operation and service information

OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
Thank you for purchasing a Gas Powered Light Duty
Utility Vehicle. Before driving the vehicle, we ask you to
spend some time reading this Owner’s Manual and Service Guide. This Guide contains the information that will
assist you in the safe operation of the vehicle. It will also
assist you in maintaining this highly reliable vehicle.
Some illustrations show items that may be optional for
your vehicle. This guide covers the operation of several
vehicles; therefore, some pictorial views may not represent your vehicle. Physical differences in controls will be
illustrated.
This vehicle has been designed and manufactured as a
‘World Vehicle’. Some countries have individual requirements to comply with their specifications; therefore,
some sections may not apply in your country.
Most of the service procedures in this guide can be
accomplished using common automotive hand tools.
Contact your service representative on servicing the
vehicle in accordance with the Periodic Service Schedule.
Service Parts Manuals and Technician’s Repair and Service Manuals are available from a local Distributor, an
authorized Branch or the Service Parts Department.
When ordering parts or requesting information for your
vehicle, provide vehicle model, serial number and manufacture code.
Hydrogen gas is generated as a natural part of
the lead acid battery charging process. A 4%
concentration of hydrogen gas is explosive and
could cause severe injury or death. Charging
must take place in an area that is adequately
ventilated (minimum of 5 air exchanges per
hour).
To reduce the chance of battery explosion that
could result in severe injury or death, never
smoke around or charge batteries in an area
that has open flame or electrical equipment
that could cause an electrical arc.
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%.
Because hydrogen gas is lighter than air, it will collect in
the ceiling of buildings necessitating proper ventilation.
Five air exchanges per hour is considered the minimum
requirement.
Never charge a vehicle in an area that is subject to
flame or spark. Pay particular attention to natural gas or
propane gas water heaters and furnaces.
Before a new vehicle is put into operation, the items
shown in the INITIAL SERVICE CHART must be performed (Ref. Fig. 1 on page 1).
BEFORE INITIAL USE
Read, understand and follow the safety label on the
instrument panel. Be sure you understand how to operate the vehicle, its equipment and how to use it safely.
Maintaining good performance depends to a large
extent on the operator.
ITEM
SERVICE OPERATION
Battery
Charge battery
Seats
Remove protective plastic covering
Brakes
Check operation and adjust if necessary
Establish acceptable stopping distance
Tires
Check air pressure (see SPECIFICATIONS)
Fuel
Fill tank with correct fuel
Engine
Check oil level
Ref Isc 2
Improper use of this vehicle could result in
severe injury or death. The ST series are light
duty utility vehicles, NOT All Terrain Vehicles
(ATV’s).
This vehicle is not a toy and using it while
engaging in horseplay is dangerous.
Plan carefully before using the vehicle to go
significant distances over questionable terrain.
Remember that a one hour drive may take
many hours to walk out should you run out of
fuel or be stranded by becoming stuck on
unsuitable terrain.
Fig. 1 Initial Service Chart
Vehicle battery must be fully charged before initial use.
Check for oil or fuel leaks that could have developed in
shipment from the factory.
Determine and record braking distance required to stop
vehicle for future brake performance tests.
Remove the protective clear plastic, that protect the seat
bottom and back rest during shipping, before placing the
vehicle in service.
Repair and Service Manual
Page 1
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
CONTROLS AND INDICATORS
Vehicle controls and indicators consist of:
•• key/light
switch
direction selector
•• choke
gauge
•• fuel
low oil pressure indicator light
pedal
•• accelerator
combination service and park brake pedal
• horn
12 volt power outlet
Located on the seat support panel, this lever permits the
selection of either ‘F’ (forward) or ‘R’ (reverse) (Ref. Fig.
3 on page 2). The vehicle should be left in ‘F’ when
unattended.
Reverse
KEY/LIGHT SWITCH
Forward
Ref Dsl 2
Fig. 3 Direction Selector
CHOKE
OFF
The choke is used to aid cold starting (Ref. Fig. 4 on
page 2). See “COLD STARTING” on page 13
ON
E
F
Key/Light Switch
FUE
L
Low Oil Pressure Light
Fuel Gauge
Ref Kes 2S
Ref Chk 1S
Fig. 2 Key/Light Switch and Fuel Gauge
Located on the dash panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the
key. To prevent inadvertent operation of the vehicle when left
unattended, the key should be turned to the ‘OFF’ position and
removed (Ref. Fig. 2 on page 2).
Choke
Fig. 4 Choke
FUEL GAUGE
The fuel gauge (if equipped) will either be located on the
dash panel or directly on the fuel tank (Ref. Fig. 2 on
page 2).
LOW OIL PRESSURE INDICATOR LIGHT
If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key
switch in the ‘OFF’ position.
If the vehicle is equipped with lights, the key switch has
a position to operate them, indicated by the light icon.
A low oil pressure indicator light is located on the dash
panel (Ref. Fig. 2 on page 2). The light illuminates when
the oil pressure is low. Check oil level. If oil level is
between ADD and FULL mark on dipstick, a mechanical
problem exists within the engine and the vehicle must
not be driven (Ref. Fig. 21 on page 12). Contact a local
distributor or authorized branch.
DIRECTION SELECTOR
To reduce the possibility of component damage, the vehicle must be completely stopped before moving the direction selector.
Page 2
To prevent engine damage, do not operate engine until oil
pressure is corrected. Do not overfill engine. Too much oil
may cause smoking or allow oil to enter the air filter
enclosure.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
If oil level is below ADD mark on dipstick, add oil to bring
level to FULL mark. Drive vehicle a short distance and
check oil pressure. If oil light does not come on, continue to use vehicle.
