-IN
Check for oil or fuel leaks that could have developed in
shipment from the factory. Avoid full throttle starts and
rapid acceleration until the engine has achieved operating temperature.
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 the rate
of consumption stabilizes.
Check the oil level per the Periodic Service Schedule.
Add oil if the level on the dipstick indicates that oil is in
the add oil range (Ref Fig. 16 on page 14).
Do not overfill engine. Too much oil may cause smoking
or allow oil to enter the air filter enclosure.
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 contaminated and/or being discharged
into the engine compartment.
The oil should be changed in accordance with the Periodic Service Schedule while the engine is warm. See
SERVICE AND MAINTENANCE for checking oil level
and changing oil procedures.
Owner’s Manual and Service Guide
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Maximum oil level
DO NOT OVERFILL
Add
oil
Safe
operating range
When the direction selector is in the reverse position, a warning
signal will sound to indicate that the vehicle is ready to run in
reverse.
STARTING THE VEHICLE ON A HILL
Full
Ref Dsk 1
Fig. 7 Check Oil Level on Dipstick
COLD STARTING
Starting a cold engine may require use of the choke.
Depress the accelerator approximately 1" (2.5 cm) or
until the starter just begins to operate. Pull the choke out
if required. Accelerate slowly and push the choke in completely when the engine runs smoothly.
Do not allow the starter to operate continuously for more
than 10 seconds. Allow 30 seconds between starting
attempts. If the vehicle does not start on the third
attempt, turn the key switch off, set the park brake and
determine the cause of the problem.
If the vehicle had been running and the engine does not
start within 10 seconds, use the choke.
To reduce the possibility of roll-back which
could result in severe injury or vehicle damage,
do not release service brake until engine has
started.
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 excessive rollback when starting the vehicle on a hill.
Place left foot on service brake and release the park
brake. Depress accelerator with right foot and release
the service brake by lifting left foot.
COASTING
STARTING AND DRIVING
To reduce the possibility of roll-back which
could result in severe injury or vehicle damage,
do not release service brake until engine has
started.
To operate vehicle:
• Apply the service brake, place the key in the key
switch and turn it to the ‘ON’ position.
• Move the direction selector to the direction
desired.
• Release the park brake by depressing the service
brake pedal until the park brake releases.
• Slowly depress the accelerator pedal to start the
engine. Release service brake when engine
starts.
• When the accelerator pedal is released, the ignition circuit is de-energized and the engine stops.
To stop the vehicle more quickly, depress the service brake pedal.
To reduce the 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 surface. To reduce the possible loss of vehicle control and
severe drivetrain damage, speeds should be limited to no
more than the maximum governed speed on level ground
(see GENERAL SPECIFICATIONS). Limit speed by
applying service brake.
FUEL
To reduce the possibility of severe injury or
death from improper fuel handling:
Do not smoke near the fuel tank.
Owner’s Manual and Service Guide
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
Do not refuel near open flame or electrical
items which could produce a spark.
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 hazardous condition.
The fuel tank is located under the seat on the passenger
side of the vehicle (Ref Fig. 8 on page 6). Fill the tank
with fresh, clean, automotive grade gasoline (Ref Fig. 37
on page 23). High altitude or heavy use/load applications
may benefit from higher octane gasoline.
Do not use gasoline which contains Methanol.
the vehicle is stopped. Do not operate accessory items
(such as lights) excessively while the vehicle is stopped.
The generator is capable of supplying 35 amps; therefore, operation of all accessories could result in the discharge of the battery even though the engine is running
and the generator operating. Discharging the battery is
known as deep cycling. The battery is not a deep cycle
model, but is a starting battery. Multiple deep cycling will
result in the premature failure of the battery.
If the vehicle battery has become discharged, it must be
charged using a 12 volt charger that is rated at 10 amps
or less and in accordance with all instructions provided
by the manufacturer of the charger.
LABELS AND PICTOGRAMS
Vehicles may be labeled with pictograms as a method of
conveying information or warnings. Appendix A illustrates and explains pictograms that may appear on the
vehicle. Not all pictograms shown in Appendix A will be
found on your vehicle.
SUN TOP AND WINDSHIELD
Some fuels, called oxygenated or reformulated 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 operating symptoms
occur, use gasoline with a lower percentage of alcohol or ether.
The sun top does not provide protection from
roll over or falling objects.
The windshield does not provide protection
from tree limbs or flying objects.
The sun top and windshield provide some protection
from the elements; however, they will not keep the operator and passenger dry in a downpour. This vehicle is not
equipped with seat belts and the sun top has not been
designed to provide roll over protection. 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.
Fuel
1" Min.
(2.5 cm)
Ref Ftl 1
Fig. 8 Fueling
BATTERY
Excessive use of accessories may drain the battery and
leave insufficient reserve to start the vehicle.
The vehicle uses a combination starter/generator to both
start the engine and charge the battery. The engine will
not idle; therefore, the battery cannot be charged while
Page 6
Owner’s Manual and Service Guide
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Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
VEHICLE CLEANING AND CARE
If the engine does not start or runs improperly after washing,
remove the spark plug wires (by pulling the spark plug boots,
never the wires). Dry all connections with forced air. Reinstall
the wires.
VEHICLE CLEANING
To reduce the possibility of severe injury or
vehicle damage, read and understand all
instructions supplied by manufacturer of pressure washer.
When pressure washing exterior of vehicle, do not use
pressure in excess of 700 psi. To reduce the possibility of
cosmetic damage, do not use any abrasive or reactive
solvents to clean plastic parts.
It is important that proper techniques and cleaning materials be used. Using excessive water pressure may
cause severe injury to operator or bystander, damage to
seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi to wash
exterior of vehicle.
Clean windshield with lots of water and a clean cloth.
Minor scratches may be removed using a commercial
plastic polish or Plexus® plastic cleaner available from
the service parts department.
Normal cleaning of vinyl seats and plastic or rubber trim
requires the 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, etc. will require
the use of a commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive
appearance and durable protection. Frequent washing
with lukewarm or cold water and mild detergent is
required to preserve the painted surfaces.
Occasional cleaning and waxing with non-abrasive products 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 the underbody of the vehicle. These materials will cause corrosion of underbody parts unless
flushed occasionally 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
Page 7
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REPAIR
Center of
Front Axle
LIFTING THE VEHICLE
Tool List
Qty. Required
Floor jack..................................................................... 1
Jack stands ................................................................. 4
Chocks ........................................................................ 4
Some servicing operations may require the front wheels,
the rear wheels, or the entire vehicle be raised.
Flat Portion
of Frame
To reduce the possibility of severe injury or
death from a vehicle falling from a jack:
Be sure the vehicle is on a firm and level
surface.
Never get under a vehicle while it is supported by a jack.
Use jack stands and test the stability of the
vehicle on the stands.
Outside End
of Rear Axle
Ref Liv 1
Fig. 9 Lifting the Vehicle
Always place chocks in front and behind the
wheels not being raised.
Use extreme care since the vehicle is
extremely unstable during the lifting process.
When lifting vehicle, position jacks and jack stands at the
areas indicated only.
To raise the entire vehicle, install chocks in front and
behind each front wheel (Ref Fig. 9 on page 8). Center
the jack under the rear frame crossmember. Raise the
vehicle enough to place a jack stand under the outer
ends of the rear axle.
Lower the jack and test the stability of the vehicle on the
two jack stands.
Place the jack at the center of the front axle. Raise the
vehicle enough to place jack stands under the frame
crossmember as indicated.
Lower the jack and test the stability of the vehicle on all
four jack stands.
If only the front or rear of the vehicle is to be raised, place
the chocks in front and behind each wheel not being
raised to stabilize the vehicle.
Lower the vehicle by reversing the lifting sequence.
Page 8
View from Underside of Vehicle
WHEELS AND TIRES
Tire Repair
Tool List
Qty. Required
Lug wrench, 3/4"..........................................................1
Impact socket, 3/4", 1/2" drive .....................................1
Impact wrench, 1/2" drive ............................................1
Torque wrench, 1/2" drive ............................................1
A tire explosion can cause severe injury or
death. Never exceed inflation pressure rating
on tire sidewall.
To reduce the possibility of tire explosion,
pressurize tire with small amount of air
applied intermittently to seat beads. Due to
the low volume of the small tires, overinflation can occur in seconds. Never exceed
the tire manufacturer’s recommendation
when seating a bead. Protect face and eyes
from escaping air when removing valve
core.
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
To reduce the possibility of severe injury
caused by a broken socket when removing
wheels, use only sockets designed for
impact wrench use.
Use caution when inflating tires. Overinflation could cause the tire to separate from
the wheel or cause the tire to explode,
either of which could cause severe injury.
Use caution when inflating tires. Due to the low volume of
the small tires, overinflation can occur in seconds. Overinflation could cause the tire to separate from the wheel
or cause the tire to explode.
Tire inflation should be determined by the condition of the
terrain. See GENERAL SPECIFICATIONS section for
recommended tire inflation pressure. For outdoor applications with major use on grassy areas, the following
should be considered. On hard turf, it is desirable to have
a slightly higher inflation pressure. On very soft turf, a
lower pressure reduces the possibility of tires cutting into
the turf. For vehicles being used on paved or hard surfaces, tire inflation pressure should be in the higher
allowable range, but under no condition should inflation
pressure be higher than recommended on tire sidewall.
All four tires should have the same pressure for optimum
handling characteristics. Be sure to install the valve dust
cap after checking or inflating.
The vehicle is fitted with low pressure tubeless tires
mounted on one piece rims; therefore, the most cost
effective way to repair a puncture in the tread is to use a
commercial tire plug.
If the tire is to be removed or mounted, the tire changing
machine manufacturer’s recommendations must be followed in order to reduce possibility of severe injury.
Wheel Installation
To reduce the possibility of component damage, do not
tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.
It is important to follow the ‘cross sequence’ pattern when
installing lug nuts. This will assure even seating of the wheel
against the hub.
With the valve stem to the outside, mount the wheel onto
the hub with lug nuts. Finger tighten lug nuts in a ‘cross
sequence’ pattern (Ref Fig. 10 on page 9) . Tighten lug
nuts in the ’cross sequence’ pattern by torquing in 20 ft.
lbs. (30 Nm) increments following the ‘cross sequence’
pattern.
