Cushman SHUTTLE 6 Specifications

Owner’s Guide
622015
ISSUED JULY 2011
WELCOME
Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this
Owner’s 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 illustrations may not represent your vehicle. Physical differences in controls will be illustrated.
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.
Repair or replacement parts are available through your E-Z-GO retailer or E-Z-GO Genuine Service Parts.
The following information is needed when contacting E-Z-GO concerning service or parts for your vehicle:
Vehicle Model ____________________________________________________________________________
SERIAL/VIN Number ______________________________________________________________________
FOREWORD
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
OWNER’S GUIDE
GASOLINE POWERED VEHICLE
SHUTTLE 2
SHUTTLE 4
SHUTTLE 6
STARTING MODEL YEAR 2012
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 specifications. Such modifications can cause serious personal injury or death. E-Z-GO Division of Textron, Inc. prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
E-Z-GO Division of Textron, Inc. reserves the right to incorporate engineering and design changes to products in this manual, without
obligation to include these changes on units sold previously.
The information contained in this manual may be revised periodically by E-Z-GO Division of Textron, Inc., and therefore is subject to
change without notice.
E-Z-GO Division of Textron, Inc. DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
TO CONTACT US
E-Z-GO Division of Textron Inc.
1451 Marvin Griffin Road.
Augusta, Georgia, USA 30906-3852
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:
Page i
FOREWORD
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
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).
Page ii
TABLE OF CONTENTS
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SECTION
PAGE NO.
SAFETY............................................................................................................................................................................... 1-1
GENERAL SPECIFICATIONS............................................................................................................................................. 2-1
INTRODUCTION.................................................................................................................................................................. 3-1
OPERATING PROCEDURES .............................................................................................................................................. 4-1
MAINTENANCE................................................................................................................................................................... 5-1
Page iii
TABLE OF CONTENTS
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Notes:
Page iv
SAFETY
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
TITLE
PAGE NO.
SAFETY................................................................................................................................................................. 1-3
NOTICES, CAUTIONS, WARNINGS, AND DANGERS......................................................................................... 1-3
GENERAL ............................................................................................................................................................. 1-5
GENERAL OPERATION ....................................................................................................................................... 1-5
MAINTENANCE .................................................................................................................................................... 1-6
VENTILATION ....................................................................................................................................................... 1-6
LABELS AND PICTOGRAMS ............................................................................................................................... 1-7
1- 1
1
SAFETY
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
1
Notes:
1- 2
SAFETY
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SAFETY
1
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.
Use extra caution when towing the vehicle(s). 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 the recommended speed may result in personal injury and/or damage to the vehicle and other
property. Vehicles equipped with the AC Drive motor must be towed with the Run-Tow switch, located under the passenger seat, in the ‘Tow’ position.
If the vehicle is to be used in a commercial environment, 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.
Observe these NOTICES, CAUTIONS, WARNINGS and DANGERS; 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.
NOTICES, CAUTIONS, WARNINGS, AND DANGERS
Throughout this guide NOTICE, CAUTION, WARNING, and DANGER will be used. Please observe these NOTICES,
CAUTIONS, WARNINGS, and DANGERS; 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.
NOTICE
Address practices not related to personal injury.
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
1- 3
SAFETY
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1
Engine exhaust from this product contains chemicals known, in certain quantities, to
cause cancer, birth defects, or other reproductive harm.
NOTICE
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.
NOTICE
This spark ignition system meets all requirements of the Canadian Interference-Causing Equipment Regulations.
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 in any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER
FEDERAL 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 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.
All customers should adhere to this SAFETY RESTRICTION, in connection with the use of all E-Z-GO 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)
1- 4
SAFETY
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GENERAL
1
All vehicles can be 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 warning can take
replace 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. E-Z-GO strongly suggests that all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.
If you have any questions regarding this vehicle, contact your E-Z-GO dealer or write to the address on the back cover
of this publication, Attention: Customer Care Department.
E-Z-GO reserves the right to make design changes without obligation to make these changes on units previously sold.
The information contained in this manual is subject to change without notice.
E-Z-GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL. E-Z-GO IS NOT LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL.
This vehicle conforms to the current applicable standard(s) for safety and performance requirements.
These vehicles are designed and manufactured for off-road use. They DO NOT conform to Federal Motor Vehicle
Safety Standards of the United States of America (USA) and are not equipped for operation on public streets. Some
communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local
ordinances.
With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.
Never use the chassis or body as a ground connection.
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 or extend the stopping distance beyond the factory specification. Such modifications can
result in serious personal injury or death.
Do not make any such modifications or changes. E-Z-GO prohibits and disclaims responsibility for all such modifications or and alterations 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.
Operation of the vehicle is limited to persons above the height of 59 inches (150 cm).
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
• Leave the vehicle when there is a risk of lightning
• Reduce speed to compensate for poor terrain or conditions
1- 5
SAFETY
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1
• 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:
• Replace damaged or missing warning, caution or information labels
• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule
• Ensure that repairs are performed by trained and qualified personnel
• Follow the manufacturer’s maintenance procedures
• Insulate any tools used within the battery area in order to prevent sparks or battery explosion
• 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 in a safe area that is free of both vehicular and pedestrian
traffic
• 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.
1- 6
SAFETY
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LABELS AND PICTOGRAMS
1
I
ON
I
ON
I
ON
O
O
cm
O
O
O
O
MIN 150
%
25%
I
ON
F
ON
O
614121
O
ON
F
O
O
O
O
R
6 4 2
!
!
P
R
F
!
< 14° 25%
< 14° 25%
N
35962-G0
35962G01
1 To Prevent Ro l Back
On a Hi l From a
Stopped Position
3 Fully
Release
Park Brake
2 App y Service
Brake W th
Left Foot
4 Depress Accelerator While
Re eas ng Serv ce Brake As
Vehicle Starts
x2
74 43G01-TM I
7
-
MAX
800 lbs
370 kg
MAX
5 in
12 cm
A
M AX
14o / 25%
9
71489G01
3 493 G0
35493G01
71417G01
71419G01
Under Seat
www.ezgo.com
608822
74 99-
AUTHORIZED REPRESENTATIVE IN EC IS:
74099 G01
RANSOMES JACOBSEN LTD.
WEST ROAD, IPSWICH,
SUFFOLK, IP3 9TT, UK
614068
28203-G01
71415G01
28203G01
1- 7
SAFETY
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1
!
1.
WARNING
9.
2.
< 14û 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
!
4.
WARNING
DO NOT OPERATE
UNDER THE INFLUENCE
OF DRUGS OR ALCOHOL
5.
MAXIMUM
CROSS HILL/RAMP
ANGLE AS SPECIFIED
MAX
14û/ 25%
< 14û 25%
13.
1- 8
12.
DANGER OF EXPLOSION
DO NOT FILL GAS CAN
IN LOAD BED
WARNING
MAXIMUM CROSS
HILL/RAMP ANGLE
AS SPECIFIED
6.
8.
DO NOT RIDE IN
LOAD BED
PP
!
7.
11.
LOAD WITH
HIGH CENTER
OF GRAVITY
COULD RESULT
IN TIP OVER
MAX
XX in.
XX cm
LOAD
CENTER
OF GRAVITY,
MAXIMUM
HEIGHT
14.
MAX LOAD
XXX LBS
in
XXX KG xxx cm
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
SAFETY
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1
15.