H
Horn
Park
Brake
Service
Brake Accelerator
ORN
ACCELERATOR PEDAL
Ref Abh 1S
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 (Ref. Fig. 5 on page 3). 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.
Fig. 5 Accelerator, Brake and Horn
12 VOLT POWER OUTLET
Overuse of accessories may drain the battery and leave
insufficient reserve to start the vehicle.
A 12 volt power outlet, rated at 15 amps, is located to
the left side of the key/light switch (Ref. Fig. 6 on page
3). It provides constant power for accessories equipped
with a 12 volt plug.
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.
Depressing the lower section of the brake pedal is the preferred method of releasing the park brake to assure the longest service life of brake components.
COMBINATION SERVICE AND PARK BRAKE
PEDAL
The brake pedal incorporates a park brake feature (Ref.
Fig. 5 on page 3). To engage, push down on the upper
section of the pedal until it locks in place. The park
brake will release when the service brake pedal is
depressed. Use the lower section of the brake pedal to
operate the service brake system.
OFF ON
F
E
FUEL
Ref Pow 1
12V Power
Outlet
Fig. 6 12 Volt Power Outlet
TERRAIN
The vehicle is designed for use on improved roads (but
not on public highways). The vehicle may also be used
on established trails or open terrain that is free from
stumps, large rocks or holes.
The vehicle should not be used to cross water.
OPTIONAL WINCH
ST 400 ONLY
HORN
The horn is operated by pushing the horn button located
on the floor to the left of the brake pedal (Ref. Fig. 5 on
page 3).
The ST 400 may be equipped with an optional winch.
Read, understand and follow all of the following information on the operation and use of winch before attempting
to operate it.
Repair and Service Manual
Page 3
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
OPERATION OF THE WINCH
The winch may be mounted at the front or rear of the
vehicle and moved to accommodate different situations.
At the front, it is mounted under the center of the front
cowl to a bracket attached to the front axle as shown
(Ref. Fig. 7 on page 4). At the rear, the winch is
mounted upside down in the hitch receiver.
If mounting winch at rear of vehicle, the winch must be
mounted upside down
handsaver bar, pull cable from winch drum. Leave at
least five turns of cable on drum. Re-engage drum by
turning clutch knob 90°, returning it to original position
(Ref. Fig. 9 on page 4).
To wind cable, use handsaver bar to keep tension on
the cable while activating remote. When winding cable,
make sure the cable winds tightly and evenly onto the
drum leaving no gaps that could cause premature wear
to the cable. When using winch under a load, operate
the remote control from as far to the side of the vehicle
as possible. Do not operate winch while sitting in passenger seat. Read the following section (WINCH
APPLICATIONS) before attempting to operate winch.
.
ENGAGED
LOCKED OUT
Winch shown mounted at front of vehicle
Front Axle
Pull out
Clutch Knob
Spring Pin
Turn 90˚
Ref Wcn 1
Fig. 9 Winch Clutch Knob
Clevis Pin
Ref Wln 1
Fig. 7 Winch Mounted to Vehicle
Before moving the winch, unplug the winch connector
from the wire harness. To move the winch from one end
of the vehicle to the other, remove the spring pin, pull
out the clevis pin and remove the winch mount tube
from the receiver. Move to opposite end of vehicle and
install by inserting clevis pin and securing with spring
pin. Plug the winch connector into wire harness.
The winch remote control plugs into the receptacle on
the seat support (Ref. Fig. 8 on page 4).
WINCH APPLICATIONS
The winch may be used for a number of purposes,
including pulling the vehicle if it loses traction on unsuitable terrain.
Improper use of the winch could result in a
number of conditions that could cause severe
injury or death to operator, occupants of vehicle or bystander.
Remote Control
Receptacle
Ref Wrc 1
Fig. 8 Winch Remote Control
To unwind the cable, locate the clutch knob on the
winch. Pull out knob and rotate 90° to lock out. Using
Page 4
It is impossible to predict all conditions that the winch
could be used, therefore the following warnings should
not be considered as complete. Before operating the
winch, consider the possible dangers and take precautions to protect yourself, your passenger and any
bystanders.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
To prevent severe injury or death to operator,
occupants or bystanders, select the object to
which the cable is attached with the following
considerations:
Make sure the object cannot be pulled
over or otherwise damaged.
The object the winch is attached to could
fall on the vehicle and it’s occupants.
If attaching the winch to a dead tree, a
section could fall.
touch, stop winching and allow the motor
to cool.
Always wear thick leather gloves when
handling the wire cable.
Replace frayed wire cable with a direct
factory replacement only.
Never operate the winch with less than
five (5) full turns of cable around the drum
(Ref. Fig. 10 on page 5). If the winch motor
stalls from overloading, do not continue to
activate the winch remote control. The
wire cable may become overstressed.
When pulling vehicle with winch, pull straight only. Do
not permit the cable to contact the side of the drum.
Do not pull vehicle at angle. If the vehicle is
pulled at an angle, it could turn over causing
severe injury or death to anyone in the area.
The winch cable could also become overstressed and break causing severe injury or
death to anyone struck by the cable.
If the vehicle becomes stuck or ‘hung up’ on an obstruction, the vehicle may be moved using the winch.
The winch may be installed in either the front or rear
receiver and held in place with the locking pin provided.
To prevent severe injury or death, read and
understand the following before attempting to
use the winch:
The winch is not intended to be used in
any hoisting operation.
The rolling load capacity of the winch
decreases with the steepness of the slope.