'Cross Sequence'
3
1
Tire style
may vary
4
2
Ref Whi 1
Fig. 10 Wheel Installation
Tire plug tools and plugs are available at most automotive parts
outlets and have the advantage of not requiring the tire be
removed from the wheel.
If the tire is flat, remove the wheel and inflate the tire to
the maximum recommended pressure for the tire.
Immerse the tire in water to locate the leak and mark with
chalk. Insert tire plug in accordance with manufacturer’s
instructions.
To reduce possibility of severe injury, be sure
mounting/demounting machine is anchored to
floor. Wear OSHA approved safety equipment
when mounting/demounting tires.
LIGHT BULB REPLACEMENT
To reduce the possibility of premature bulb failure, do not
touch new bulbs with bare fingers. Use clean, dry tissue
or paper towel to handle the glass portion of the bulb.
For vehicles equipped with lights mounted below cowl,
locate bulb socket on backside of light bar (Ref Fig. 11 on
page 10) and turn bulb socket a quarter turn counterclockwise to unlock and pull out bulb. Insert new bulb
(Ref Fig. 37 on page 23) and rotate socket a quarter turn
clockwise to secure.
To replace the tail and brake light bulb, remove hardware
securing lens and remove lens (Ref Fig. 12 on page 10).
Install replacement bulb (Ref Fig. 37 on page 23).
Owner’s Manual and Service Guide
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
VEHICLE WITH A DISCHARGED BATTERY
Turn Signal Lens
Headlight
Bulb
Turn
Signal
Light
Marker
Light
Marker
Light
Inside
of Cowl
Turn Signal
Light
Headlights
Turn
G Signal
RHousing
Ref Hdr 2
Y R
Ref Hdr 1
Fig. 11 Headlight, Turn Signal & Marker Light Bulb
Replacement
Rear
Fender
To reduce the possibility of severe injury or
death from inadvertent motion, do not attempt
to ‘jump start’ a vehicle.
The vehicle is equipped with a starter/generator and
does not idle. When starting the engine, the starter/generator functions as a starter and with the engine running,
it functions as a generator.
With the short running times associated with this kind of
vehicle, the generator is more than adequate to maintain
the battery charge level. The generator is not designed to
charge a discharged battery.
When engine starts, the clutches engage and cause
vehicle to move making ‘jump starting’ both dangerous
and impractical.
If the vehicle battery has become discharged, it must be
charged using a 12 volt charger that is rated at 10 amps
or less. Read and understand all instructions provided by
the manufacturer of the charger.
TRANSPORTING VEHICLE
Tail Light
Lens
TOWING
To reduce the possibility of severe injury or
death
Ref Tlr 1
Tail Light
Bulb
Use extra caution when towing a vehicle.
Fig. 12 Tail and brake light bulb replacement
FUSE REPLACEMENT
To replace fuses, locate the fuse block under the driver
side seat. Pull out old fuse and replace with a new automotive type fuse. Headlights and taillights bulbs and
fuses are available from a local Distributor, an authorized
Branch or the Service Parts Department.
Do not ride on vehicle being towed.
Do not attempt to tow the vehicle with
ropes, chains or any device other than a
factory approved tow bar.
Do not tow vehicle on highways.
Do not tow a single vehicle at speeds in
excess of 12 mph (19 kph).
Do not tow more than three vehicles at a
time.
Do not exceed 5 mph (8 kph) while towing
multiple vehicles.
Page 10
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
Unlocked
Position
Place direction selector in neutral. The neutral lock
should be used to lock the direction selector in position.
This will reduce the possibility of it moving into ‘F’ (for ward) or ‘R’ (reverse) while being towed, causing possible damage to the rear axle.
Unlocked
1
Pull out and rotate 180 o
to lock
Locked
Position
Locked
Do not tow a single vehicle at speeds in excess of 12
mph (19 kph). Do not tow more than three vehicles at a
time. Do not exceed 5 mph (8 kph) while towing multiple
vehicles. Towing the vehicle at above recommended
speed may result in severe injury and/or damage to vehicle and other property.
Tow bars are not intended for road use.
Never use ropes or chains to tow vehicle(s). Tow bars
are available from the Service Parts Department.
Tow bars are not intended for highway use. Before towing, place direction selector in neutral and engage neutral lock. Do not ride on vehicle being towed. Tow bars
are designed to tow only one vehicle at a maximum
speed of 12 mph (19 kph) and up to three vehicles at a
maximum speed of 5 mph (8 kph).
NEUTRAL LOCK
To prevent the driven clutch from turning the rear wheels
during service operations and to prevent wear to the belt
while being towed, a neutral lock is located at the direction selector or the rear axle.
On Rear Axle
Long Tab
2
1
Short Tab
2
Pull out and rotate 180 o
to unlock
Ref Nlk 1
Fig. 13 Neutral Lock on Rear Axle
On Direction Selector
To operate:
Turn key switch to ‘OFF’ and lift seat. Pull out and rotate
the neutral lock pin handle so that the pointed portion of
the handle is to the side of the direction selector cam
(Ref Fig. 14 on page 11). Move direction selector towards
the area between ‘F’ and ‘R’. During that motion, the pin
will snap into the hole in the direction selector mounting
bracket preventing any movement. When in this position,
the direction selector remains locked in the neutral position. To unlock the direction selector, pull the neutral lock
pin handle out and rotate until the pointed portion of the
handle fits into the hole in the direction.
To operate:
Position direction selector lever between ‘F’ and ‘R’. Turn
key switch to ‘OFF’. Rotate pin on rear axle shift lever as
shown (Ref Fig. 13 on page 11). The pin will snap into a
cavity in the differential case. When in this position, the
direction selector remains locked in the neutral position.
To unlock the direction selector, pull the pin out and
rotate until the pointed portion of the pin handle fits into
the detent position in the rear axle shift lever.
Hole in Direction
Selector Cam
Hole in Direction
Selector Mounting
Bracket
Locked
Unlocked
2
1
Ref Nlk 2
Neutral Lock
Pin Handle
Fig. 14 Neutral Lock on Direction Selector
Owner’s Manual and Service Guide
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
HAULING
To reduce the possibility of severe injury or
death while transporting vehicle:
Secure the 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 the vehicle is to be transported at highway speeds, the
sun top must be removed and the seat bottom secured.
When transporting vehicle below highway speeds, check
for tightness of hardware and cracks in sun top at mounting points. Always remove windshield when transporting.
Always check that the vehicle and contents are adequately secured before transporting. The rated capacity
of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle
weight) and load. Lock the park brake and secure the
vehicle using ratchet tie downs.
SERVICE AND MAINTENANCE
To reduce the possibility of severe injury or
death from improper servicing techniques:
Do not attempt any type of servicing operations before reading and understanding all
notes, cautions and warnings in this manual.
Any servicing requiring adjustments to be
made to the powertrain while the engine is
running must be made with both drive
wheels raised and vehicle properly supported on jack stands.
To reduce the possibility of engine damage,
never operate vehicle at full throttle for more
than 4 - 5 seconds while vehicle is in a ‘no
load’ condition.
Wear eye protection when working on the vehicle. Use extra care
when working around batteries,
or using solvents or compressed
air.
Page 12
To reduce the possibility of causing an electrical arc, which could result in a battery
explosion, turn off all electrical loads from
the battery before removing battery wires.
Wrap wrenches with vinyl
tape to reduce the possibility of a dropped wrench
‘shorting out’ a battery, which could result in
an explosion.
Reduce the possibility of accidental starting
by removing and grounding spark plug
wires and disconnecting battery at negative
terminal before servicing.
The electrolyte in a battery is an acid solution which can cause severe burns to the
skin and eyes. Treat all electrolyte spills to
the body and eyes with extended flushing
with clear water. Contact a physician 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.
Aerosol containers of battery terminal protectant must be used with extreme care.
Insulate metal container to reduce the possibility of can contacting battery terminals
which could result in an explosion.
It is in the best interest of both vehicle owner and service
technician, to carefully follow the procedures recommended in this manual. Preventative maintenance,
applied at recommended intervals, is the best guarantee
for keeping the vehicle both dependable and economical.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic
Service Schedule for appropriate service intervals (Ref
Fig. 16 on page 14). Refer to Lubrication Points for
appropriate lubrication locations (Ref Fig. 34 on page
21).
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
SERIAL NUMBER LABEL & LOCATION
.
Lift Flap on Access Panel
To prolong vehicle life, some maintenance items must be
serviced more frequently on vehicles used under severe
driving conditions such as extreme temperatures,
extreme dust/debris conditions, frequent use with maximum load.
Part A and B
Serial Number
Labels
To access powertrain for routine maintenance, lift or
remove seat. For major repair, refer to appropriate Technician’s Repair and Service Manual.
Some service procedures may require the vehicle to be
lifted. Refer to LIFTING THE VEHICLE for proper lifting
procedure and safety information.
Part C/D
Two serial number and manufacture date code plates are
on the vehicle. One is placed on the body below the
front, driver side of the seat. The other is located on the
chassis between the seat back supports. To access it,
raise the seat and lift up the flap on the access panel
(Ref Fig. 15 on page 13).
PART A
Design changes take place on an ongoing basis. In order
to obtain correct components for the vehicle, the manufacture date code, serial number and vehicle model must
be provided when ordering service parts.
Ref Spl 3
Label No.
PART C/D
PART B
V
Fig. 15 Serial Number Plate & Location
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
PERIODIC SERVICE SCHEDULE
9 Check
 Clean, Adjust, etc.
SReplace
To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see
the Repair and Service Manual for this vehicle.