PP
16.
17.
18.
PP
3
2
1
H 2O
PP
28.
UNLEADED
GASOLINE
DO NOT
SPILL FUEL
ON A HOT
ENGINE
PP
CLEAN UP
GASOLINE
SPILLS WITH
WATER BEFORE
STARTING ENGINE
29.
DO NOT
DISPOSE OF
BATTERIES
IN LANDFILL
DO NOT
DRIVE ON
HIGHWAY
30.
WINDSHIELDS
DO NOT
PROVIDE
PROTECTION
FROM
FLYING OBJECTS
GROUND
FUEL PUMP
19.
LOW OIL PRESSURE
20.
NEGATIVE
GROUND
BATTERY
31.
BATTERIES ARE
HEAVY.
USE CARE
LIFTING
21.
DO NOT CONNECT
POSITIVE BATTERY
TERMINAL TO GROUND
32.
USE INSULATED
TOOLS
22.
SHORTING BATTERY
TERMINALS MAY
CAUSE EXPLOSION
23.
NO
TAMPERING.
KEEP HANDS
OUT
24.
WARNING
CORROSIVE
25.
WARNING
EXPLOSIVE
26.
27.
33.
34.
WEAR EYE
PROTECTION
NO SMOKING
35.
HOT SURFACE
36.
OPERATE
FROM
DRIVERS SIDE
ONLY
WARNING
LETHAL
VOLTAGE
DO NOT
EXPOSE
TO FLAME
1- 9
SAFETY
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1
45.
HEADLIGHTS
KEEP ARMS
AND LEGS
WITHIN VEHICLE
37.
UNLOCKED
46.
38.
F
TO OPERATE VEHICLE IN FORWARD:
Q TURN KEY TO ON
Q MOVE DIRECTION SELECTOR TO
FORWARD
Q DEPRESS ACCELERATOR PEDAL
AND ACCELERATE SMOOTHLY
TO OPERATE VEHICLE IN REVERSE:
Q TURN KEY TO ON
Q MOVE DIRECTION SELECTOR TO
REVERSE
Q AN AUDIBLE DEVICE WILL SOUND
Q DEPRESS ACCELERATOR PEDAL
AND ACCELERATE SMOOTHLY
39.
R
P
40.
TO LEAVE A GASOLINE POWERED
VEHICLE IN PARK:
Q APPLY PARKING BRAKE
Q TURN KEY TO OFF
Q MOVE DIRECTION SELECTOR TO
FORWARD
LOCKED
47.
48.
DIFFERENTIAL
LOCKED
49.
WARNING
KEEP ENTIRE BODY
INSIDE CAR
50.
MAXIMUM
TAILGATE
LOAD
F
P
41.
TO LEAVE AN ELECTRIC POWERED
VEHICLE IN PARK:
Q APPLY PARKING BRAKE
Q TURN KEY TO OFF
Q MOVE DIRECTION SELECTOR TO
NEUTRAL
51.
LEAVE VEHICLE
WHEN LIGHTNING
IS IN THE AREA
52.
N
KEEP CLEAR
HAND OR
FINGERS CAN
BE TRAPPED
42.
53.
1 - 10
ENGINE
CRANKING
POSITION
START
43.
ON
ON
POSITION
44.
OFF
OFF
POSITION
cm
150
MINUMUM HEIGHT
TO OPERATE
VEHICLE
SAFETY
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Notes:
1
1 - 11
SAFETY
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1
Notes:
1 - 12
GENERAL SPECIFICATIONS
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TITLE
PAGE NO.
Vehicle Specifications SHUTTLE 2 ................................................................................................................................. 2 - 3
Vehicle Specifications SHUTTLE 4 ................................................................................................................................. 2 - 4
Vehicle Specifications SHUTTLE 6 ................................................................................................................................. 2 - 5
Vehicle Dimensions SHUTTLE 4 and SHUTTLE 6 .......................................................................................................... 2 - 6
Vehicle Dimensions SHUTTLE 2...........................................................................................................................................2 - 7
Vehicle Incline Information ............................................................................................................................................. 2 - 8
Turning Clearance Diameter and Intersecting Aisle Clearence..........................................................................................2 - 9
2- 1
2
GENERAL SPECIFICATIONS
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2
Notes:
2- 2
GENERAL SPECIFICATIONS
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2
MODEL: SHUTTLE™ 2
TYPE: GASOLINE POWERED CARGO CARRIER
MODEL YEAR: 2012
Part No:. 618849
PRODUCT SPECIFICATION
CONFIGURATION HIGHLIGHTS
Engine:
13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki
Valve Train:
Lubrication:
Overhead valve
Pressurized oil system, spin-on oil filter
Fuel System:
Ignition:
Fixed float bowl with remote pulse fuel pump
Electronic spark/magneto
Balancer:
Internal counter rotating balance shaft
Air Cleaner:
Replaceable dry cartridge
Electrical:
Drive Train:
Brakes:
Transaxle:
Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve)
Automatic, continuously variable transmission (CVT)
Dual rear wheel mechanical self-adjusting drum brakes.Single point park brake release with self-compensating system
Differential with helical gears, ground speed governor, forward/reverse
PRODUCT OVERVIEW
Dimensions
Overall Length
Overall Width
Overall Height (No Canopy)
Overall Height (With Canopy)
Wheel Base
Front Wheel Track
Rear Wheel Track
Gnd Clearance @ Differential
Cargo Bed Width
Cargo Bed Length
Vehicle Power
Power Source
Valve Train
Horsepower (kW)
Electrical System
Battery (Qty, Type)
Key or Pedal Start
Air Cleaner
Lubrication
Oil Filter
Cooling System
Fuel Capacity
Drive Train
Transaxle
Gear Selection
Rear Axle Ratio
138.5 in (352.0 cm)
46.5 in (118.0 cm)
48.6 in (123.0 cm) (Top of steering wheel)
74.0 in (188.0 cm)
93.5 in (237.0 cm)
34.2 in (89.0 cm)
38.0 in (97.0 cm)
4.75 in (12.0 cm)
44.0 in (112.0 cm)
68.5 in (174.0 cm)
4 Cycle 24.5 cu in (401 cc). Low Emission
Single Cylinder OHV
13 hp (9.7 kW) Exceeds SAE J1940 Std.