The winch is designed for intermittent duty
only. The electric motor should not be
allowed to become excessively hot. If the
motor becomes uncomfortably hot to the
Ref Wdt 1
Fig. 10 Never Operate Winch with Less Than Five
Turns Around Drum
Do not attempt to pull loads exceeding
1500 lbs. (680 kg).
To pull out the cable, the free spool clutch
knob must be used. Pull out and rotate the
knob. If the cable is under any load the
clutch may not release easily. Jog out
some of the cable to release the tension
and operate clutch. Pull out the desired
amount of cable and secure. Engage the
drum by rotating the knob until it snaps in
place. Never operate the winch unless the
clutch is engaged.
Have all persons and pets leave the area
while operating winch. Never allow anyone
to remain in the vehicle.
To prevent damage to the wire cable, never hook the cable to itself. Always use a
nylon sling (Ref. Fig. 11 on page 6) (Ref.
Fig. 12 on page 6).
Stay clear of the winch, the cable and the
cable hook. Place a heavy cloth, jacket or
blanket over the cable to act as a damper
Repair and Service Manual
Page 5
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
should the cable break when operating the
winch (Ref. Fig. 11 on page 6).
Damper
ment, nylon sling (if required) and load
attachment.
Do not pull at an angle. This will cause the
wire cable to pile up on one end of the
winch. This may jam the winch causing
damage to the cable and/or the winch.
Pulling the vehicle at an angle can cause
damage to the front suspension and may
cause the vehicle to overturn. When pulling vehicle, pull straight only (Ref. Fig. 13
on page 6).
Nylon
Sling
Correct
Ref Wcd 2
Fig. 11 Use a Nylon Sling and Install a Damper when
Winching
Incorrect
Ref Wps 2
Ref Wca 2
Fig. 13 Do Not Pull at Angle
Fig. 12 Do Not Hook Cable to Itself
Remember that the winch operation will
drain the battery and may leave insufficient power to start the vehicle.
When operating the winch, keep the entire
area in view.
Never release the free spool clutch while
the cable is under load.
Never work around the winch drum or the
winch cable while it is under tension.
Unplug the winch switch before working on
the winch drum in order to prevent inadvertent operation.
When operating winch, take up slack slowly. Stop winch before cable becomes tight
and inspect all winching connections.
Check winch attachment, hook attach-
Page 6
If the vehicle is being used as an anchor to
winch a load, it should have the park brake
set and chocks installed on all wheels.
Never use the winch to lift people or other
overhead loads.
Do not use the winch to secure loads. Use
a tie down designed for the job.
Do not apply shock loads to the winch.
Do not attempt to modify or weld the
winch.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
COMMON SENSE OPERATION
To prevent severe injury or death, observe the
following:
Never transport loaded firearms on or in
vehicle.
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. Do not tamper with the exhaust
system or governor of gasoline powered vehicles. The
exhaust system has been tuned to the engine for maximum performance. Removal or modification of the
exhaust is annoying to other people and will not improve
the performance of the 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.
This vehicle is not a toy. If not operated properly and
responsibly, it can cause severe injury or death to the
operator, 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.
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.
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.
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.
Protective clothing and an approved motorcycle helmet
are recommended for operator and passengers when
operating vehicle in rough or densely wooded terrain.
VEHICLE CAPACITY
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.
Due to the variety of ways the vehicle may be
used, it is important that the operator consider
any potential hazards before use to prevent
serious injury or death.
The vehicle may be configured with a variety of load bed
options. (Ref. Fig. 14 on page 8). The weight of the
driver and passengers plus any options or accessories
must be deducted from the total payload rating to determine the cargo capacity. Never exceed the rated capacity of the load bed.
Repair and Service Manual
Page 7
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
MODIFICATIONS TO VEHICLE
prone to roll over which could result in severe
injury or death to the operator or passengers.
Changes to the weight distribution or the center of gravity may make vehicle unstable or
Do not modify the vehicle in any manner that will
change the weight distribution of the vehicle. Changes
to the weight distribution or the center of gravity may
make it unstable or prone to roll over which could result
in severe injury or death to the operator or passengers.
CONVERTIBLE CARRIER
(Rear Facing Seat/Cargo
Deck)
2 Persons. or Cargo not to exceed 250 Lbs (113 kg)
Maximum Vehicle Capacity 800 lbs. (360 kg)
FIXED ROTOMOLDED BED
Maximum Bed Capacity 250 lbs. (115 kg)
Maximum Vehicle Capacity 650 lbs. (290 kg)
ROTOMOLDED BED
with Manual Dump
or Optional Electric Dump
Maximum Bed Capacity 500 lbs. (225 kg)
Maximum Vehicle Capacity 800 lbs. (360 kg)
Ref Lbc 2 S
Fig. 14 Load Bed Configurations and Capacities
LOAD BED
To reduce the possibility of severe injury or
death, read, understand and follow the Warning label affixed to the front of the load bed. An
electric lift bed is the standard bed for the ST
400. Lower capacity vehicles have a manual
dump feature. A load bed warning label is
affixed to the front of the bed. See Appendix
A. For safe operation of the vehicle, this label
must be understood. See the load bed warnPage 8
ing label for maximum load. The load must be
positioned in the bed as far forward as possible, distributed in such a way that its center of
gravity must not be higher than height noted
on label, and secured. Failure to follow these
instructions may result in severe injury, damage the vehicle and/or cause the vehicle to tip
over. Use extra care when operating loaded
vehicle.
Do not permit any one to ride in the load bed.
Do not drive the vehicle with the load bed raised or with
the tailgate unsupported.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
When using a load bed, be sure to avoid backing up to
the edge of a drop off, such as a loading dock or ravine.