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions
DAILY
BEFORE USE:
9Check service brake general operation
9Check park brake function
9Check warning device function in reverse (if vehicle is equipped with device
9Check tire condition
9Check overall vehicle condition
WEEKLY
TIRES
WHEELS
ENGINE OIL
STARTER/GENERATOR BELT
9Examine
for cuts, excessive wear and pressure (See GENERAL SPECIFICATIONS)
9 Check for bent rims, missing or loose lug nuts
9 Check and add if required - DO NOT OVERFILL
9 Check for tension, wear, cracks
MONTHLY - 20 HOURS (includes items listed in previous table & the following)
WIRING
ACCELERATOR
SERVICE BRAKE
(MECHANICAL BRAKES)
PARK BRAKE
CHOKE CABLE
CARBURETOR LINKAGE
DIRECTION SELECTOR
ENGINE
COOLING FAN
STEERING ASSEMBLY
TIE ROD/LINKAGES
REAR AXLE
9Check all wiring for loose connections and broken/missing insulation
9Check for smooth movement - DO NOT LUBRICATE CABLE
9Conduct brake performance test
9Check brake performance and adjust if required
9Check for smooth movement and adjustment - DO NOT LUBRICATE CABLE
9Check attachment, adjust as required
9Check attachment, adjust as required
9Check for unusual noise, vibration, acceleration, oil leaks
9Check for build-up of foreign matter inside blower housing and fins, clean if required
9Check for abnormal play, tightness of all hardware
9Check for excessive play, bent components or loose connections
9Check for leakage, add SAE 30 oil as required
QUARTERLY - 50 HOURS (includes items listed in previous tables & the following)
PARK BRAKE
9Check for damage to axle and loose or missing hardware
9Check for oil leakage and loose fasteners
9Check for loose hardware, cracks at attachments
9Check for unusual tire wear, align if required
9Check for bent/binding linkage rod
9Check for damage or wear to latch arm or catch bracket
REAR SHOCK ABSORBERS
ENGINE ELECTRICAL SYSTEM
Lubricate as required, use light oil. DO NOT LUBRICATE CABLES OR BRAKE
LATCH
9Check for oil leakage, loose mounting hardware
9Check coil/spark plug wires for cracks/loose connections
FRONT AXLE
FRONT SHOCK ABSORBERS
FRONT SPRINGS
FRONT WHEEL ALIGNMENT

Fig. 16 Periodic Service Schedule
Page 14
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
FUEL SYSTEM
THROTTLE/GOVERNOR LINKAGE
HARDWARE AND FASTENERS
9Check for leaks at tank, cap, system lines, filters, pump, carburetor
9Check system lines for cracks/deterioration
9Check operation and governed speed
9Check for loose or missing hardware and components
 Tighten or replace missing hardware
SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)
BATTERY
DIRECTION SELECTOR
KING PINS
STEERING ASSEMBLY
RACK END BALL JOINT
REAR AXLE
AIR FILTER ELEMENT
OIL FILTER
Clean battery & terminals
9Check for wear and smooth movement (lubricate shaft with light oil if required)
9Check for excessive play and tightness of retaining nuts
9Check bellows and pinion seal for damage or grease leakage
 Lubricate, use wheel bearing grease
9Check for unusual noise and loose or missing mounting hardware
9Check filter element, clean/replace as required
ENGINE OIL
 Clean in solvent (at oil change), replace ‘O’ rings if required
SReplace with SAE 10W-30 or 10W-40 that meets or exceeds SF, SG, CC oil,
DRIVE BELT
9Check for cracks, fraying and excessive wear
DO NOT OVERFILL
ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)
FRONT WHEEL BEARINGS
REAR AXLE
9 Check and adjust as required, see Technician’s Repair and Service Manual
9Check lubricant, add lubricant (Ref Fig. 37 on page 23) as required
Clean and adjust, see Technician’s Repair and Service Manual
SERVICE BRAKES
FUEL FILTER
SPARK PLUGS
MUFFLER/EXHAUST
VALVES
9Check brake shoe linings, see Technician’s Repair and Service Manual
9Check level, add if required (DOT 3) and check for leakage
 Replace
 Replace, gap new plugs (Ref Fig. 37 on page 23)
9Check mounting hardware; check for leaks at head and muffler gaskets
9Check cold (intake/exhaust) per Technician’s Repair and Service Manual
500 HOURS (includes items listed in previous tables & the following)
TIMING BELT
CARBURETOR
CYLINDER HEAD AND PISTONS
9Check tension and for signs of wear/damage, replace if worn or damaged
 Clean
 Remove carbon from cylinder head and pistons
9Check valve seats for carbon buildup and clean as required
Fig. 16 Periodic Service Schedule
TIRE INSPECTION
.
Tire condition should be inspected per the Periodic Service Schedule (Ref. Fig. 16 on page 14). Inflation pressures should be checked when the tires are cool. Be sure
to install the valve dust cap after checking or inflating.
When adding oil between oil changes, do not mix brands and
viscosity grades of oil. 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 contaminated and/or
oil being discharged into the engine compartment.
CHECKING THE OIL LEVEL
Do not overfill engine. Too much oil may cause engine to
smoke or spark plug fouling.
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
The oil should be checked with the engine warm. The
vehicle must be on a level surface with the park brake
engaged. Allow adequate time for oil to drain into the
crankcase before checking.
Remove the dipstick and wipe off the entire area indicated with a lint free cloth (Ref Fig. 17 on page 16).
oil, whereas vehicles used at capacity or near capacity
load applications will require 10W-40 oil after run-in (Ref
Fig. 19 on page 16).
To reduce the possibility of severe injury, wear
rubber gloves to protect skin from exposure to
hot, used oil and degreaser. These fluids contain chemicals known to cause cancer.
F
HEAVY DUTY WORK
10W-40
10W-30
Ref Ced 1
Fig. 17 Clean Entire Dipstick
Insert the dipstick fully into the dipstick hole and remove.
Examine the level of oil on the dipstick.
The engine can be operated safely as long as oil is within
the safe operating range as indicated on the dipstick. Do
not operate vehicle if oil level is below the safe area
indicated on the dipstick (Ref Fig. 18 on page 16).
Maximum oil level
DO NOT OVERFILL
Add
oil
Safe
operating range
LIGHT DUTY WORK
10W-30
F
0
-20
C 0 -30
0
-20
Ref Ovc 1
20
40
60
80
-10
0
10
20
(AIR TEMPERATURE)
100
30
40
Fig. 19 Oil Viscocity Chart
The oil should be changed with the engine warm. Park the vehicle on a level surface, engage the park brake and remove the
key. Place a drain pan under the engine. Wipe the top of the
engine clean with a cloth (Ref Fig. 20 on page 16). Remove the
oil fill cap.
Full
Ref Dsk 1
Fig. 18 Check Oil Level on Dipstick
Oil should be added to bring the level into the safe operating range. Do not overfill. Check that the oil fill cap
and dipstick are firmly in place.
Oil Fill Cap
CHANGING THE OIL
Tool List
Qty. Required
Socket, 10 mm, 3/8" drive ........................................... 1
Ratchet, 3/8" drive ....................................................... 1
Extension, 8", 3/8" drive .............................................. 1
Oil drain pan ................................................................ 1
For maximum performance and longevity, the engine oil
should be replaced every 125 hours of operation or semiannually, whichever comes first.
The selection of oil is dependent upon the service that
the vehicle will perform. Most vehicles require 10W-30
Page 16
Ref Cte 1
Fig. 20 Clean Top of Engine
Clean the area around the filter. Oil drainage is accomplished by removing the three bolts securing the oil filter
to the engine. Remove the filter by pulling it from the
engine and allow the oil to drain. The ‘O’ rings may
remain on the engine or the filter (Ref Fig. 21 on page
17).
Owner’s Manual and Service Guide
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Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Large
'O' Ring
Ref Rof 1
Oil
Filter
Small 'O' Ring Inside
End Of Oil Filter
.
Fig. 21 Remove Oil Filter
At each oil change, thoroughly inspect filter before cleaning. At the first oil change, metal chips and lint may be
found. This is normal, resulting from engine run-in. At
subsequent oil changes, the presence of metal chips
may indicate possible engine damage.
Wipe the area around the filter mount with a clean, lint
free cloth and inspect both filter ‘O’ rings for damage;
replace if necessary. Install the filter into the engine. The
filter engages over a short nipple in the engine. The filter
should slide easily onto the nipple and seat against the
engine using light hand pressure only. Align the holes in
the filter mounting plate with the holes in the engine.
Install and hand tighten the bolts before tightening them
firmly.
Add slightly less than 1 1/2 quarts (1.4 liters) to allow for
possible residual oil left in engine (Ref Fig. 24 on page
17). The oil must be high quality oil that meets or
exceeds API SF, SG, CC standards (Ref Fig. 37 on page
23). Check oil level on dipstick. If necessary, continue to
add oil slowly and allow time for oil to flow down into
engine. Check oil level on dipstick. Do not overfill.
.
Wear eye protection to reduce the
possibility of splashed solvent contacting the eyes when cleaning oil filter.
Clean the filter by washing in any shop degreaser and
brushing the metal screen clean with a soft brush (Ref
Fig. 22 on page 17).
Do not overfill engine. Too much oil may cause smoking
or allow oil to enter the air filter enclosure.
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 being discharged into the engine compartment.
'O' Ring
Ref Cof 1
Fig. 22 Clean Oil Filter
Blow out the filter with low pressure air 30 psi (210 kPa)
or less from no closer than 3" (8 cm) and allow to air dry
(Ref Fig. 23 on page 17).
.
3" (8 cm)
Minimum
Ref Bof 1
30 psi (210 kPa) Maximum
Fig. 23 Blowing Out Oil Filter
Ref Aeo 1
Fig. 24 Add Engine Oil
Inspect oil fill cap ‘O’ ring and replace if necessary. Install
the oil fill cap. Run the vehicle for one or two minutes and
check the filter for oil leaks.
Check the oil level again with the vehicle on level ground.
Oil should be added to bring the level into the safe operating range. Do not overfill. The engine can be operated
safely as long as the oil is within the safe operating range
as indicated on the dipstick. Do not operate vehicle if
oil level is below the safe area indicated on the dipstick.
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
STARTER/GENERATOR BELT TENSION
Tool List
Qty. Required
Belt tension gauge....................................................... 1
Wrench, 3/4"................................................................ 1
Wrench, 9/16".............................................................. 2
Ratchet, 3/8" drive ....................................................... 1
Socket, 3/4", 3/8" drive ................................................ 1
The starter/generator belt tension should be checked
after the first 15 - 20 hours and set to 75 - 80 lbs. (34 - 36
kg).
lower nut up or down the adjustment bolt until proper belt
tension is achieved. Hold the lower nut in place and
tighten the upper jam nut against it (Ref Fig. 27 on page
18).