Starter/Generator. Solid State Regulator
One, 12 Volt Maintenance Free
Pedal
Industrial Rated Dry Filter
Pressurized Oil System
Spin-On
Air Cooled
5.8 Gallon (22.0 L) tank
Continuously variable transmission (CVT)
Differential with helical gears
Forward - Reverse
11.42:1 (Forward) 15.78:1 (Reverse)
Performance
Seating Capacity
Dry Weight
Curb Weight
Vehicle load capacity
Outside Clearance Circle
Intersecting Aisle Clearance
Speed (Level Ground)
Towing Capacity
Steering & Suspension
Steering
Front Suspension
Rear Suspension
Service Brake
Parking Brake
Front Tires
Rear Tires
Body & Chassis
Frame
Front Body & Finish
Rear Body & Finish
Standard Color
2 Persons
851 lb (385 kg)
891 lb (405 kg)
1200 lb (545 kg)
25.5 ft (7.8 m)
N/A
16 mph ± 0.5 mph (26 kph ± 0.8 kph)
N/A
Self-compensating rack and pinion
Leaf springs with hydraulic shock absorbers
Leaf springs with hydraulic shock absorbers
Rear wheel mechanical self-adjusting drum
Self-compensating, single point engagement
Links 18 x 8.50 - 8 (4 Ply Rated)
Links 18 x 8.50 - 8 (4 Ply Rated)
Welded steel. DuraShield™ powder coat
Injection molded TPO
Steel. Base coat/clear coat
Champagne
Some items shown may be optional equipment
Specifications are subject to change without notice
* Field installed accessories may require installation charges
2- 3
GENERAL SPECIFICATIONS
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2
MODEL: SHUTTLE™ 4
TYPE: GAS POWERED PERSONNEL CARRIER
MODEL YEAR: 2012
Part No:. 618851
PRODUCT SPECIFICATION
CONFIGURATION HIGHLIGHTS
Engine:
Valve Train:
Lubrication:
Balancer:
13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki
Overhead valve
Fuel System: Fixed float bowl with remote pulse fuel pump
Pressurized oil system, spin-on oil filter
Ignition:
Electronic spark/magneto
Internal counter rotating balance shaft
Air Cleaner:
Replaceable dry cartridge
Electrical:
Drive Train:
Brakes:
Transaxle:
Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve)
Automatic, continuously variable transmission (CVT)
Dual rear wheel mechanical self-adjusting drum brakes.Single point park brake release with self-compensating system
Differential with helical gears, ground speed governor, forward/reverse
PRODUCT OVERVIEW
Performance
Dimensions
Overall Length
Overall Width
Overall Height (No Canopy)
Overall Height (With Canopy)
Wheel Base
133.5 in (339.0 cm)
46.5 in (119.0 cm)
48.6 in (123.0 cm) (Top of steering wheel)
72.0 in (183.0 cm)
93.5 in (237.0 cm)
Seating Capacity
Dry Weight
Curb Weight
Bed Load Capacity
Vehicle load capacity
4 Person
896 lb (405 kg)
936 lb (425 kg)
400 lb (180 kg)
1200 lb (540 kg)
Front Wheel Track
Rear Wheel Track
Gnd Clearance @ Differential
Cargo Box Width (inside)
34.2 in (86.7 cm)
38.0 in (97.0 cm)
4.3 in (11.0 cm)
42.5 in (108.0 cm)
Outside Clearance Circle
Intersecting Aisle Clearance
Speed (Level Ground)
Towing Capacity
25.5 ft (7.8 m)
N/A
16 mph ± 0.5 mph (26 kph ± 0.8 kph)
N/A
Cargo Box Length (inside)
Cargo Box Depth (inside)
Cargo Box Capacity
Cargo Box material
Vehicle Power
32.0 in (80.0 cm)
11.5 in (29.0 cm)
9 cu ft (.25.0 m3)
Wood Stake Sides
Steering & Suspension
Steering
Front Suspension
Rear Suspension
Service Brake
Self-compensating reduction rack and pinion
Leaf springs with hydraulic shock absorbers
Leaf springs with hydraulic shock absorbers
Rear wheel mechanical self-adjusting drum
Power Source
Valve Train
Horsepower (kW)
Electrical System
Battery (Qty, Type)
Key or Pedal Start
Air Cleaner
Lubrication
Oil Filter
Cooling System
Fuel Capacity
Drive Train
Transaxle
Gear Selection
Rear Axle Ratio
4 Cycle 24.5 cu in (401 cc). Low Emission
Single Cylinder OHV
13 hp (9.7 kW) Exceeds SAE J1940 Std.
Starter/Generator. Solid State Regulator
One, 12 Volt Maintenance Free
Pedal
Industrial Rated Dry Filter
Pressurized Oil System
Spin-On
Air Cooled
5.8 Gallon (22.0 L) tank
Continuously variable transmission (CVT)
Differential with helical gears
Forward - Reverse
11.42:1 (Forward) 15.78:1 (Reverse)
Parking Brake
Front Tires
Rear Tires
Body & Chassis
Frame
Front & Rear Body & Finish
Seat Pod & Finish
Standard Color
Self-compensating, single point engagement
Links 18 x 8.50 - 8 (4 Ply Rated)
Links 18 x 8.50 - 8 (4 Ply Rated)
Welded steel. DuraShield™ powder coat
Injection molded TPO
Fiberglass & Gelcoat
Champagne
Some items shown may be optional equipment
Specifications are subject to change without notice
* Field installed accessories may require installation charges
2- 4
GENERAL SPECIFICATIONS
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2
MODEL: SHUTTLE™ 6
TYPE: GAS POWERED PERSONNEL CARRIER
MODEL YEAR: 2012
Part No:. 618853
PRODUCT SPECIFICATION
CONFIGURATION HIGHLIGHTS
Engine:
Valve Train:
13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki
Overhead valve
Fuel System: Fixed float bowl with remote pulse fuel pump
Lubrication:
Pressurized oil system, spin-on oil filter
Ignition:
Electronic spark/magneto
Balancer:
Internal counter rotating balance shaft
Air Cleaner:
Replaceable dry cartridge
Electrical:
Drive Train:
Brakes:
Transaxle:
Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve)
Automatic, continuously variable transmission (CVT)
Dual rear wheel mechanical self-adjusting drum brakes.Single point park brake release with self-compensating system
Differential with helical gears, ground speed governor, forward/reverse
PRODUCT OVERVIEW
Dimensions
Overall Length
Overall Width
Overall Height (No Canopy)
Overall Height (With Canopy)
Wheel Base
133.5 in (339.0 cm)
46.5 in (119.0 cm)
48.6 in (123.0 cm) (Top of steering wheel)
72.0 in (183.0 cm)
93.5 in (237.0 cm)
Performance
Seating Capacity
Dry Weight
Curb Weight
Vehicle load capacity
Outside Clearance Circle
6 Person
896 lb (405 kg)
936 lb (425 kg)
1200 lb (540 kg)
25.5 ft (7.8 m)
Front Wheel Track
34.2 in (86.7 cm)
Rear Wheel Track
38.0 in (97.0 cm)
Gnd Clearance @ Differential 4.3 in (11.0 cm)
Vehicle Power
Speed (Level Ground)
Towing Capacity
Steering & Suspension
Steering
Power Source
4 Cycle 24.5 cu in (401 cc). Low Emission
Front Suspension
Leaf springs with hydraulic shock absorbers
Valve Train
Horsepower (kW)
Electrical System
Battery (Qty, Type)
Single Cylinder OHV
13 hp (9.7 kW) Exceeds SAE J1940 Std.
Starter/Generator. Solid State Regulator
One, 12 Volt Maintenance Free
Rear Suspension
Service Brake
Parking Brake
Front Tires
Leaf springs with hydraulic shock absorbers
Rear wheel mechanical self-adjusting drum
Self-compensating, single point engagement
Links 18 x 8.50 - 8 (4 Ply Rated)
Links 18 x 8.50 - 8 (4 Ply Rated)
Key or Pedal Start
Pedal
Rear Tires
Air Cleaner
Industrial Rated Dry Filter
Body & Chassis
Lubrication
Oil Filter
Cooling System
Fuel Capacity
Pressurized Oil System
Spin-On
Air Cooled
5.8 Gallon (22.0 L) tank
Frame
Front & Rear Body & Finish
Seat Pod & Finish
Standard Color
Drive Train
Continuously variable transmission (CVT)
Transaxle
Gear Selection
Rear Axle Ratio
Differential with helical gears
Forward - Reverse
11.42:1 (Forward) 15.78:1 (Reverse)
16 mph ± 0.5 mph (26 kph ± 0.8 kph)
N/A
Self-compensating reduction rack and pinion
Welded steel. DuraShield™ powder coat
Injection molded TPO
Fiberglass & Gelcoat
Champagne
Some items shown may be optional equipment
Specifications are subject to change without notice
* Field installed accessories may require installation charges
2- 5
GENERAL SPECIFICATIONS
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2
Lowest Clearance
At Differential
4.3 in. (11.0 cm)
(All Models)
SHUTTLE 4
SHUTTLE 6
93.5 in. (237.0 cm)
122.0 in. (310.0 cm)
133.0 in. (338.0 cm)
46.5 in.