A misjudgment of distance or an unstable surface could
result in the vehicle falling backwards.
MANUAL LIFT BED
Exercise caution while operating the manual lift
bed to ensure the bed is not released during
lifting or lowering procedure. Severe injury
could result if bed is released and traps fingers
or other body parts.
To lift the manual lift bed, pull back on the latch release
handle immediately behind the driver seat (Ref. Fig. 15
on page 9). Raise the bed using the handle on the side
of the bed.
Ref Gss 1
Fig. 16 Gas Strut with Tether Cable
straight down, move tail gate panel straight up to remove
from pins and remove from the load bed. Reassemble in
reverse order.
Front of Vehicle
Never fill a gas can in the bed of a vehicle.
Static discharge could ignite gasoline vapor
and cause an explosion.
Manual Load Bed Latch
Pull Up to Release
Ref Mbl 3
Fig. 15 Manual Bed Latch
On the ST 400, the gas strut will assist in raising the
empty load bed and will keep the bed raised (Ref. Fig.
16 on page 9).
Over time, the gas strut may allow the load bed to slowly lower.
If this condition is evident, replacement of gas strut is required.
To lower the manual lift bed, grasp the bed handle and
lower the bed to the rest position. Be sure hands are
not trapped by the bed.
TAIL GATE OPERATION
To open the tail gate, lift tail gate straight up with a sharp
upward pull to lift out of the closed position and pivot out
for open position. To remove the tail gate, remove the
side cables from the load bed and open tail gate until it is
Always place a gas can on the ground before filling.
Never fill a gas can in the bed of the vehicle. Static electricity is built up during the fueling process and could
discharge causing the gasoline vapor to ignite.
ELECTRIC LIFT BED OPERATION
(ST 400 Only)
Exercise caution while operating the electric lift
bed to ensure clothing is not caught during lifting or lowering procedure. Severe injury could
result if bed is lowered and traps fingers or other body parts.
The electric lift switch is located on the driver side of the
front seat panel (Ref. Fig. 17 on page 10). Move the toggle switch lever up to raise the load bed and down to
lower.
Before operating load bed, check to ensure no one is
behind the vehicle.
Repair and Service Manual
Page 9
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
MANUAL LOAD BED OPERATION
Cargo Platform
Exercise caution while operating the manual
load bed to ensure clothing is not caught during lifting or lowering procedure. Severe injury
could result if bed is lowered and traps fingers
or other body parts.
Passengers should never be allowed to ride on
the cargo platform. Severe injury or death
could result if they should fall out or the vehicle
is involved in an accident or sudden maneuver.
To prevent damage to rear seat, be sure to move any
obstructing accessories mounted to rear handrail when
folding seat up or down.
Rais
e
Low
er
Ref Lbs 1
Fig. 17 Electric Lift Switch
Refer to the illustration for location of load bed release lever. (Ref. Fig.
15 on page 9).
SEATING
VEHICLES EQUIPPED WITH CONVERTIBLE
CARRIER
The cargo platform is accessed by folding the rear seat
down (Ref. Fig. 18 on page 11). Be careful when loading
the vehicle. Tie down loads to prevent shifting. Do not
overload vehicle. The cargo platform is limited to a maximum load of 250 lbs. (115 kg). The load must be positioned on the platform as far forward as possible, its
center of gravity must not be higher than 4" (10 cm)
above the platform, and securely fastened down. Failure
to follow these instructions could cause personal injury,
damage to the vehicle and/or cause the vehicle to tip
over. Be aware that increased loads may effect driving
characteristics.
REAR STORAGE COMPARTMENT
The rear storage compartment is not weather tight.
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.
Be sure that all passengers are seated and holding onto
both the hip restraint and the rear hand hold (rear facing
passengers) before operating vehicle.
STORAGE
VEHICLES EQUIPPED WITH
CONVERTIBLE CARRIER
Page 10
The rear storage compartment can be accessed with the
rear seat folded down by reaching under the central portion of the cargo platform and lifting the platform up (Ref.
Fig. 18 on page 11).
GLOVE COMPARTMENTS
A lockable glove compartment is located on each side of
the instrument panel (Ref. Fig. 20 on page 11).
CARGO BASKET - IF EQUIPPED
Never overload the basket. An overloaded basket could negatively affect vehicle handling characteristics and cause the vehicle to tip over or cause
structural damage to the vehicle.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
Front of Vehicle
REAR SEAT FOLDED UP
Ref Bsk1S
Rear
Handrail
Cargo
Platform
Check that firearms are unloaded with the safety
engaged before securing to holder. A maximum of two
firearms can be secured in the gun holder.
Rear
Storage
Compartment
Ref Rse 1S
Fig. 19 Cargo Basket
Lockable Glove
Compartments
REAR SEAT FOLDED DOWN
Fig. 18 Cargo Platform and Rear Compartment
Do not overload basket (Ref. Fig. 19 on page 11). The
basket is limited to a maximum load of 25 lbs. (11 kg).
Failure to follow these instructions could cause personal
injury, damage to the vehicle and/or cause the vehicle to
tip over. Be aware that increased loads may effect driving characteristics.
Ref Ghr 1S
Gun
Holder
GUN HOLDER - IF EQUIPPED
Fig. 20 Gun Holder and Glove Compartments
OPERATING THE VEHICLE
To prevent severe injury or death, 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.
Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance.
The gun holder is mounted to the floor of the vehicle
near the accelerator pedal (Ref. Fig. 20 on page 11).
Read and understand the following warnings before
attempting to operate the vehicle.