Jam Nut
.
A loose belt can cause audible vibration and squeal.
Adjusting Nut
Tighten a new starter/generator belt (Ref Fig. 37 on page
23) to 90 - 110 lbs. (41-50 kg) tension when a gauge is
applied half way between the two pulleys (Ref Fig. 25 on
page 18).
Ref Abt 1
Fig. 27 Adjusting Belt Tension
Tighten the starter/generator pivot bolt.
BATTERY CLEANING
Ref Cbg 1
Fig. 25 Checking Belt Tension with Gauge
A new belt may be checked manually. A maximum
deflection of 3/8" (10 mm) is acceptable (Ref Fig. 26 on
page 18).
3/8" (1 cm) Max. Deflection for New Belt
1/2" (1.3 cm) Max. Deflection for Existing
Belt
Ref Cbm 1
Fig. 26 Checking Belt Tension Manually
Tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the same technique and inspect for cracking
or wear. A maximum deflection of 1/2" (13 mm) is acceptable.
Adjusting The Belt
Loosen the starter/generator pivot bolt.
While holding the lower adjusting nut with a wrench,
loosen the upper jam nut with another wrench. Move the
Page 18
To reduce the possibility of damage to vehicle or floor,
neutralize acid before rinsing battery.
To reduce the possibility of damage to electrical components while cleaning, do not use a pressure washer.
Cleaning should take place per the Periodic Service
Schedule (Ref Fig. 16 on page 14).
When cleaning the outside of the 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 the top of the battery to another area
of the vehicle or storage facility where it will attack the
metal structure or the concrete/asphalt floor. Additionally,
a residue will be left on the battery which is conductive
and will contribute to the discharge of the battery.
.
To reduce the 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 the battery.
Owner’s Manual and Service Guide
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Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
The correct cleaning technique is to spray the top and
sides of the battery with a solution of sodium bicarbonate
(baking soda) and water. This solution is best applied
with a garden type sprayer equipped with a non metallic
spray wand or a plastic spray bottle. The solution
should consist of the amounts of sodium bicarbonate
(baking soda) and clear water shown below (Ref Fig. 28
on page 19). In addition to the battery, special attention
should be paid to metal components adjacent to the battery which should also be sprayed with the sodium bicarbonate (baking soda) solution.
1 1/2 gallons
(6 liters)
Clear Water
1 quart
(1 liter)
Clear Water
1/4 Cup (60 ml)
Sodium Bicarbonate
(Baking Soda)
OR
Non
Metallic
Wand
2 Gallon
(7.5 liter)
Garden
Sprayer
Dry, Level, Clean, Paved Surface
Accelerate To
Maximum Speed
2 Teaspoons
(10 ml)
Sodium
Bicarbonate
(Baking Soda)
Latch
Parking Brake
and Take Foot
Off Pedal
Plastic
Spray
Bottle
Line or Marker
Ref Pns 1
Fig. 28 Preparing Acid Neutralizing Solution
Allow the solution to sit for at least three minutes; use a
soft bristle brush or cloth to wipe the tops of the battery to
remove any residue that could contribute to the self discharge of the battery. Rinse the entire area with low pressure clear water. Do not use a pressure washer.
Acceptable
Stopping 4 ft. (1.2 m)
Distance
BRAKES
Ref Bpt 1
Line or Marker
Normal Range of
Stopping Distance
Any vehicles that stop
more than 4 ft. (1.2 m)
beyond the Acceptable
Stopping Distance or
pulls to one side should
be removed from service
and inspected by a
qualified mechanic
Fig. 29 Typical Brake Performance Test
To reduce the possibility of severe injury or
death, always evaluate pedal travel before
operating a vehicle to verify some braking function is present.
All driving brake tests must be done in a safe
location with regard for the safety of all personnel.
Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.
The Periodic Brake Performance Test should be performed regularly (Ref. Fig. 16 on page 14) as an evaluation of braking system performance or if there is a
decrease in braking effectiveness. It is useful as a
method of identifying subtle loss of performance over
time.
Owner’s Manual and Service Guide
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
Periodic Brake Test for Mechanical Brakes
The purpose of this test is to compare the braking performance of the vehicle to the braking performance of new
or ‘known to be good’ vehicles or to an established
acceptable stopping distance. Actual stopping distances
will be influenced by weather conditions, terrain, road
surface condition, actual vehicle weight (accessories
installed) and vehicle speed. No specific braking distance
can be reliably specified. The test is conducted by latching the parking brake to eliminate different pedal pressures and to include the affects of linkage misadjustment.
Establish the acceptable stopping distance by testing a
new or ‘known to be good’ vehicle and recording the
stopping location or stopping distance. For fleets of vehicles, several vehicles should be tested when new and
the range of stopping locations or distances recorded.
Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.
Drive the vehicle at maximum speed on a flat, dry, clean,
paved surface (Ref. Fig. 29 on page 19). Quickly depress
the brake pedal to latch the parking brake at the line or
marker in the test area and remove foot from pedal. The
vehicle should stop aggressively. The wheel brakes may
or may not lock. Observe the vehicle stopping location or
measure the vehicle stopping distance from the point at
which the brakes were latched. The vehicle should stop
within the ‘normal’ range of stopping distances. If the
vehicle stops more than 4 ft. (1.2 m) beyond the acceptable stopping distance or pulls to one side, the vehicle
has failed the test and should be tested again.
If the vehicle fails the second test, it should immediately
be removed from service. The vehicle must be inspected
by a qualified mechanic who should refer to the TROUBLESHOOTING section in the Technician’s Repair and
Service Manual.
Ref Cai 1
Fig. 30 Cleaning Air Intake
After every off road use, allow to cool and then check for
a build up of dirt and debris in the air intake and cooling
fins. Dirt and debris may clog the engine’s air cooling
system. Clean areas shown to prevent engine damage
(Ref Fig. 30 on page 20) (Ref Fig. 31 on page 20). Keep
linkages, springs and controls clean. Keep area around
muffler free of any combustible material.
Ref Ccf 1
Fig. 31 Cleaning the Cooling Fins
REAR AXLE
The rear axle is provided with a lubricant level check plug
located on the driver side at the rear of the housing (Ref
Fig. 32 on page 20). Unless leakage of rear axle lubricant
is evident, an annual lubricant check is sufficient
.
Fill Plug
AIR INTAKE AND COOLING FINS
Check Plug
To prevent possible burns, engine parts should
be kept clean to reduce risk of overheating and
ignition of accumulated debris.
Page 20
Ref Raf 2
Drain Plug
Fig. 32 Add, Check and Drain Rear Axle Lubricant
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
engine..
Checking the Lubricant Level
Tool List
Qty. Required
Air Cleaner
Canister
Air Filter
Element
Socket, 13 mm, 3/8" drive ........................................... 1
Ratchet, 3/8" drive....................................................... 1
Funnel ......................................................................... 1
Clean the area around the check and fill plugs. Remove
the check plug. The correct lubricant level is just below
the bottom of the threaded hole (Ref Fig. 37 on page 23).
If lubricant is to be added, remove the fill plug and add
lubricant using a funnel. Add lubricant slowly until lubricant starts to seep from the check plug hole. Install the
check plug and the fill plug. In the event that the lubricant
is to be replaced, a drain plug is provided at the bottom of
the differential housing.
Air Cleaner
Cover
Dust
Collector
Ref Air 2
Fig. 33 Canister Type Air Cleaner
If the element is in acceptable condition, loose dirt may
be removed by tapping the filter lightly. Do not use oil on
the filter element or any part of the unit. Install the element in the same way it was removed, being sure that
the clips are fastened securely.
AIR CLEANER INSPECTION AND REPLACEMENT
LUBRICATION
To reduce the possibility of engine damage, be sure that
bottom tabs of cover are installed in enclosure and top of
cover is installed under top tabs. Secure all spring clips.
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.
The air cleaner unit on the vehicle is a dry unit. Do not use oil
on the filter element or any part of the unit.
Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature
bearing failure (Ref Fig. 34 on page 21).
The air cleaner is attached to the engine and may be
accessed by raising the seat. Inspect and replace air filter in accordance with the Periodic Service Schedule
(Ref. Fig. 16 on page 14).
Canister Type Air Cleaner
Rack Ball Joint
The air cleaner element is accessible by unsnapping the
clips on the air canister and removing the cover and air
filter element (Ref Fig. 33 on page 21). Clean inside of
cover, cannister and dust collector. Install the element
and cover the same way they were removed. Be sure the
positioning arrow on cover is pointing upward and all the
clips are fastened securely.
Ref Lub 1
Fig. 34 Lubrication Points
SPARK PLUGS
Tool List
Cleaning the Air Filter Element
Do not use compressed air to clean the air filter; doing so
will damage the filter which may result in damage to the
View From Underside Of Vehicle
Qty. Required
Spark plug socket, 13/16", 1/2" drive........................... 1
Ratchet, 1/2" drive ....................................................... 1
Plug gauge, wire type.................................................. 1
Anti-seize compound................................................ AR
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
Owner’s Manual and Service Guide
Page 21
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 to over-tighten the plug. Over-tightening can
cause damage to the aluminum cylinder head threads.
Remove and inspect the spark plugs at intervals indicated in the Periodic Service Schedule (Ref Fig. 16 on
page 14). All new spark plugs should be properly gapped
before installation (Ref Fig. 37 on page 23). Apply a light
coat of anti-seize compound and tighten to specified torque.
Fouled spark plugs are indicated by a wet, black appearance. This could be caused by a dirty air filter element or
other restrictions in the air intake system. Incorrectly
adjusted valves, spark plug wires which are in poor condition or poor quality fuel could also contribute to the
problem.
DIRECTION SELECTOR (Dual Cable system)
The direction selector is a mechanical device that operates cables connected to the rear axle. The cables are
sealed and do not require lubrication, but may require
occasional adjustment (Ref Fig. 35 on page 22). The only
other maintenance required is periodic lubrication of the
linkage and related moving parts.