(119.0 cm)
TE5
93.5 in. (238.0 cm)
122.0 in. (310.0 cm)
46.5 in.
(119.0 cm)
2- 6
GENERAL SPECIFICATIONS
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2
SHUTTLE 2
93.5 in. (237.0 cm)
122 in. (310.0 cm)
138 in. (351.0 cm)
46.5 in.
(119.0 cm)
2- 7
GENERAL SPECIFICATIONS
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2
72.0 in.
(183.0 cm)
48.6 in.
(123.0 cm)
Front Wheel Track
34.2 in. (86.7 cm)
Rear Wheel Track
38.0 in. (97 cm)
RECOMMENDED MAX SIDE TILT
25% or 14° MAX
RECOMMENDED
MAX RAMP GRADE
25% or 14° MAX
2- 8
GENERAL SPECIFICATIONS
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2
TURNING
CLEARANCE
DIAMETER
25ft 6inches (7.8 m)
TE5 SHOWN
94 in.
(240.0 cm)
INTERSECTING
AISLE CLEARANCE
94 in.
(240.0 cm)
2- 9
GENERAL SPECIFICATIONS
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2
Notes:
2 - 10
INTRODUCTION
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TITLE
PAGE NO.
FEATURES.......................................................................................................................................................................... 3-3
General Information .................................................................................................................................................................................... 3-3
Key Switch / Headlight Switch..................................................................................................................................................................... 3-3
Low Oil Pressure Indicator Light ................................................................................................................................................................. 3-4
Fuel Guage ................................................................................................................................................................................................. 3-4
Direction Selector........................................................................................................................................................................................ 3-4
Accelerator Pedal........................................................................................................................................................................................ 3-4
Brake and Park Brake ................................................................................................................................................................................. 3-4
Horn ............................................................................................................................................................................................................ 3-4
Rear View Mirror ......................................................................................................................................................................................... 3-5
Ffront Seats................................................................................................................................................................................................. 3-5
Hip Restraint - Front.................................................................................................................................................................................... 3-5
Brake Light/ Turn Signal.............................................................................................................................................................................. 3-5
Glove Box.................................................................................................................................................................................................... 3-5
Cup Holder .................................................................................................................................................................................................. 3-5
Steering Wheel............................................................................................................................................................................................ 3-5
Choke.......................................................................................................................................................................................................... 3-5
Rear Seat (SHUTTLE 4 and 6 Only)........................................................................................................................................................... 3-5
Hip Restraint - Rear (SHUTTLE 4 and 6 Only) ........................................................................................................................................... 3-6
3- 1
3
INTRODUCTION
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Notes:
3
3- 2
INTRODUCTION
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FEATURES
General Information
NOTICE
If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key
switch in the ‘OFF’ position.
8
3
OFF
E
F
FUEL
1
Reverse
2
Forward
4
9
7
5
6
10
PARK
5. Accelerator
3- 3
3
INTRODUCTION
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1. Key Switch / Headlight 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.
2. Low Oil Pressure Indicator Light
low oil pressure indicator light is located on the dash panel . The light illuminates when the oil pressure is low.
3 ACheck
oil level. If oil level is between ADD and FULL mark on dipstick, a mechanical problem exists within the engine
and the vehicle must not be driven. Contact a local distributor or authorized branch
3. Fuel Gauge
The fuel gauge (if equipped) will either be located on the dash panel (electric) or directly on the fuel tank (mechanical).
4. Direction Selector
To reduce the possibility of component damage, the vehicle must be completely stopped before moving the direction selector.
Located on the seat support panel, this lever permits the selection of either ‘F’ (forward) or ‘R’ (reverse). Vehicle
should be left in ‘F’ when unattended.
5. Accelerator Pedal
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.
With the key switch ‘ON’, depressing the accelerator pedal starts the engine. When the pedal is released, the engine
will stop. To stop the vehicle more quickly, depress the service brake.
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.
NOTICE
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.
3- 4
INTRODUCTION
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6. Brake and Park Brake
The brake pedal incorporates a park brake feature. 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.
7. Horn
3
The horn is operated by pushing the horn button located on the floor to the left of the brake pedal.
8. Rear View Mirror
The rear view mirror is a two-position mirror manually adjusted for day and nighttime conditions.Sun Top kit is
required to install rear view mirror.
9. Front Seats
The split bench front seat is designed for one occupant on each side of the center console.
10. Hip Restraint - Front
The front hip restraints are designed to help keep the occupants properly positioned in the event of sudden vehicle
position changes.
11. Brake Light/Turn Signal
The combination brake light/turn signal assemblies are located on the rear fenders.
12. Glove Box
A passenger-side locking glove box is standard, driver-side is offered as an option. A separate key is used for the
locking glove boxes.
13. Cup Holder
A cup holder is provided for convenience of both the driver and passenger.
14. Steering Wheel
The steering wheel located in front of the driver seat is used to steer the vehicle. The steering wheel is also installed
with scorecard holder assembly.
15. Choke
The choke is used to aid cold starting . See COLD STARTING section for operating instructions.
16. Rear Seat (SHUTTLE 4 and 6 only)
The rear seats is designed for two occupant on each side of the seat.
To prevent severe injury or death, rear seat passengers should hold on to both the hip restraints
and the rear hand hold when the vehicle is in motion. Always be sure that all passengers are
seated and holding on before operating vehicle.
3- 5
INTRODUCTION
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17. Hip Restraint - Rear (SHUTTLE 4 and 6 only)
The rear hip restraints are designed to help keep the occupants properly positioned in the event of sudden vehicle
position changes. Be sure that all passengers are seated and holding onto both the hip restraint and the rear hand
hold (rear facing passengers) before operating the vehicle.
3
12
13
14
15
11
3- 6
INTRODUCTION
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Notes:
3
3- 7
INTRODUCTION
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Notes:
3
3- 8
OPERATING PROCEDURES
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TITLE
PAGE NO.
SERIAL NUMBER LOCATION ............................................................................................................................................ 4-3
BEFORE INITIAL USE ........................................................................................................................................................ 4-4
OPERATING THE VEHICLE ............................................................................................................................................... 4-4
RUN IN........................................................................................................................................................................................................ 4-5
COLD STARTING ....................................................................................................................................................................................... 4-6
STARTING AND DRIVING .................................................................................................................................................. 4-6
STARTING THE VEHICLE ON A HILL................................................................................................................................ 4-6
COASTING .......................................................................................................................................................................... 4-7
FUEL ................................................................................................................................................................................... 4-7
BATTERY ............................................................................................................................................................................ 4-8
SUN TOP AND WINDSHIELD ............................................................................................................................................. 4-8
4- 1
4
OPERATING PROCEDURES
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Notes:
4
4- 2
OPERATING PROCEDURES
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SERIAL NUMBER LOCATION
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.