Repair and Service Manual
Page 11
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
To reduce the possibility of severe injury or
death resulting from loss of vehicle control, the
following warnings must be observed:
When driving vehicle, consider the terrain,
traffic conditions and the environmental
factors which effect the terrain and the
ability to control the vehicle.
Use extra care and reduced speed when
driving on poor surfaces, such as loose
dirt, wet grass, gravel, etc.
Stay in designated areas and avoid
extremely rough terrain.
Maintain a safe speed when driving down
hill. Use service brake to control speed
when traveling down an incline. A sudden
stop or change of direction may result in
loss of control.
Slow down before and during turns. All
turns should be made at reduced speed.
Never drive vehicle up, down, or across an
incline that exceeds 14° (25% grade).
To reduce the possibility of severe injury
or death resulting from improper vehicle
operation, the following warnings must be
observed:
Refer to GENERAL SPECIFICATIONS for
seating capacity.
Depressing accelerator pedal will release
foot operated park brake and may cause
inadvertent vehicle movement. Turn the
key to the ‘OFF’ position whenever the
vehicle is parked.
To prevent inadvertent movement when
the 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.
Page 12
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 runin, oil consumption should gradually decrease until the
rate of consumption stabilizes.
Check the oil level per the Periodic Service Schedule
(Ref. Fig. 32 on page 21). Add oil if the level on the dipstick indicates that oil is in the add oil range (Ref. Fig. 21
on page 12).
Fill Cold Engine
To This Point
Add Oil
Maximum Oil Level
For Hot Engine
Do Not Overfill
Safe
Operating Range
Hot Engine
Fig. 21 Check Oil Level on Dipstick
Do not overfill engine. Too much oil may cause smoking
or allow oil to enter the air filter enclosure.
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
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
The oil should be changed in accordance with the Periodic Service Schedule while the engine is warm.
• 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.
Fig. 22 Clean Entire Dipstick
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
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.
Do not hold vehicle on hill by using accelerator and
engine. This will cause premature and excessive wear to
drive train components.
To reduce the possibility of permanent damage to the
drive system, it is important to prevent excessive rollback when starting the vehicle on a hill.
Place left foot on service brake and release the park
brake. Depress accelerator with right foot and release
the service brake by lifting left foot.
COASTING
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:
• switch
Apply the service brake, place the key in the key
and turn it to the ‘ON’ position.
• Move
the direction selector to the direction
desired.
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
Repair and Service Manual
Page 13
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
ground (see GENERAL SPECIFICATIONS). Limit speed
by applying service brake.
FUEL
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.
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.
Use fresh regular grade unleaded fuel. Ethanol blend fuel
up to 10% is permissible.
BATTERY
Always handle gasoline in a well ventilated
area.
Always wear eye protection to protect
against splashed fuel and fuel vapors.
Always allow adequate space for the
expansion of gasoline. Leave at least 1"
(2.5 cm) space below bottom of filler neck.
Inspect fuel cap, tank and other components for leaks or deterioration that could
cause a hazardous condition.
The fuel tank is located under the seat on the passenger
side of the vehicle (Ref. Fig. 23 on page 14). Fill the tank
with fresh, clean, automotive grade gasoline. High altitude or heavy use/load applications may benefit from
higher octane gasoline.
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 accessory lights, radios, winch, etc.) 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.
Fuel
1" Min.
(2.5 cm)
Ref Ftl 1S
LABELS AND PICTOGRAMS
Fig. 23 Fuel Tank Location
Do not use gasoline which contains Methanol.
Page 14
Excessive use of accessories may drain the battery and
leave insufficient reserve to start the vehicle.
Vehicles may be labeled with pictograms as a method of
conveying information or warnings. Appendix A illustrates and explains pictograms that may appear on the
vehicle. Not all pictograms shown in Appendix A will be
found on your vehicle.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
plastic polish or Plexus® plastic cleaner available from
the service parts department.
SUN TOP & WINDSHIELD (If Equipped)
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 top does not provide protection from roll
over or falling objects.
The windshield does not provide protection
from tree limbs or flying objects.
The top and windshield provide some protection from
the elements; however, they will not keep the operator
and passengers dry in a downpour. For complete protection from the elements, a weather enclosure can be
installed. This vehicle is not equipped with seat belts
and has not been designed to provide roll over protection.
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.
VEHICLE CLEANING AND CARE
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.
If the engine does not start or runs improperly after washing,
remove the spark plug wires (by pulling the spark plug boots,
never the wires). Dry all connections with forced air. Reinstall
the wires.
VEHICLE CLEANING
To reduce the possibility of severe injury or
vehicle damage, read and understand all
instructions supplied by manufacturer of pressure washer.
When pressure washing exterior of vehicle, do not use
pressure in excess of 700 psi (4800 kpa). 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 (4800
kpa) to wash exterior of vehicle.
Clean windshield with lots of water and a clean cloth.
Minor scratches may be removed using a commercial
Repair and Service Manual
Page 15
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
REPAIR
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.
LIFTING THE VEHICLE
Tool List
Qty. Required
Lower the vehicle by reversing the lifting sequence.
Floor jack ..................................................................... 1
Jack stands.................................................................. 4
Chocks......................................................................... 4
Center of
Front Axle
Some servicing operations may require the front wheels,
the rear wheels, or the entire vehicle be raised.
Flat Portion
of Frame
To reduce the possibility of severe injury or
death from a vehicle falling from a jack:
Be sure the vehicle is on a firm and level
surface.
Never get under a vehicle while it is supported by a jack.