Factory Installed
Length
1 3/8" (3.5 cm)
Ref Sca 1
NEUTRAL
Fig. 35 Shift Cable Adjustment
PROLONGED STORAGE
To reduce the possibility of severe injury or
death resulting from a possible explosion:
Do not handle fuel in an area that is not
adequately ventilated. Do not smoke near
the 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 create a
spark.
Page 22
When refueling, inspect the 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. Raise the rear of the vehicle and
support on jack stands before attempting to
run the engine.
Preparing the engine 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 the carburetor and corrosion in the engine.
• Raise the rear of the vehicle and support on jack
stands. Refer to ‘Lifting the Vehicle’ for proper lifting procedure and safety information.
• Disconnect the fuel hose at the fuel tank and plug
hose.
• With proper ventilation, depress the accelerator
pedal and allow engine to run until it stops due to
lack of fuel.
• Remove spark plugs (Refer to SPARK PLUGS on
page 21) 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.
• Add a gasoline additive to the tank in accordance
with the manufacturer’s recommendations.
• Reattach fuel line to tank and drive the vehicle for
several minutes to circulate the additive through
the carburetor.
• While engine is still warm, change oil (Refer to
CHANGING THE OIL on page 16).
• Clean body, chassis and engine of debris, mud,
chaff or grass (Refer to AIR INTAKE AND COOLING FINS on page 20).
HARDWARE
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref Fig. 36 on page
23).
Use care when tightening fasteners and refer to the
Technician’s Repair and Service Manual for specific
torque values.
Generally, three grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three
marks on the hexagonal head and grade 8 hardware is
identified by 6 marks on the head. Unmarked hardware is
Grade 2 (Ref Fig. 36 on page 23).
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
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"
9/16"
5/8"
3/4"
7/8"
1"
Grade 2
4
(5)
8
(11)
15
(20)
24
(33)
35
(47)
55
(75)
75
(102)
130
(176)
125
(169)
190
(258)
Grade 5
6
(8)
13
(18)
23
(31)
35
(47)
55
(75)
80
(108)
110
(149)
200
(271)
320
(434)
480
(651)
Grade 8
6
(8)
18
(24)
35
(47)
55
(75)
80
(108)
110
(149)
170
(230)
280
(380)
460
(624)
680
(922)
BOLT SIZE
M4
M5
M6
M8
M10
M12
M14
Class 5.8
(Grade 2)
5.8
1
(2)
2
(3)
4
(6)
10
(14)
20
(27)
35
(47)
55
(76.4)
Class 8.8
(Grade 5)
8.8
2
(3)
4
(6)
7
(10)
18
(24)
35
(47)
61
(83)
97
(131)
Class 10.9
(Grade 8) 10.9
3
(4)
6
(8)
10
(14)
25
(34)
49
(66)
86
(117)
136
(184)
Ref Tsp 1
Fig. 36 Torque Specification
CAPACITIES AND REPLACEMENT PARTS
Fuel Tank / Fuel
6.0 gal (22.5 liters) / 87 Octane
Engine Oil
1 1/2 qt (1.4 liters)
Oil Filter
P/N 26591-G01
Air Filter (Canister)
P/N 28463-G01
9HP
NGK FR2A-D (P/N 25523-G5)
0.035" (0.9 mm) Gap
11HP
NGK BPR5ES (P/N 72867-G01)
.028 - .032" (.7 - .8 mm) Gap
Spark Plugs
Starter/Generator Belt
P/N 26414-G01
Clutch Belt
P/N 72054-G01
Rear Axle Oil
40 oz (1.2 liters) / SAE 30
Fuse
15 amp (P/N 18392-G1)
Headlight Bulb
#894 (P/N 74004-G01)
Marker Bulb
#912 (P/N 74005-G01)
Turn Signal Bulb
#921 (P/N 74006-G01)
Tail Light Bulb
#1157 (P/N 21759-G1)
Fig. 37 Capacities and Replacement Parts
Owner’s Manual and Service Guide
Page 23
OPERATION AND SERVICE INFORMATION
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Notes:
Page 24
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Owner’s Manual and Service Guide
Page 25
GENERAL SPECIFICATIONS
TXT- GASOLINE
STANDARD EQUIPMENT:
BATTERY
ENGINE
One 12 Volt Maintenance Free (430 CCA, 60 Minute Reserve)
9 hp (6.7 kW)(295 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
Pressurized Lubrication with Washable, Permanent Oil Filter
Internal Balance Shaft
Solid State Ignition with RPM Limiter
Replaceable Dry Cartridge Air Filter
Fixed Jet Bowl Carburetor, Pulse Fuel Pump
TRANSAXLE
TRANSMISSION
FUEL TANK
BRAKES
PARKING BRAKE
FRONT SUSPENSION
REAR SUSPENSION
STEERING
STEERING WHEEL
SEATING
SEATING CAPACITY
TOTAL LOAD CAPACITY
SPEED
CHASSIS
BODY
13.32:1 Helical Geared with Neutral Lock & Ground Speed Governor
Automatic Continuously Variable Transmission (CVT)
6 Gallon (23 Liters) Tank, 36 lbs. (16 kg) Fuel Weight
Dual Rear Wheel, Self-Adjusting Mechanical Drum Brakes
Automatic Parking Brake Release with Self-Compensating System.
Leaf Springs with Hydraulic Shock Absorbers
Leaf Springs with Hydraulic Shock Absorbers
Single Reduction Rack & Pinion.
Dual Handgrips, Pencil Holder & Scorecard Holder
Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold
Operator & 1 Passenger
800 lbs. (360 kg) Including Operator, Passenger, Accessories & Cargo Bed
12 - 14 mph (19 - 23 kph)
Welded Tubular Steel; Powder Coated (DuraShield™)
Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer)
with Base Coat/Clear Coat
Champagne/Hunter Green
Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) with 4 Drink Holders, Tee & Ball
Storage
18 x 8.50 - 8 (4 Ply Rated) Load Range B
18 - 22 psi (124 - 152 kPa)
669 lbs. (304 kg)
STANDARD COLORS
DASH PANEL
TIRES
TIRE PRESSURE
WEIGHT (Without Fuel)
OPERATING CONTROLS &
INSTRUMENTATION
NOISE
VIBRATION, WBV
VIBRATION, HAV
Removable Key, ‘Deadman’ Accelerator Control, Direction Selector, Audible Reverse Warning
Sound pressure; continuous A - weighted less than 75dB(A)
The weighted RMS acceleration is 0.8 m/s²
the weighted RMS acceleration; less than 2.5 m/s²
WARNING (Europe Only): This is a Class A product. In a domestic environment, this product may cause radio interference, in which
case the user may be required to take adequate measures.
TXT GASOLINE - CE
Same as TXT Gasoline Fleet 9 hp, except for, 11 hp (8.2 kW)(350 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
TXT GASOLINE - CARB
Same as TXT Gasoline Fleet 9 hp, except for, fuel system parts to meet Califoria emissions standards. See Parts Manual for
replacement parts.
*Specifications subject to change without notice
Page 26
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
TXT GASOLINE - FREEDOM™ SE
STANDARD EQUIPMENT:
BATTERY
ENGINE
TRANSAXLE
TRANSMISSION
FUEL TANK
BRAKES
PARKING BRAKE
FRONT SUSPENSION
REAR SUSPENSION
STEERING
STEERING WHEEL
SEATING
SEATING CAPACITY
TOTAL LOAD CAPACITY
SPEED
CHASSIS
BODY
STANDARD COLORS
DASH PANEL
LIGHTING/HORN
TIRES
TIRE PRESSURE
WEIGHT (Without Fuel)
OPERATING CONTROLS &
INSTRUMENTATION
FEATURES
NOISE
VIBRATION, WBV
VIBRATION, HAV
One 12 Volt Maintenance Free (430 CCA, 60 Minute Reserve)
9 hp (6.7 kW)(295 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
Pressurized Lubrication with Washable, Permanent Oil Filter
Internal Balance Shaft
Solid State Ignition with RPM Limiter
Replaceable Dry Cartridge Air Filter
Fixed Jet Bowl Carburetor, Pulse Fuel Pump
13.32:1 Helical Geared with Neutral Lock & Ground Speed Governor
Automatic Continuously Variable Transmission (CVT)
6 Gallon (23 Liters) Tank, 36 lbs. (16 kg) Fuel Weight
Dual Rear Wheel, Self-Adjusting Mechanical Drum Brakes
Automatic Parking Brake Release with Self-Compensating System
Leaf Springs with Hydraulic Shock Absorbers
Leaf Springs with Hydraulic Shock Absorbers
Single Reduction Rack & Pinion
Dual Handgrips, Pencil Holder & Scorecard Holder
Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold
Operator & 1 Passenger
800 lbs. (360 kg) Including Operator, Passenger, Accessories & Cargo Bed
15 mph (23 kph)
Welded Tubular Steel; Powder Coated (DuraShield™)
Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer)
with Base Coat/Clear Coat
Champagne/Hunter Green
Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) with 4 Drink Holders, Tee & Ball
Storage
Single Halogen Light Bar, Tail & Brake Lights, Horn
18 x 8.50 - 8 (4 Ply Rated) Load Range B
18 - 22 psi (124 - 152 kPa)
679 lbs. (308 kg)
Removable Key, ‘Deadman’ Accelerator Control, Direction Selector, Audible Reverse Warning,
Analog Fuel Gauge, Low Oil Pressure Indicator
Center Basket
Sound pressure; continuous A - weighted less than 75dB(A)
The weighted RMS acceleration is 0.8 m/s²
the weighted RMS acceleration; less than 2.5 m/s²
WARNING (Europe Only): This is a Class A product. In a domestic environment, this product may cause radio interference, in which
case the user may be required to take adequate measures.
TXT GASOLINE - FREEDOM™ SE - CE
Same as TXT Gasloine Freedom SE 9 hp, except for, 11 hp (8.2 kW)(350 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead
Valve
TXT GASOLINE - FREEDOM™ SE - CARB
Same as TXT Gasoline Freedom SE 9 hp, except for, fuel system parts to meet Califoria emissions standards. See Parts Manual for
replacement parts.