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 mustacture date code, serial number and vehicle model must be
provided when ordering service parts.
4
Lift Flap on Access Panel
Serial Number
Labels
Ref Spl 3
Label No.
V
Serial Number & Location
4- 3
OPERATING PROCEDURES
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BEFORE INITIAL USE
Read and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle and its
equipment as well as how to use it safely. Maintaining good performance depends to a large extent on the operator.
Before a new vehicle is put into operation, the items shown in the INITIAL SERVICE CHART must be performed.
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.
4 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
Battery
Seats
Brakes
Tires
Fuel
Engine
SERVICE OPERATION
Charge battery
Remove protective plastic covering
Check operation and adjust if necessary
Check hydraulic brake fluid level if
equipped
Establish mechanical brake base line
Check pressure (see SPECIFICATIONS)
Fill tank with correct fuel
Check oil level
Initial Service Chart
OPERATING THE VEHICLE
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).
4- 4
OPERATING PROCEDURES
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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 vehicle is to be left unattended, engage the park
brake, move direction selector to forward position, turn key to ‘OFF’ position and remove key.
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.
Fill Cold Engine
To This Point
Add Oil
Maximum Oil Level
For Hot Engine
Do Not Overfill
Safe
Operating Range
Hot Engine
Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.
NOTICE
The oil dipstick/fill cap must be in place before operating the engine. Failure to install the dipstick/fill cap will result in oil
becoming contaminated and/or being discharged into the engine compartment.
Oil dipsticks are unique to this model vehicle. Do not interchange oil dipsticks between models.
4- 5
4
OPERATING PROCEDURES
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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.
4
Clean Entire 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.
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
NOTICE
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
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.
4- 6
OPERATING PROCEDURES
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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 roll-back
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
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.
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. Fill the tank with fresh, clean, automotive grade gasoline. High altitude or heavy use/load applications may benefit from higher octane gasoline.
Do not use gasoline which contains Methanol.
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.
Use fresh regular grade unleaded fuel. Ethanol blend fuel upto 10% is permissible.
4- 7
4
OPERATING PROCEDURES
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1" minimum (2.5 cm)
FUEL
4
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 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.
SUN TOP AND WINDSHIELD
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.
To prevent damage to the vehicle, do not hold on to sun top struts and stand on body panels.
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.
4- 8
OPERATING PROCEDURES
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Notes:
4
4- 9
OPERATING PROCEDURES
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Notes:
4
4 - 10
MAINTENANCE
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TITLE
PAGE NO.
VEHICLE CLEANING AND CARE ...................................................................................................................................... 5-3
Vehicle Cleaning ......................................................................................................................................................................................... 5-3
COMMON SENSE OPERATION ......................................................................................................................................... 5-4
ENVIRONMENTAL CONCERNS......................................................................................................................................... 5-4
REPAIR ............................................................................................................................................................................... 5-5
Lifting the Vehicle........................................................................................................................................................................................ 5-5
WHEELS AND TIRES.......................................................................................................................................................... 5-6
Tire Repair .................................................................................................................................................................................................. 5-6
Wheel Installation........................................................................................................................................................................................ 5-7
LIGHT BULB REPLACEMENT ........................................................................................................................................... 5-8
FUSE REPLACEMENT ....................................................................................................................................................... 5-8
VEHICLE WITH A DISCHARGED BATTERY ..................................................................................................................... 5-8
TRANSPORTING VEHICLE ................................................................................................................................................ 5-9
TOWING ..................................................................................................................................................................................................... 5-9
NEUTRAL LOCK......................................................................................................................................................................................... 5-9
Hauling ........................................................................................................................................................................................................ 5-9
SERVICE AND MAINTENANCE ....................................................................................................................................... 5-10
ROUTINE MAINTENANCE................................................................................................................................................ 5-11
Tire Inspection........................................................................................................................................................................................... 5-11
Rear Axle .................................................................................................................................................................................................. 5-11
FOUR CYCLE ENGINE ............................................................................................................................................................................ 5-11
Engine Specifications................................................................................................................................................................................ 5-11
Engine Description .................................................................................................................................................................................... 5-11
CHECKING THE OIL LEVEL .................................................................................................................................................................... 5-11
Changing the Oil ....................................................................................................................................................................................... 5-12
STARTER/ GENERATOR BELT TENSION.............................................................................................................................................. 5-15
Adjusting the Belt ...................................................................................................................................................................................... 5-15
BATTERY CLEANING .............................................................................................................................................................................. 5-16
BRAKES.................................................................................................................................................................................................... 5-17
PERIODIC BRAKE TEST FOR MECHANICAL BRAKES ................................................................................................. 5-17
AIR INTAKE AND COOLING FINS ................................................................................................................................... 5-18
REAR AXLE ...................................................................................................................................................................... 5-18
Checking the Lubricant Level.................................................................................................................................................................... 5-18
AIR CLEANER INSPECTION AND REPLACEMENT ....................................................................................................... 5-19
5- 1
5
MAINTENANCE
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Cleaning the Air Filter Element.................................................................................................................................................................. 5-19
LUBRICATION ..................................................................................................................................................................5-20
SPARK PLUGS .................................................................................................................................................................5-20
PROLONGED STORAGE..................................................................................................................................................5-20
HARDWARE ......................................................................................................................................................................5-22
CAPACITIES AND REPLACEMENT PARTS ....................................................................................................................5-22
PERIODIC SERVICE SCHEDULE .....................................................................................................................................5-23
5
5- 2
MAINTENANCE
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VEHICLE CLEANING AND CARE
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.
NOTICE
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.
5- 3
5
MAINTENANCE
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COMMON SENSE OPERATION
To prevent severe injury or death, observe the following:
Never transport loaded firearms on or in vehicle
Check that firearms are unloaded with the safety engaged and are properly secured with muzzle
pointing in a safe direction before operating vehicle.
Be aware of other firearms in proximity to operator and passengers.
vehicle is not a toy. If not operated properly and responsibly, it can cause severe injury or death to the opera5 This
tor, passengers or bystanders. All operators should possess a valid driver’s license. Children should not be permitted
to operate the vehicle. Children may not have the skill, judgement or strength to operate this or similar vehicles.
Alcohol, drugs and many over the counter medications reduce the ability of the driver to operate the vehicle safely.
Always review side effects of any medication with a doctor or pharmacist before operating vehicle.
Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when operating vehicle in rough or densely wooded terrain.
When driving at full speed on a dirt road, loose surfaces or wet grass, vehicle stopping distance will increase. If the
vehicle is fully loaded, it will take longer to stop than with no load. When operating vehicle in wet weather conditions,
remember that the brakes may need to be lightly applied in order to provide enough friction to dry the brake unit. If
wet, the brakes will lose much of their effect.
Slow down when in unfamiliar terrain. Slow down when cresting a hill in an area that you are unfamiliar with.
Some hills are too steep to climb. If you attempt to climb a hill that is too steep or if you are unable to achieve adequate traction, do not attempt to turn around on the hill. Slowly back straight down the hill using the service
brake to control speed.