Outside End
of Rear Axle
Use jack stands and test the stability of the
vehicle on the stands.
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.
View from Underside of Vehicle
Fig. 24 Lifting the Vehicle
WHEELS AND TIRES
Tire Repair
Tool List
When lifting vehicle, position jacks and jack stands at the
areas indicated only.
To raise the entire vehicle, install chocks in front and
behind each front wheel (Ref. Fig. 24 on page 16). 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.
Qty. Required
Lug wrench, 3/4" ..........................................................1
Impact socket, 3/4", 1/2" drive .....................................1
Impact wrench, 1/2" drive ............................................1
Torque wrench, 1/2" drive ............................................1
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.
A tire explosion can cause severe injury or
death. Never exceed inflation pressure rating
on tire sidewall.
Lower the jack and test the stability of the vehicle on all
four jack stands.
To reduce the possibility of tire explosion,
pressurize tire with small amount of air applied
Page 16
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
intermittently to seat beads. Due to the low volume of the small tires, overinflation can occur
in seconds. Never exceed the tire manufacturer’s recommendation when seating a bead.
Protect face and eyes from escaping air when
removing valve core.
To reduce the possibility of severe injury
caused by a broken socket when removing
wheels, use only sockets designed for impact
wrench use.
Use caution when inflating tires. Overinflation
could cause the tire to separate from the wheel
or cause the tire to explode, either of which
could cause severe injury.
Use caution when inflating tires. Due to the low volume
of the small tires, overinflation can occur in seconds.
Overinflation could cause the tire to separate from the
wheel or cause the tire to explode.
Tire inflation should be determined by the condition of
the terrain. See GENERAL SPECIFICATIONS section
for recommended tire inflation pressure. For outdoor
applications with major use on grassy areas, the following should be considered. On hard turf, it is desirable to
have a slightly higher inflation pressure. On very soft
turf, a lower pressure reduces the possibility of tires cutting into the turf. For vehicles being used on paved or
hard surfaces, tire inflation pressure should be in the
higher allowable range, but under no condition should
inflation pressure be higher than recommended on tire
sidewall. All four tires should have the same pressure
for optimum handling characteristics. Be sure to install
the valve dust cap after checking or inflating.
To reduce the possibility of severe injury, be
sure 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.
Wheel Installation
To reduce the possibility of component damage, do not
tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.
It is important to follow the ‘cross sequence’ pattern when
installing lug nuts. This will assure even seating of the wheel
against the hub.
With the valve stem to the outside, mount the wheel
onto the hub with lug nuts. Finger tighten lug nuts in a
‘cross sequence’ pattern (Ref. Fig. 25 on page 17).
Tighten lug nuts to 50 - 85 ft. lbs. (70 - 115 Nm) torque in
20 ft. lbs. (30 Nm) increments following the ‘cross
sequence’ pattern.
'Cross Sequence'
1
3
The vehicle is fitted with low pressure tubeless tires
mounted on one piece rims; therefore, the most cost
effective way to repair a puncture in the tread is to use a
commercial tire plug.
4
2
Tire style may vary
Ref Whi 3S
Fig. 25 Wheel Installation
Tire plug tools and plugs are available at most automotive
parts outlets and have the advantage of not requiring the tire
be removed from the wheel.
Unidirectional Tires
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.
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. (Ref. Fig. 26 on page 18).
Repair and Service Manual
Page 17
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
Rot
a
Roll Rubber
Bezel Away
From Body
'Cross Sequence'
1
3
n
tio
Front of
Vehicle
Ref Whi 4
Tail/Brake
Light
2
4
Rear
Fender
Tire style may vary
Fig. 26 Unidirectional Tire Wheel Installation
Ref Tlr 2
LIGHT BULB REPLACEMENT
For vehicles with headlights, locate the two screws on
backside of cowl that secure headlight (Ref. Fig. 27 on
page 18). Remove screws, pull headlight out and disconnect wires. Connect wires to new headlight, install in
cowl and secure with screws previously removed.
Fig. 28 Tail and Brake Light Bulb Replacement
Rear
Fender
Tail Light
Lens
Turn Signal Lens
Inside
of Cowl
Headlight
Bulb
Ref Tlr 1
Turn Signal
Housing
Ref Hdr 2
Fig. 27 Headlight Replacement
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.
Tail Light
Bulb
Fig. 29 Tail and Brake Light Bulb Replacement
motive 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 replace the tail and brake light bulb, roll the rubber
bezel from around the edge of the taillight and remove
lens (Ref. Fig. 28 on page 18). Install replacement bulb
and replace lens.
To replace the tail and brake light bulb, remove hardware securing lens and remove lens. Install replacement
bulb (Ref. Fig. 29 on page 18).
To reduce the possibility of severe injury or
death from inadvertent motion, do not attempt
to ‘jump start’ a vehicle.
FUSE REPLACEMENT
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.
To replace fuses, locate the fuse block under the driver
side seat. Pull out old fuse and replace with a new auto-
Page 18
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
With the short running times associated with this kind of
vehicle, the generator is more than adequate to maintain
the battery charge level. The generator is not designed
to charge a discharged battery.
When engine starts, the clutches engage and cause
vehicle to move making ‘jump starting’ both dangerous
and impractical.
If the vehicle battery has become discharged, it must be
charged using a 12 volt charger that is rated at 10 amps
or less. Read and understand all instructions provided
by the manufacturer of the charger.
TRANSPORTING VEHICLE
HAULING
To reduce the possibility of severe injury or
death while transporting vehicle:
Secure the vehicle and contents.
Never ride on vehicle being transported.
Always remove windshield before transporting.