*Specifications subject to change without notice
Owner’s Manual and Service Guide
Page 27
GENERAL SPECIFICATIONS
TXT GASOLINE - FREEDOM™ LE
STANDARD EQUIPMENT:
BATTERY
ENGINE
TRANSAXLE
TRANSMISSION
FUEL TANK
BRAKES
PARKING BRAKE
FRONT SUSPENSION
REAR SUSPENSION
STEERING
STEERING WHEEL
SEATING
SEATING CAPACITY
TOTAL LOAD CAPACITY
SPEED
CHASSIS
BODY
STANDARD COLORS
DASH PANEL
LIGHTING/HORN
TIRES
TIRE PRESSURE
WEIGHT (Without Fuel)
OPERATING CONTROLS &
INSTRUMENTATION
FEATURES
NOISE
VIBRATION, WBV
VIBRATION, HAV
One 12 Volt Maintenance Free (430 CCA, 60 Minute Reserve)
9 hp (6.7 kW)(295 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
Pressurized Lubrication with Washable, Permanent Oil Filter
Internal Balance Shaft
Solid State Ignition with RPM Limiter
Replaceable Dry Cartridge Air Filter
Fixed Jet Bowl Carburetor, Pulse Fuel Pump
13.32:1 Helical Geared with Neutral Lock & Ground Speed Governor
Automatic Continuously Variable Transmission (CVT)
6 Gallon (23 Liters) Tank, 36 lbs. (16 kg) Fuel Weight
Dual Rear Wheel, Self-Adjusting Mechanical Drum Brakes
Automatic Parking Brake Release with Self-Compensating System
Leaf Springs with Hydraulic Shock Absorbers
Leaf Springs with Hydraulic Shock Absorbers
Single Reduction Rack & Pinion
Dual Handgrips, Pencil Holder & Scorecard Holder
Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold
Operator & 1 Passenger
800 lbs. (360 kg) Including Operator, Passenger, Accessories & Cargo Bed
15 mph (23 kph)
Welded Tubular Steel; Powder Coated (DuraShield™)
Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer)
with Base Coat/Clear Coat
Champagne/Hunter Green/Cloud Gray/Bright Silver Metallic/Flame Red/Dark Garnet/Patriot Blue
Pearl/Black/Steel Blue Pearl
Wood Grain with 4 Drink Holders
Single Halogen Light Bar, Tail & Brake Lights, Horn
18 x 8.00 - 10 (4 Ply Rated) Load Range B
20 - 25 psi (140 - 170 kPa)
679 lbs. (308 kg)
Removable Key, ‘Deadman’ Accelerator Control, Direction Selector, Audible Reverse Warning,
Analog Fuel Gauge, Low Oil Pressure Indicator
Sun Top, Fold Down Windshield, Center Basket, Turn Signal with 4-Way Flasher, Wood Grain
Locking Glove Box Doors
Sound pressure; continuous A - weighted less than 75dB(A)
The weighted RMS acceleration is 0.8 m/s²
the weighted RMS acceleration; less than 2.5 m/s²
WARNING (Europe Only): This is a Class A product. In a domestic environment, this product may cause radio interference, in which
case the user may be required to take adequate measures.
TXT GASOLINE - FREEDOM™ LE - CE
Same as TXT Gasloine Freedom LE 9 hp, except for, 11 hp (8.2 kW)(350 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead
Valve.
TXT GASOLINE - FREEDOM™ LE - CARB
Same as TXT Gasoline Freedom LE 9 hp, except for, fuel system parts to meet Califoria emissions standards. See Parts Manual for
replacement parts.
*Specifications subject to change without notice
Page 28
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
TXT GASOLINE - FREEDOM™ HP SE
STANDARD EQUIPMENT:
BATTERY
ENGINE
TRANSAXLE
TRANSMISSION
FUEL TANK
BRAKES
PARKING BRAKE
FRONT SUSPENSION
REAR SUSPENSION
STEERING
STEERING WHEEL
SEATING
SEATING CAPACITY
TOTAL LOAD CAPACITY
SPEED
CHASSIS
BODY
STANDARD COLORS
DASH PANEL
LIGHTING/HORN
TIRES
TIRE PRESSURE
WEIGHT (Without Fuel)
OPERATING CONTROLS &
INSTRUMENTATION
FEATURES
NOISE
VIBRATION, WBV
VIBRATION, HAV
One 12 Volt Maintenance Free (430 CCA, 60 Minute Reserve)
9 hp (6.7 kW)(295 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
Pressurized Lubrication with Washable, Permanent Oil Filter
Internal Balance Shaft
Solid State Ignition with RPM Limiter
Replaceable Dry Cartridge Air Filter
Fixed Jet Bowl Carburetor, Pulse Fuel Pump
10.67:1 Helical Geared with Neutral Lock & Ground Speed Governor
Automatic Continuously Variable Transmission (CVT)
6 Gallon (23 Liters) Tank, 36 lbs. (16 kg) Fuel Weight
Dual Rear Wheel, Self-Adjusting Mechanical Drum Brakes
Automatic Parking Brake Release with Self-Compensating System
Leaf Springs with Hydraulic Shock Absorbers
Leaf Springs with Hydraulic Shock Absorbers
Single Reduction Rack & Pinion
Dual Handgrips, Pencil Holder & Scorecard Holder
Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold
Operator & 1 Passenger
800 lbs. (360 kg) Including Operator, Passenger, Accessories & Cargo Bed
16 - 18 mph (26 - 29 kph)
Welded Tubular Steel; Powder Coated (DuraShield™)
Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer)
with Base Coat/Clear Coat
Champagne/Hunter Green
Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) with 4 Drink Holders, Tee & Ball
Storage
Single Halogen Light Bar, Tail & Brake Lights, Horn
18 x 8.50 - 8 (4 Ply Rated) Load Range B
18 - 22 psi (124 - 152 kPa)
679 lbs. (308 kg)
Removable Key, ‘Deadman’ Accelerator Control, Direction Selector, Audible Reverse Warning,
Analog Fuel Gauge, Low Oil Pressure Indicator
Center Basket
Sound pressure; continuous A - weighted less than 75dB(A)
The weighted RMS acceleration is 0.8 m/s²
the weighted RMS acceleration; less than 2.5 m/s²
WARNING (Europe Only): This is a Class A product. In a domestic environment, this product may cause radio interference, in which
case the user may be required to take adequate measures.
TXT GASOLINE - FREEDOM™ HP SE - CE
Same as TXT Gasloine Freedom HP SE 9 hp, except for, 11 hp (8.2 kW)(350 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
TXT GASOLINE - FREEDOM™ HP SE - CARB
Same as TXT Gasoline Freedom HP SE 9 hp, except for, fuel system parts to meet Califoria emissions standards. See Parts Manual
for replacement parts.
*Specifications subject to change without notice
Owner’s Manual and Service Guide
Page 29
GENERAL SPECIFICATIONS
TXT GASOLINE - FREEDOM™ HP LE
STANDARD EQUIPMENT:
BATTERY
ENGINE
TRANSAXLE
TRANSMISSION
FUEL TANK
BRAKES
PARKING BRAKE
FRONT SUSPENSION
REAR SUSPENSION
STEERING
STEERING WHEEL
SEATING
SEATING CAPACITY
TOTAL LOAD CAPACITY
SPEED
CHASSIS
BODY
STANDARD COLORS
DASH PANEL
LIGHTING/HORN
TIRES
TIRE PRESSURE
WEIGHT (Without Fuel)
OPERATING CONTROLS &
INSTRUMENTATION
FEATURES
NOISE
VIBRATION, WBV
VIBRATION, HAV
One 12 Volt Maintenance Free (430 CCA, 60 Minute Reserve)
9 hp (6.7 kW)(295 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
Pressurized Lubrication with Washable, Permanent Oil Filter
Internal Balance Shaft
Solid State Ignition with RPM Limiter
Replaceable Dry Cartridge Air Filter
Fixed Jet Bowl Carburetor, Pulse Fuel Pump
10.67:1 Helical Geared with Neutral Lock & Ground Speed Governor
Automatic Continuously Variable Transmission (CVT)
6 Gallon (23 Liters) Tank, 36 lbs. (16 kg) Fuel Weight
Dual Rear Wheel, Self-Adjusting Mechanical Drum Brakes
Automatic Parking Brake Release with Self-Compensating System
Leaf Springs with Hydraulic Shock Absorbers
Leaf Springs with Hydraulic Shock Absorbers
Single Reduction Rack & Pinion
Dual Handgrips, Pencil Holder & Scorecard Holder
Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold
Operator & 1 Passenger
800 lbs. (360 kg) Including Operator, Passenger, Accessories & Cargo Bed
16 - 18 mph (26 - 29 kph)
Welded Tubular Steel; Powder Coated (DuraShield™)
Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer)
with Base Coat/Clear Coat
Champagne/Hunter Green/Cloud Gray/Bright Silver Metallic/Flame Red/Dark Garnet/Patriot Blue
Pearl/Black/Steel Blue Pearl
Wood Grain with 4 Drink Holders
Single Halogen Light Bar, Tail & Brake Lights, Horn
18 x 8.00 - 10 (4 Ply Rated) Load Range B
20 - 25 psi (140 - 170 kPa)
679 lbs. (308 kg)
Removable Key, ‘Deadman’ Accelerator Control, Direction Selector, Audible Reverse Warning,
Analog Fuel Gauge, Low Oil Pressure Indicator
Sun Top, Windshield Fold Down, Center Basket, Turn Signal with 4-Way Flasher, Glove Box Doors
Sound pressure; continuous A - weighted less than 75dB(A)
The weighted RMS acceleration is 0.8 m/s²
the weighted RMS acceleration; less than 2.5 m/s²
WARNING (Europe Only): This is a Class A product. In a domestic environment, this product may cause radio interference, in which
case the user may be required to take adequate measures.
TXT GASOLINE - FREEDOM™ HP LE - CE
Same as TXT Gasloine Freedom HP LE 9 hp, except for, 11 hp (8.2 kW)(350 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
TXT GASOLINE - FREEDOM™ HP LE - CARB
Same as TXT Gasoline Freedom HP LE 9 hp, except for, fuel system parts to meet Califoria emissions standards. See Parts Manual
for replacement parts.