ENVIRONMENTAL CONCERNS
As a responsible user, practice respect for all wildlife and their habitat. Respect private property
and comply with all local laws and regulations governing the use of light duty utility vehicles. To
prevent severe injury or death while driving, be aware of the following:
Environmental hazards such as steep slopes, overhanging limbs, etc.
Danger of fire when vehicle is operated over dry combustible organic material.
When driving, be aware of environmental hazards such as steep slopes, overhanging limbs, etc. Be aware of the
danger of fire when the gasoline powered vehicle is operated over dry combustible organic material.
5- 4
MAINTENANCE
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REPAIR
Some servicing operations may require the front wheels, the rear wheels, or the entire vehicle to be raised.
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.
5
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 the vehicle, position the jacks and jack stands at the areas indicated only.
Lifting The Vehicle
Tool List
Qty.
Floor jack .................................................................... 1
Wheel Chocks ............................................................. 4
Tool List
Qty.
Jack stands ............................................................. 4
Remove payload from vehicle before lifting. No person(s)
should be in or on the vehicle while lifting.
Center of
Front Axle
To raise the entire vehicle, install chocks in front and behind
each front wheel. 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.
Flat Portion
of Frame
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.
Outside End
of Rear Axle
View From Underside Of Vehicle
5- 5
MAINTENANCE
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WHEELS AND TIRES
A tire explosion can cause severe injury or death. Never exceed the inflation pressure rating on
the tire sidewall.
To reduce the possibility of tire explosion, pressurize tire with small amounts 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 a valve core.
5 only sockets designed for impact wrench use.
To reduce the possibility of severe injury caused by a broken socket when removing wheels, use
DO NOT use low inflation tires on any E-Z-GO vehicle. DO NOT use any tire which has a recommended inflation pressure less than the inflation pressure recommended in the owner’s guide.
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.
Tire Repair
Tool List
Qty.
Lug wrench, 3/4" ..........................................................1
Impact wrench .............................................................1
Tool List
Qty.
Impact socket, 3/4" ................................................. 1
Torque wrench, ft. lbs.............................................. 1
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 stem dust cap after checking or inflating.
The vehicle is fitted with low pressure tubeless tires mounted on one piece rims; the
ore, the most cost effective way to repair a puncture in the tread is to use a commercial tire plug.
NOTICE
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 the possibility of severe injury, be sure the mounting/demounting machine is anchored
to floor. Wear OSHA approved safety equipment when mounting/demounting tires.
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.
5- 6
MAINTENANCE
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Wheel Installation
To reduce the possibility of component damage, do not tighten lug nuts to
more than 85 ft. lbs. (115 Nm) torque.
Valve Stem Cap
NOTICE
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 the lug nuts (1) in a ‘cross sequence’ pattern. Tighten
the lug nuts to 50 to 85 ft. lbs. (68 to 115 Nm) torque in 20 ft. lbs. (27 Nm)
increments following the ‘cross sequence’ pattern.
5
Tire style may vary
Unidirectional Tires
Some vehicles may be fitted with unidirectional tires. These tires may be
identified by a directional arrow on the sidewall. Be sure to position the
wheel on hub correctly with arrow indicating direction of rotation when
moving forward.
Cross Sequence
Rota
'Cross Sequence'
1
3
tion
Front of
Vehicle
4
2
Tire style may vary
5- 7
MAINTENANCE
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LIGHT BULB REPLACEMENT
Inside
of Cowl
Headlight
Casing
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.
Screw
Headlight
Bulb
For vehicles with headlights, locate the screws on backside of cowl that secure headlight. Remove screws, pull
headlight out and disconnect wires. Connect wires to
new headlight, install in cowl and secure with screws
previously removed.
5 To replace the turn signal light bulb, support turn signal housing from backside
of cowl while removing two screws securing lens. Install new bulb and replace
lens.
To replace the tail and brake light bulb, roll the rubber bezel from around the
edge of the taillight and remove lens. Install replacement bulb and replace
lens. To replace the tail and brake light bulb, remove hardware securing lens
Rear
Fender
Roll Rubber
Bezel Away
From Body
Tail/Brake
Light
Rear
Fender
Tail Light
Lens
Tail Light
Bulb
and remove lens. Install replacement bulb.
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. Headlight and taillight bulbs and fuses are available from a local Distributor, an authorized Branch or
the Service Parts Department.
VEHICLE WITH A DISCHARGED BATTERY
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.
5- 8
MAINTENANCE
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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
TOWING
This vehicle is not designed to be towed
It is recommended that the vehicle be moved by placing the entire vehicle on a trailer, flatbed truck or other suitable
transport.
NEUTRAL LOCK
To prevent the driven clutch from turning the rear wheels during service operations, a neutral lock is located on the
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. 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.
2
3
1
Hole in Direction
Selector Cam
Unlocked
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
selector cam.
HAULING
To reduce the possibility of severe injury or death while transporting the vehicle:
Secure the vehicle and contents.
Never ride on the vehicle being transported.
Always remove the windshield before transporting.
5- 9
5
MAINTENANCE
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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 plus 1000 lbs. (454 kg). Secure the vehicle using ratchet
tie downs.
SERVICE AND MAINTENANCE
5 To reduce the possibility of severe injury or death from improper servicing techniques:
DO NOT attempt any type of servicing operations before reading all notes, cautions and warnings in this manual.
Any servicing requiring adjustments to be made to the powertrain while the motor is running
must be made with both drive wheels raised and vehicle properly supported on jack stands.
To reduce the possibility of motor damage, never operate vehicle at full throttle for more than
4 - 5 seconds while vehicle is in a ‘no load’ condition.
Reduce the possibility of accidental starting by disconnecting battery at negative terminal
before servicing.
Wear eye protection when working on the vehicle. Use extra care when working around batteries, or using solvents or compressed air.
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.
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.
5 - 10
MAINTENANCE
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ROUTINE MAINTENANCE
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, or frequent use with maximum
load.
To access the powertrain for routine maintenance, lift or remove the seat and remove the rear access panel. For
major repair, refer to the 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.
Tire Inspection
Tire condition should be inspected per the Periodic Service Schedule. Inflation pressures should be checked when
the tires are cool. Be sure to install the valve dust cap after checking or inflating.
Rear Axle
The only maintenance required for the first five years is the periodic inspection of the rear axle for lubricant leakage.
Unless leakage is evident, the lubricant need only be replaced after five years. Refer to the Service and Repair Manual for the fluid replacement procedure.
FOUR CYCLE ENGINE
Engine Specifications
Engine model .............................................................................................................................................. FJ400D
Type ............................................................................................................................................... Four cycle, OHV
Number of cylinders ................................................................................................................................................1
Displacement ................................................................................................................................................. 401 cc
Rated horsepower............................................................................................................................................13 hp
Spark plug type ..................................................................................................................................NGK BPR2ES
Spark plug gap .............................................................................................................. .028" - .031" (.70 - .80 mm)
Cooling .......................................................................................................................................... Forced air cooled
Oil Filter......................................................................................................................... Cartridge type full flow filter
Oil Pump ...................................................................................................................... Positive displacement pump
Engine Description
The engine is an air cooled, 4-stroke, OHV, single cylinder gasoline engine. It incorporates a pressure fed lubrication
positive displacement oil pump with a cartridge type full flow oil filter and a counter rotating balance shaft.
CHECKING THE OIL LEVEL
Do not overfill engine. Too much oil may cause engine to smoke or cause spark plug fouling.
Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.
The oil should be checked with the engine warm. The vehicle should be on a level surface with the parking (PARK)
brake engaged. Allow adequate time for oil to drain into the crankcase before checking.
5 - 11
5
MAINTENANCE
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Remove the dipstick and wipe off the entire area with a lint free cloth.
5
Insert the dipstick fully into the dipstick hole and remove. Examine the level of the oil on the dipstick.
Fill Cold Engine
To This Point
Add Oil
Maximum Oil Level
For Hot Engine
Do Not Overfill
Safe
Operating Range
Hot Engine
The engine can be operated safely as long as oil is within the safe operating range as indicated on the dip stick. Do
not operate vehicle if oil level is below the safe area indicated on the dipstick.
Oil should be added to bring the level into the safe operating range. Remember that oil expands as it gets hot, Do
not overfill. Check that the oil cap is firmly in place.
NOTICE
When adding oil between oil changes, do not mix brands and viscosity grades of oil
The oil dipstick/fill cap must be in place before operating the engine. Failure to install the dipstick/fill cap will result in
oil becoming contaminated and/or oil being discharged into the engine compartment.
Changing the Oil
Tool List
Qty.
Socket, 3/8" drive.................................................................................................................................................... 1
Ratchet, 3/8" drive .................................................................................................................................................. 1
Extension, 3/8" drive, 8".......................................................................................................................................... 1
Oil drain pan ........................................................................................................................................................... 1
Wrench, 3/4" ........................................................................................................................................................... 1
For maximum performance and longevity, the engine oil should be replaced after the first 8 hours of operation. After
the initial oil change, it should be changed every 125 hours of operation or semi-annually, whichever comes first.
5 - 12
MAINTENANCE
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The selection of oil is dependent upon the service that the vehicle will perform. Most vehicles require 10W-30 oil,
whereas vehicles used at capacity or near capacity load applications will utilize 10W-40 oil after a break-in period of
100 hours.
HEAVY DUTY WORK
10W-40
10W-30
LIGHT DUTY WORK
10W-30
F
0
C
0
-20
-30
0
-20
20
40
60
-10
0
10
20
(AIR TEMPERATURE)
80
100
30
5
40
NOTICE
If vehicle is to be stored over winter months, it can be stored with old oil left in engine. The oil should be changed as
part of spring maintenance. This will remove any moisture that has accumulated during storage.
Be aware that engine fluids may be hot and contact to the skin may cause severe burns. Wear
rubber gloves to protect skin from exposure to the old oil and de greaser.
The oil should be changed with engine warm. Park vehicle on a level surface, engage parking brake and remove key. Place a drain
pan under engine. Wipe top of the engine clean with a cloth. Remove the oil fill cap.
Oil Fill Cap
Clean the area around filter. Using a filter wrench, strap wrench or other suitable wrench, remove the filter (B) from
the engine and allow the oil to drain. The ‘O’ rings may remain on engine (A) or filter (B)
5 - 13
MAINTENANCE
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Inspect the filter. Make sure the ‘O’ ring is not left on the engine surface.
5
Be careful of hot oil when drained. It may be hot enough to burn you severely
Drain the oil by removing the drain plug found at the rear of the engine base. Remove using a 3/4" wrench. At the
first oil change, small metal chips and lint may be found. This is normal, resulting from the break-in period. Inspect
the filter at every oil change. The presence of large metal chips could indicate possible damage to the engine.
Wipe the area around the drain plug mount with a lint free cloth and inspect the drain plug (A) for damage; replace if
necessary. Replace the "O"-ring (B) with a new one and tighten to 61 in. lbs. (7.0 Nm) torque. Apply engine oil to the
oil filter seal and install oil filter onto the engine until the seal contacts mounting surface of the engine. Then turn the
filter 2/3 to 3/4 rotations by HAND(S). Pour in the specified type and amount of oil See "Capacity and Replacement
Parts" chart on page 55.
Oil capacity is 1 1/3 quarts (1.3 liters). Add slightly less than 1 1/3 quarts (1.3 liters) to allow for possible residual oil
left in engine. The oil must be high quality oil that meets or exceeds API SF, SG, CC standards. Check oil level on
dipstick. Oil should be slightly below ‘H’ to allow for expansion. 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.
Do not overfill engine. Too much oil may cause smoking or
allow oil to enter the air filter enclosure.
NOTICE
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
5 - 14
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
As a final check, check the oil level again with the vehicle on level ground. Like all liquids, oil increases in volume
when warm. The full ‘H’ mark on the dipstick is calibrated for an engine at operating temperature. When the engine is
cold, the oil will be below the full mark. 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.
STARTER/GENERATOR BELT TENSION
Tool List
Qty.
Belt tension gauge ..................................................................................................................................................1
Wrench, 3/4" ...........................................................................................................................................................1
Wrench, 9/16" .........................................................................................................................................................2
Ratchet, 3/8" drive...................................................................................................................................................1
Socket, 3/4", 3/8" drive............................................................................................................................................1
5
The starter/generator belt tension should be checked after the first 15 - 20 hours and set to 75 - 80 lbs. (34 - 36 kg)
NOTICE
A loose belt can cause audible vibration and squeal.
Tighten a new starter/generator belt to 90 - 110 lbs. (41-50 kg) tension when a gauge is applied half way between
the two pulleys.
3/8" (1 cm) Maximum
Deflection (New Belt)
1/2" (1.3 cm) Maximum
Deflection (Existing Belt)
A new belt may be checked manually. A maximum deflection of 3/8" (10 mm) is acceptable. 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 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.
5 - 15
MAINTENANCE
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Tighten the starter/generator pivot bolt.
5
BATTERY CLEANING
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. Periodic Service Schedule)
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.
Non-Metalic Wandr
1/4 Cup (60 ML)
Sodium Bicarbonate
(Baking Soda)
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. 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.
Allow the solution to sit for at least three minutes; use
a soft bristle brush or cloth to wipe the tops of the bat1 1/2 GAL (6 Liters) Water
5 - 16
2 GAL (8 Liters)
Gargen Sprayer
(1 1/2 GAL (6 Liters)
Baking Powder Solution
MAINTENANCE
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tery 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.
BRAKES
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.
NOTICE
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 as an evaluation of braking system performance. It is useful as a method of identifying subtle loss of performance over time.
Periodic Brake Test For Mechanical Brakes
Dry, Level, Clean, Paved Surface
Accelerate To
Maximum Speed
Latch
Parking Brake
and Take Foot
Off Pedal
Line or Marker
Line or Marker
Acceptable
Stopping 4 ft. (1.2 m)
Distance
Ref Bpt 2S
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
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 park
brake to eliminate different pedal pressures and to include the affects of linkage mis-adjustment.
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.
NOTICE
5 - 17
5
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
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. 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.
5 AIR INTAKE AND COOLING FINS
To prevent possible burns, engine parts should be kept clean to reduce risk of overheating and
ignition of accumulated debris. 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. Keep linkages, springs and controls clean. Keep area around muffler free of any combustible material.
At least once a year, (or more often under adverse conditions) the cooling system should be cleaned. Cleaning will
assure an adequate supply of air to the cooling fins. Compressed air may be used for routine cooling system maintenance.
REAR AXLE
The rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing.
Unless leakage of rear axle lubricant is evident, an annual lubricant check is sufficient.