TOWING
Maximum speed with sun top installed is
50 m.p.h. (80 kph).
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.
2
3
NEUTRAL LOCK
1
To prevent the driven clutch from turning the rear wheels
during service operations and to prevent wear to the belt
while being towed, a neutral lock is located on the direction selector.
The neutral lock is located on the direction selector. To
operate neutral lock, first turn the key switch to ‘OFF’,
place direction selector in ‘R’ and remove seat. Pull out
(motion 1) and rotate (motion 2) the neutral lock pin handle so that the pointed portion of the handle is over the
side of the direction selector cam (Ref. Fig. 30 on page
19). Move direction selector lever 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 of the lever. When in this
position, the direction selector remains locked in the
neutral position.
Spring loaded mechanism. To prevent possibility of fingers becoming pinched in the direction
selector mechanism, hold direction selector
lever when releasing neutral lock pin handle.
Hole in Direction
Selector Cam
Unlocked
Fig. 30 Neutral Lock
If the vehicle is to be transported at highway speeds, the
sun top must be removed and the seat bottom secured.
When transporting vehicle below highway speeds,
check for tightness of hardware and cracks in sun top at
mounting points. Always remove windshield when transporting. Always check that the vehicle and contents are
adequately secured before transporting. The rated
capacity of the trailer or truck must exceed the weight of
the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load. Lock the park brake and secure
the vehicle using ratchet tie downs.
Repair and Service Manual
Page 19
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
SERVICE AND MAINTENANCE
To reduce the possibility of severe injury or
death from improper servicing techniques:
Do not attempt any type of servicing operations before reading and understanding
all notes, cautions and warnings in this
manual.
Any servicing requiring adjustments to be
made to the powertrain while the engine is
running must be made with both drive
wheels raised and vehicle properly supported on jack stands.
To reduce the possibility of engine damage, never operate vehicle at full throttle
for more than 4 - 5 seconds while vehicle
is in a ‘no load’ condition.
Wear eye protection when working
on the vehicle. Use extra care
when working around batteries, or
using solvents or compressed air.
Sgl 1
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 possibiliRef Isl 1S
ty of a dropped wrench
‘shorting out’ a battery, which could result
in an explosion.
Reduce the possibility of accidental starting by disconnecting battery at negative
terminal before servicing.
The electrolyte in a battery is an acid solution which can cause severe burns to the
skin and eyes. Treat all electrolyte spills to
the body and eyes with extended flushing
with clear water. Contact a physician
immediately.
Any electrolyte spills should be neutralized
with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking soda) dissolved in
1 quart (1 liters) of water and flushed with
water.
Aerosol containers of battery terminal proPage 20
tectant must be used with extreme care.
Insulate metal container to reduce the possibility of can contacting battery terminals
which could result in an explosion.
It is in the best interest of both vehicle owner and service
technician, to carefully follow the procedures recommended in this manual. Preventative maintenance,
applied at recommended intervals, is the best guarantee
for keeping the vehicle both dependable and economical.
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic Service Schedule for appropriate service intervals
(Ref. Fig. 32 on page 21). Refer to Lubrication Points for
appropriate lubrication locations (Ref. Fig. 49 on page
30).
SERIAL NUMBER LABEL 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 (Ref. Fig. 31 on
page 20).
Lift Flap on Access Panel
Serial Number
Labels
Ref Spl 3
Label No.
V
Fig. 31 Serial Number Label Location
Design changes take place on an ongoing basis. In
order to obtain correct components for the vehicle, the
manufacture date code, serial number and vehicle
model must be provided when ordering service parts.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
mum load.
To access powertrain for routine maintenance, lift or
remove seat. For major repair, refer to appropriate Technician’s Repair and Service Manual.
To prolong vehicle life, some maintenance items must be
serviced more frequently on vehicles used under severe
driving conditions such as extreme temperatures,
extreme dust/debris conditions, frequent use with maxi-
Some service procedures may require the vehicle to be
lifted. Refer to LIFTING THE VEHICLE for proper lifting
procedure and safety information.
3 Check
 Clean, Adjust, etc.
S 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:
3 Check service brake general operation
3 Check park brake operation - does it hold on a hill.
3 Check warning device function in reverse
3 Check tire pressure, condition of tires & rims.
3 Check smooth operation of accelerator.
3 Check for loose or missing hardware.
3 Check Battery - state of charge, condition, loose terminals, corrosion, hold down &
hardware
3 Check overall vehicle condition
WEEKLY (includes items listed in previous table & the following)
TIRES
WHEELS
FUEL GAUGE
ENGINE OIL
COOLING FAN
STARTER/GENERATOR BELT
3Examine for cuts, excessive wear & pressure (See GENERAL SPECIFICATIONS)