*Specifications subject to change without notice
Page 30
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
TXT GASOLINE - SHUTTLE 2+2
STANDARD EQUIPMENT:
BATTERY
ENGINE
TRANSAXLE
TRANSMISSION
FUEL TANK
BRAKES
PARKING BRAKE
FRONT SUSPENSION
REAR SUSPENSION
STEERING
STEERING WHEEL
SEATING
SEATING CAPACITY
TOTAL LOAD CAPACITY
SPEED
CHASSIS
BODY
STANDARD COLORS
DASH PANEL
LIGHTING/HORN
TIRES
TIRE PRESSURE
WEIGHT (Without Fuel)
OPERATING CONTROLS &
INSTRUMENTATION
NOISE
VIBRATION, WBV
VIBRATION, HAV
One 12 Volt Maintenance Free (430 CCA, 60 Minute Reserve)
9 hp (6.7 kW)(295 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead Valve
Pressurized Lubrication with Washable, Permanent Oil Filter
Internal Balance Shaft
Solid State Ignition with RPM Limiter
Replaceable Dry Cartridge Air Filter
Fixed Jet Bowl Carburetor, Pulse Fuel Pump
13.32:1 Helical Geared with Neutral Lock & Ground Speed Governor
Automatic Continuously Variable Transmission (CVT)
6 Gallon (23 Liters) Tank, 36 lbs. (16 kg) Fuel Weight
Dual Rear Wheel, Self-Adjusting Mechanical Drum Brakes
Automatic Parking Brake Release with Self-Compensating System
Leaf Springs with Hydraulic Shock Absorbers
Leaf Springs with Hydraulic Shock Absorbers
Single Reduction Rack & Pinion
Dual Handgrips, Pencil Holder & Scorecard Holder
Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold, Fold Down Rear Facing Seat
Operator & 3 Passengers
800 lbs. (360 kg) Including Operator, Passenger, Accessories & Cargo Bed
12 - 14 mph (19 - 23 kph)
Welded Tubular Steel; Powder Coated (DuraShield™)
Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer)
with Base Coat/Clear Coat
Champagne/Hunter Green
Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) with 4 Drink Holders, Tee & Ball
Storage
Single Halogen Light Bar, Tail & Brake Lights, Horn
18 x 8.50 - 8 (4 Ply Rated) Load Range B
18 - 22 psi (124 - 152 kPa)
765 lbs. (347 kg)
Removable Key, ‘Deadman’ Accelerator Control, Direction Selector, Audible Reverse Warning,
Analog Fuel Gauge, Low Oil Pressure Indicator
Sound pressure; continuous A - weighted less than 76dB(A)
The weighted RMS acceleration is 0.8 m/s²
the weighted RMS acceleration; less than 2.5 m/s²
WARNING (Europe Only): This is a Class A product. In a domestic environment, this product may cause radio interference, in which
case the user may be required to take adequate measures.
TXT GASOLINE - SHUTTLE 2+2 - CE
Same as TXT Gasloine Shuttle 2+2 9 hp, except for, 11 hp (8.2 kW)(350 cc) Twin Cylinder, Air Cooled, Overhead Cam, Overhead
Valve
TXT GASOLINE - SHUTTLE 2+2 - CARB
Same as TXT Gasoline Shuttle 2+2 9 hp, except for, fuel system parts to meet Califoria emissions standards. See Parts Manual for
replacement parts.
*Specifications subject to change without notice
Owner’s Manual and Service Guide
Page 31
GENERAL SPECIFICATIONS
67 in.
(170 cm)
49 in.
(124 cm)
Front
33.5 in. (85 cm)
4.25 in.
(10.8 cm)
Ground
Clearance
Rear
38 in. (97 cm)
65.5 in. (166 cm)
92.5 in. (235 cm)
105 in. (267 cm)
NOTE: Shaded Area Indicates SHUTTLE 2+2
46.5 in.
(118 cm)
Ref Dim 1-1
Fig. 36 Vehicle Dimensions
Page 32
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
RECOMMENDED MAX RAMP
25% GRADE or 14o MAX
RECOMMENDED MAX SIDE TILT
25% GRADE or 14o MAX
TURNING CLEARANCE
DIAMETER
19 ft. (5.8 m)
Ref Dim 1-2
Fig. 37 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter
Owner’s Manual and Service Guide
Page 33
GENERAL SPECIFICATIONS
Notes:
Page 34
Owner’s Manual and Service Guide
VEHICLE WARRANTIES
VEHICLE WARRANTIES
Owner’s Manual and Service Guide
Page 35
VEHICLE WARRANTIES
DOMESTIC WARRANTY
(U.S. AND CANADA)
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch
or the Warranty Department with vehicle serial number and manufacturer date code.
FOR FURTHER INFORMATION, CALL 001-706-798-4311 OR WRITE TO E-Z-GO Division of Textron, Inc. ATTENTION: WARRANTY DEPARTMENT, P.O. BOX 388, AUGUSTA, GEORGIA 30906-3852.
Page 36
Owner’s Manual and Service Guide
VEHICLE WARRANTIES - FEDERAL (2006)
FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY
EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States,
except the State of California
Fuji Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the
initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed,
built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S. Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this
engine to fail to conform with EPA regulations during its warranty period.
For the components listed under PARTS COVERED, the distributor, dealer, or service provider authorized by E-ZGO will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine
complies with applicable U.S. EPA regulations.
EMISSISON COMPONENT DEFECT WARRANTY PERIOD
The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of
2 years.
PARTS COVERED
Listed below are the parts covered by the Emission Components Defect Warranty. Some of the parts listed below
may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part.
1) Fuel Metering System
(i) Carburetor and internal parts (and/or pressure regulator or fuel injection system)
(ii) Air/fuel ratio feedback and control system, if applicable.
(iii) Cold start enrichment system, if applicable.
(iv) Regulator assy (gaseous fuel, if applicable)
2) Air Induction System
(i) Intake manifold, if applicable
(ii) Air filter.
3) Ignition System
(i) Spark plugs.
(ii) Magneto or electronic ignition system.
(iii) Spark advance/retard system, if applicable.
4) Exhaust manifold, if applicable
5) Miscellaneous Items Used in Above Systems
(i) Electronic controls, if applicable
(ii) Hoses, belts, connectors, and assemblies.
(iii) Filter lock assy (gaseous fuel, if applicable)
OBTAINING WARRANTY SERVICE
To obtain warranty service, take your engine to the nearest authorized E-Z-GO distributor, dealer, or service provider. Bring your sales receipts indicating date of purchase for this engine. The distributor, dealer, or service provider
authorized by E-Z-GO will perform the necessary repairs or adjustments within a reasonable amount of time and
furnish you with a copy of the repair order. All parts and accessories replaced under this warranty become the property of E-Z-GO.
WHAT IS NOT COVERED
• Conditions resulting from tampering, misuse, improper adjustment (unless they were made by the distributor,
dealer, or service provider authorized by E-Z-GO during a warranty repair), alteration, accident, failure to use the
recommended fuel and oil, or not performing required maintenance services.
• The replacement parts used for required maintenance services.
• Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.
• Diagnosis and inspection charges that do not result in warranty-eligible service being performed.
• Any non-authorized replacement part, or malfunction of authorized parts due to use of non-authorized parts.
OWNER’S WARRANTY RESPONSIBILITIES
As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s
manual. E-Z-GO recommends that you retain all receipts covering maintenance on your engine, but E-Z-GO cannot
Owner’s Manual and Service Guide
Page 37
VEHICLE WARRANTIES - FEDERAL (2006)
deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a
part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by
E-Z-GO when a problem exists.
If you have any questions regarding your warranty rights and responsibilities, you should contact the E-Z-GO Warranty Department at 1-800-241-5855 for the information.
THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY
MAINTENANCE AND REPAIRS
You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance
records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine. E-Z-GO reserves the right to deny
warranty coverage if the engine has not been properly maintained. Warranty claims will not be denied, however,
solely because of the lack of required maintenance or failure to keep maintenance records.
MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS
MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY
REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR, DEALER OR, SERVICE PROVIDER AUTHORIZED BY E-Z-GO. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM.
If other than the parts authorized by E-Z-GO are used for maintenance replacements or for the repair of components
affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be
equivalent to the parts authorized by E-Z-GO in their performance and durability.
HOW TO MAKE A CLAIM
All repair qualifying under this limited warranty must be performed by a distributor, dealer, or service provider authorized by E-Z-GO. In the event that any emission-related part is found to be defective during the warranty period, you
shall notify E-Z-GO Warranty Department at 1-800-241-5855 and you will be advised of the appropriate warranty
service providers where the warranty repair can be performed.
Page 38
Owner’s Manual and Service Guide
VEHICLE WARRANTIES - CALIFORNIA (2007)
CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT
YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board and the E-Z-GO Division
of Textron Inc. (E-Z-GO) are pleased to explain the evaporative emission control system (EECS) on your 2007
gasoline powered vehicle. In California, new equipment that uses small off-engines must be designed, built,
and equipped to meet the State’s stringent anti-smog standards. E-Z-GO must warrant the EECS on your vehicle for the period listed below provided there has been no abuse, neglect or improper maintenance of your
equipment. For model year 2007 the EECS on your vehicle includes the liquid fuel lines, fuel line connectors,
and fuel line clamps. Where a warrantable condition exists, E-Z-GO will repair your EECS at no cost to you.
Expenses covered under warranty include diagnosis, parts, and labor.
MANUFACTURER’S WARRANTY COVERAGE: If any evaporative emission-related part included in the list of
EECS parts for your vehicle is defective, the part will be repaired or replaced by E-Z-GO.
OWNER’S WARRANTY RESPONSIBILITIES: As the vehicle owner, you are responsible for performance of the
required maintenance listed in your owner’s manual. E-Z-GO recommends that you retain all receipts covering
maintenance on your vehicle, but E-Z-GO cannot deny warranty solely for the lack of receipts. As the vehicle
owner, you should be aware that E-Z-GO may deny you warranty coverage if your vehicle or a covered part has
failed due to abuse, neglect, or improper maintenance, unapproved modifications, or the use of parts not made
or approved by E-Z-GO. You are responsible for performance of the required maintenance listed in your
owner’s manual. Your are responsible for presenting your vehicle to an E-Z-GO service center as soon as the
problem exists. Warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If
you have a question regarding your warranty rights and responsibilities, you should contact your nearest
authorized service center or call the E-Z-GO Warranty Department at 1-800-448-7476.