Checking The Lubricant Level
Tool List
Qty.
Socket, 13 mm, 3/8" drive....................................................................................................................................... 1
Ratchet, 3/8" drive .................................................................................................................................................. 1
Funnel..................................................................................................................................................................... 1
5 - 18
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
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. 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.
Fill / Check Plug
5
Drain Plug
AIR CLEANER INSPECTION AND REPLACEMENT
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. To aide installation and sealing, petroleum jelly may be applied to back side of cover tabs and each side of filter seal.
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
engine.
5 - 19
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
The air cleaner element is accessible by unsnapping the clips on the air canister and removing the cover and air filter element. Clean inside of cover, canister 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 clips are fastened securely.
Air Cleaner
Canister
Air Filter
Element
Air Cleaner
Cover
Dust
Collector
5 If the element is in acceptable condition, loose dirt may be removed by tapping the filter lightly. Do not use oil on the filter
Ref Air 2
element or any part of the unit.
LUBRICATION
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.
Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure.
Lubrication Points
Rack
Ball
Joint
View from Underside of Vehicle
SPARK PLUGS
Tool List
Qty.
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
Use care not to over-tighten the plug. Over-tightening can cause damage to the aluminum cylinder head threads.
Remove and inspect the spark plug at intervals indicated in the Periodic Service Schedule. Spark plug should be
5 - 20
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
properly gapped. Tighten to 16 ft. lbs. (22 Nm) torque
Remove and inspect the spark plug at intervals indicated in the Periodic Service Schedule. Spark plug should be properly gapped. Tighten to 16 ft. lbs. (22 Nm) torque.
Fouled spark plug is 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 wire which are in poor condition or poor
quality fuel could also contribute to the problem.
Spark Plug
5
.030"
(.75 mm)
Gap
Ref Spg 1S
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.
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 plug and pour about 1 oz. (30 ml) of engine oil into the cylinder. Replace spark plug, ground spark
plug wire 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.
• Clean body, chassis and engine of debris, mud, chaff or grass.
5 - 21
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Hardware
Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the
Torque Specifications table.
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.
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.
5
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)
Capacities and Replacement Parts
Fuel Tank / Fuel
6.0 gal (22.5 liters) / 87 Octane Min.
Engine Oil
1.4 US qt (1.3 liters)
Oil Filter
P/N 26591-G01
Air Filter
P/N 28463-G01
Spark Plug
NGK BPR2ES (P/N 25523-G3)
.020 - .030" (.71 - .75 mm) Gap
Starter/Generator Belt
P/N 606138
Clutch Belt
P/N 606136
Rear Axle Oil
51 oz (1.5 liters) / SAE 30
Fuse
15 amp (P/N 18392-G1)
LED Bulb
(P/N 619101)
Headlight Bulb
(P/N 619100)
Turn Signal Bulb
(P/N 619102)
Tail Light Bulb
#1157 (P/N 21759-G1)
5 - 22
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
PERIODIC SERVICE SCHEDULE
 Check
 Clean, Adjust, etc.
Replace
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:
 Check service brake general operation
 Check park brake operation - does it hold on a hill.
 Check warning device function in reverse
 Check tire pressure, condition of tires & rims.
 Check smooth operation of accelerator.
 Check for loose or missing hardware.
 Check Battery - state of charge, condition, loose terminals, corrosion, hold down &
hardware
 Check overall vehicle condition
WEEKLY (includes items listed in previous table & the following)
Examine
TIRES
WHEELS
COOLING FAN
ENGINE OIL
STARTER/GENERATOR BELT
for cuts, excessive wear and pressure (See GENERAL SPECIFICATIONS)
 Check for bent rims, missing or loose lug nuts
Check for build-up of foreign matter inside blower housing and fins, clean if required
 Check and add if required - DO NOT OVERFILL
 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
Check all wiring for loose connections and broken/missing insulation
Check for smooth movement - DO NOT LUBRICATE CABLE
Conduct brake performance test
Check brake performance and adjust if required
Check for smooth movement and adjustment - DO NOT LUBRICATE CABLE
Check attachment, adjust as required
Check attachment, adjust as required
Check for unusual noise, vibration, acceleration, oil leaks
Check for build-up of foreign matter inside blower housing and fins, clean if required
Check for abnormal play, tightness of all hardware
Check for excessive play, bent components or loose connections
Check for leakage, add SAE 30 oil as required
QUARTERLY - 60 HOURS (includes items listed in previous tables & the following)
PARK BRAKE
Check for damage to axle and loose or missing hardware
Check for oil leakage and loose fasteners
Check for loose hardware, cracks at attachments
Check for unusual tire wear, align if required
Check for bent/binding linkage rod
Check for damage or wear to latch arm or catch bracket
REAR SHOCK ABSORBERS
ENGINE ELECTRICAL SYSTEM
Check for oil leakage, loose mounting hardware
Check coil/spark plug wires for cracks/loose connections
FRONT AXLE
FRONT SHOCK ABSORBERS
FRONT SPRINGS
FRONT WHEEL ALIGNMENT
 Lubricate as required, use light oil. DO NOT LUBRICATE CABLES OR BRAKE
LATCH
5 - 23
5
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
FUEL SYSTEM
THROTTLE/GOVERNOR LINKAGE
HARDWARE AND FASTENERS
Check for leaks at tank, cap, system lines, filters, pump, carburetor
Check system lines for cracks/deterioration
Check operation and governed speed
Check for loose or missing hardware and components
 Tighten or replace missing hardware
SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)
5
BATTERY
DIRECTION SELECTOR
KING PINS
STEERING ASSEMBLY
RACK END BALL JOINT
REAR AXLE
AIR FILTER ELEMENT
OIL FILTER
Clean battery & terminals
Check for wear and smooth movement (lubricate shaft with light oil if required)
Check for excessive play and tightness of retaining nuts
Check bellows and pinion seal for damage or grease leakage
 Lubricate, use wheel bearing grease
Check for unusual noise and loose or missing mounting hardware
Check filter element, clean/replace as required
ENGINE OIL
Replace (at oil change)
Replace with SAE 10W-30 or 10W-40 that meets or exceeds SF, SG, CC oil,
DRIVE BELT
Check 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
 Check and adjust as required, see Technician’s Repair and Service Manual
Check lubricant, add lubricant as required
Clean and adjust, see Technician’s Repair and Service Manual
SERVICE BRAKES
FUEL FILTER
SPARK PLUG
MUFFLER/EXHAUST
VALVES
Check brake shoe linings, see Technician’s Repair and Service Manual
Check level, add if required (DOT 3) and check for leakage
 Replace
 Replace, gap new plug
Check mounting hardware; check for leaks at head and muffler gaskets
Check cold (intake/exhaust) per Technician’s Repair and Service Manual
500 HOURS (includes items listed in previous tables & the following)
CARBURETOR
CYLINDER HEAD AND PISTON
5 - 24
 Clean
 Remove carbon from cylinder head and piston
Check valve seats for carbon buildup and clean as required
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Notes:
5
5 - 25
MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.
Notes:
5
5 - 26
E-Z-GO Division of Textron Inc.,
1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA
Service Parts Manuals, as well as Repair and Service Manuals
are available from a local Distributor, an authorized Branch,
Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.
Copyrighted Material
This manual may not be reproduced in whole or
in part without the express permission of
E-Z-GO Division of Textron Inc.
Technical Communications Department