WARRANTY COMMENCEMENT DATE: The warranty period begins on the date the vehicle is purchased.
LENGTH OF COVERAGE: This warranty shall be for a period of two (2) years from the initial date of purchase.
WHAT IS COVERED
REPAIR OR REPLACEMENT OF PARTS: Repair or replacement of warranted part will be performed at no charge
to the owner at an authorized E-Z-GO Service Center. If you have a question regarding your rights and responsibilities, you should contact your nearest service center or call the E-Z-GO Warranty Department at
1-800-448-7476.
WARRANTY PERIOD: Any warranted part that is not scheduled for replacement as required maintenance, or
which is scheduled for regular inspection to the effect of “repair or replace as necessary” shall be warranted
for two (2) years. Any warranted part that is scheduled for replacement as required maintenance shall be
warranted for the period of time up to the first scheduled replacement point for that part.
DIAGNOSIS: The owner shall not be charged for diagnostic labor that leads to the determination that the
warranted part is defective if the diagnostic work is performed at an authorized E-Z-GO service center.
CONSEQUENTIAL DAMAGE: E-Z-GO may be liable for damages to the engine or other equipment components
caused by the failure of an EECS warranted part still under warranty.
WHAT IS NOT COVERED: All failures caused by abuse, neglect, or improper maintenance are not covered.
ADD-ON OR MODIFIED PARTS: The use of add-on or modified parts may be grounds for disallowing a warranty
claim. E-Z-GO is not liable to cover failures of warranted parts caused by the use of add-on or modified part.
HOW TO FILE A CLAIM: If you have questions regarding your warranty rights and responsibilities, you should
contact your nearest authorized service center or call the E-Z-GO Warranty Department at 1-800-448-7476.
WHERE TO GET WARRANTY SERVICE: Warranty services or repairs shall be provided at all authorized E-Z-GO
service centers.
MAINTENANCE, REPAIR, AND REPLACEMENT OF EVAPORATIVE EMISSION RELATED PARTS: Any E-Z-GO
approved replacement part used in the performance of any warranted maintenance or repair on evaporative
Owner’s Manual and Service Guide
Page 39
VEHICLE WARRANTIES - CALIVORNIA (2007)
emission related parts will be provided without charge to the owner if the part is under warranty.
EVAPORATIVE EMISSION CONTROL WARRANTY PARTS LIST: Fuel Line, fuel line fittings, and fuel line clamps.
MAINTENANCE STATEMENT: The owner is responsible for the performance of all required maintenance as
defined in the owner’s manual.
Page 40
Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS
LABELS AND PICTOGRAMS
Owner’s Manual and Service Guide
Appendix A - 1
LABELS AND PICTOGRAMS
OFF
ON
71145-G01
71145G01
OFF
See Following
Pages For
Explanation
Of These
Pictograms
(19,43,44,45)
!
!
P
ON
R
F
!
<14 °25 %
<14 °25 %
F
71127-G01
71127G01
OFF
35962-G01
ON
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN SEVERE PERSONAL INJURY.
71131-G01
71131G01
Avoid standing in front of or behind vehicle.
No more than 2 occupants per seat.
Always remain seated and hold on while vehicle is in motion.
Keep feet, legs, hands and arms inside the vehicle
at all times.
Do not leave children unattended on seat while
vehicle is moving.
74132G01
74132G01
Ref Lal 2-1
Appendix A - 2
Owner’s Manual and Service Guide
35962-G01
LABELS AND PICTOGRAMS
See Following Pages
For Explanation Of These
Pictograms (23,27,18,20,22,17,15)
PP
3
2
1
PP
H2O
PP
74093-G01
74093G01
WARNING
THIS VEHICLE IS EQUIPPED WITH A NEGATIVE GROUND SYSTEM.
NEVER ALLOW THE POSITIVE BATTERY POST OR CABLE TO
CONTACT THE FRAME AS THIS COULD RESULT IN A BATTERY
EXPLOSION AND SERIOUS PERSONAL INJURY.
WARNING
DO NOT TAMPER WITH OR CHANGE THIS ADJUSTMENT OF THE
GOVERNOR. FAILURE TO COMPLY COULD RESULT IN SERIOUS
PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY.
24876G01
Raise Seat To Find These
Labels Located On The
Air Cleaner And Chassis.
24880G01
See Following Pages For
Explanation Of Pictogram (30)
WARNING
See Following Pages For
Explanation Of Pictogram (49)
Windshields do not
provide protection
from golf balls or
other flying objects.
WARNING
Keep entire body
inside car.
EGWHL14
27653G01
Ref Lal 2-2
Owner’s Manual and Service Guide
Appendix A - 3
LABELS AND PICTOGRAMS
1.
!
WARNING
9.
2.
< 14O/25 %
READ MANUAL
WARNING
READ MANUAL
FOR MAXIMUM
LOAD BED
CAPACITY.
MAXIMUM RAMP/HILL
SECURE LOAD
MAX
AS FAR FORWARD
XXX lbs. AS POSSIBLE.
XXX kg MAXIMUM LOAD BED
10.
3.
WARNING
USE CAUTION IN
INCLEMENT WEATHER
!
CAPACITY
11.
4.
WARNING
DO NOT OPERATE
UNDER THE INFLUENCE
OF DRUGS OR ALCOHOL.
5.
MAXIMUM
CROSS HILL/RAMP
ANGLE AS SPECIFIED
MAX
14O/25 %
DO NOT RIDE IN
LOAD BED
12.
PP
DANGER OF EXPLOSION
DO NOT FILL GAS CAN
IN LOAD BED
!
WARNING
MAXIMUM CROSS
HILL/RAMP
ANGLE AS
SPECIFIED
6.
< 14O/25 %
7.
8.
LOAD WITH
HIGH CENTER
OF GRAVITY
COULD RESULT
IN TIP OVER
MAX
LOAD
XX in.
CENTER
XX cm OF GRAVITY,
MAXIMUM
HEIGHT
13.
MAX LOAD
XXX LBS
in
XXX KG xxx cm
14.
Ref Pic 1-1
NOTE: All Pictograms may not apply to your product.
Appendix A - 4
Owner’s Manual and Service Guide
WARNING
MAXIMUM LOAD
& CENTER OF
GRAVITY.
KEEP LOAD
AS FAR
FORWARD AS
POSSIBLE.
DO NOT RIDE
IN LOAD BED
KEEP HANDS &
FINGERS AWAY
FROM DUMP BED.
DO NOT STAND
BEHIND DUMP
BED
LABELS AND PICTOGRAMS
3
1
15.
PP
16.
17.
18.
PP
H2O
UNLEADED
GASOLINE
PP
PP
GROUND
FUEL PUMP
LOW OIL PRESSURE
20.
NEGATIVE
GROUND
BATTERY
21.
DO NOT CONNECT
POSITIVE BATTERY
TERMINAL TO GROUND
22.
SHORTING BATTERY
TERMINALS MAY
CAUSE EXPLOSION
23.
NO
TAMPERING.
KEEP HANDS
OUT
25.
26.
27.
28.
DO NOT
SPILL FUEL
ON A HOT
ENGINE
19.
24.
CLEAN UP GASOLINE
SPILLS WITH WATER
BEFORE STARTING
ENGINE
DO NOT
EXPOSE
TO FLAME
DO NOT
DISPOSE OF
BATTERIES
IN LANDFILL
29.
DO NOT
DRIVE ON
HIGHWAY
30.
WINDSHIELDS
DO NOT
PROVIDE
PROTECTION
FROM
FLYING OBJECTS
31.
BATTERIES ARE
HEAVY.
USE CARE LIFTING
32.
USE INSULATED
TOOLS
33.
WEAR EYE
PROTECTION
WARNING
CORROSIVE
34.
NO SMOKING
35.
HOT SURFACE
WARNING
EXPLOSIVE
WARNING
LETHAL
VOLTAGE
Ref Pic 1-2
NOTE: All Pictograms may not apply to your product.
Owner’s Manual and Service Guide
Appendix A - 5
LABELS AND PICTOGRAMS
OPERATE
FROM
DRIVERS SIDE
ONLY
36.
42.
43.
KEEP ARMS
AND LEGS
WITHIN VEHICLE
37.
38.
F
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
39.
R
40.
P
F
P
41.
TO OPERATE VEHICLE IN FORWARD:
✱ TURN KEY TO ON
✱ MOVE DIRECTION SELECTOR TO
FORWARD
✱ 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
44.
45.
46.
47.
Appendix A - 6
ON
ON
POSITION
OFF
OFF
POSITION
HEADLIGHTS
UNLOCKED
LOCKED
48.
DIFFERENTIAL
LOCKED
49.
WARNING
KEEP ENTIRE BODY
INSIDE CAR
50.
WARNING
POSSIBILE ELECTRIC
ARC OR BATTERY
EXPLOSION. WEAR
EYE PROTECTION.
N
Ref Pic 1-3
KEEP CLEAR
HAND OR
FINGERS CAN
BE TRAPPED
NOTE: All Pictograms may not apply to your product.
Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS
51.
MAXIMUM
TAILGATE
LOAD
NOTE: All Pictograms may not apply to your product.
Ref Pic 1-4
Owner’s Manual and Service Guide
Appendix A - 7
DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
(EUROPE ONLY)
Owner’s Manual and Service Guide
Appendix B - 1
DECLARATION OF CONFORMITY
Appendix B - 2
Owner’s Manual and Service Guide
DECLARATION OF CONFORMITY
Owner’s Manual and Service Guide
Appendix B - 3
DECLARATION OF CONFORMITY
Notes:
Appendix B - 4
Owner’s Manual and Service Guide
Read and understand the following warnings before attempting
to operate the vehicle:
To prevent personal 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.
Drive vehicle only as fast as terrain and safety
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.
Check area behind the 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 vehicle 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 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 component 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 diagnosing, 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 corrosive, 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.
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 rear of 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:
• 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.