3 Check for bent rims, missing or loose lug nuts
3 Check for proper operation (at fueling), and fuel cap vent is free of dirt
3 Check and add if required - DO NOT OVERFILL
3 Check for build up of debris inside blower housing & clean if required.
3 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
3 Check all wiring for loose connections and broken/missing insulation
3 Check for smooth movement - DO NOT LUBRICATE CABLE
3 Conduct brake performance test
3 Check brake performance and adjust if required
3 Check for smooth movement and adjustment - DO NOT LUBRICATE CABLE
3 Check attachment, adjust as required
3 Check attachment, adjust as required
3 Check for unusual noise, vibration, acceleration, oil leaks
3 Check for build-up of foreign matter inside blower housing & fins, clean if required
3 Check for abnormal play, tightness of all hardware
3 Check for excessive play, bent components or loose connections
3 Check for leakage, add SAE 30 oil as required
QUARTERLY - 60 HOURS (includes items listed in previous tables & the following)
FRONT SHOCK ABSORBERS
3 Check for oil leakage and loose fasteners
Fig. 32 Periodic Service Schedule
Repair and Service Manual
Page 21
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
FRONT AXLE
FRONT SPRINGS
FRONT WHEEL ALIGNMENT
PARK BRAKE
3 Check for damage to axle and loose or missing hardware
3 Check for loose hardware, cracks at attachments
3 Check for unusual tire wear, align if required
3 Check for bent/binding linkage rod
3 Check for damage or wear to latch arm or catch bracket
 Lubricate as required, use light oil. DO NOT LUBRICATE CABLES OR BRAKE
LATCH
REAR SHOCK ABSORBERS
ENGINE ELECTRICAL SYSTEM
FUEL SYSTEM
THROTTLE/GOVERNOR LINKAGE
HARDWARE AND FASTENERS
3 Check for oil leakage, loose mounting hardware
3 Check coil/spark plug wires for cracks/loose connections
3 Check for leaks at tank, cap, system lines, filters, pump, carburetor
3 Check system lines for cracks/deterioration
3 Check operation and governed speed
3 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)
 Clean battery & terminals
BATTERY
DIRECTION SELECTOR
KING PINS
STEERING ASSEMBLY
RACK END BALL JOINT
REAR AXLE
AIR FILTER ELEMENT
OIL FILTER
3 Check charge condition and all connections
3 Check for wear and smooth movement (lubricate shaft with light oil if required)
3 Check for excessive play and tightness of retaining nuts
 Lubricate, use wheel bearing grease
3 Check bellows and pinion seal for damage or grease leakage
 Lubricate, use wheel bearing grease
3 Check for unusual noise and loose or missing mounting hardware
3 Check filter element, clean/replace as required
ENGINE OIL
S Replace (at oil change)
S Replace with SAE 10W-30 or 10W-40 that meets or exceeds SF, SG, CC oil,
DRIVE BELT
3 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
SERVICE BRAKES
FUEL FILTER
SPARK PLUG
MUFFLER/EXHAUST
VALVES
3 Check and adjust as required, see Technician’s Repair and Service Manual
3 Check lubricant, add lubricant (Ref. Fig. 47 on page 29) as required
 Clean and adjust, see Technician’s Repair and Service Manual
3 Check brake shoe linings, see Technician’s Repair and Service Manual
S Replace
S Replace, gap new plug (Ref. Capacities and Replacement Parts on Page 31)
3 Check mounting hardware; check for leaks at head and muffler gaskets
3 Check cold (intake/exhaust) per Technician’s Repair and Service Manual
500 HOURS (includes items listed in previous tables & the following)
CARBURETOR
 Clean
 Remove carbon from cylinder head and piston
CYLINDER HEAD AND PISTON
3 Check valve seats for carbon buildup and clean as required
Fig. 32 Periodic Service Schedule
TIRE INSPECTION
Tire condition should be inspected per the Periodic Service Schedule (Ref. Fig. 32 on page 21). Inflation pressures should be checked when the tires are cool. Be
Page 22
sure to install the valve dust cap after checking or inflating.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
FOUR CYCLE ENGINE
Insert the dipstick fully into the dipstick hole and
remove. Examine the level of the oil on the dipstick.
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 spark plug fouling.
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.
Remove the dipstick and wipe off the entire area with a
lint free cloth (Ref. Fig. 33 on page 23).
Fill Cold Engine
To This Point
Add Oil
Maximum Oil Level
For Hot Engine
Do Not Overfill
Safe
Operating Range
Hot Engine
Fig. 34 Check Oil Level on Dipstick
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 (Ref. Fig. 34 on page 23). Check that the
oil cap is firmly in place.
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. Required
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.
Fig. 33 Clean Entire Dipstick
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 (Ref. Fig. 35 on page 24).
Repair and Service Manual
Page 23
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
Clean the area around filter. Using a filter wrench, strap
wrench or other suitable wrench (A), remove the filter
(B) from the engine and allow the oil to drain. The ‘O’
rings may remain on engine (A) or filter (B) (Ref. Fig. 37
on page 24)
HEAVY DUTY WORK
10W-40
10W-30
LIGHT DUTY WORK
10W-30
F
0
-20
C 0 -30
0
-20
20
40
60
-10
0
10
20
(AIR TEMPERATURE)
80
100
30
40
Fig. 35 Oil Viscosity Chart
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.
Fig. 37 Remove Oil Filter
Inspect the filter. Make sure the ‘O’ ring is not left on the
engine surface.
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 degreaser.
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 (Ref. Fig. 36 on page 24). Remove the oil fill cap.
Oil Fill Cap
Fig. 38 Inspect Oil Filter
Be careful of hot oil when drained. It may be
hot enough to burn you severely
Fig. 36 Cleaning Top of Engine
Page 24
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.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
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.
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.
Fig. 39 Oil Drain Plug
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 “Capacities and Replacement Parts” on page 31.
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 (Ref. Fig.
40 on page 25). 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.
STARTER/GENERATOR BELT TENSION
Tool List
Qty. Required
Belt tension gauge .......................................................1
Wrench, 3/4" ................................................................1
Wrench, 9/16" ..............................................................2
Ratchet, 3/8" drive .......................................................1
Socket, 3/4", 3/8" drive ................................................1
The starter/generator belt tension should be checked
after the first 15 - 20 hours and set to 75 - 80 lbs. (34 36 kg).
Fig. 41 Check Belt Tension with Gauge
A loose belt can cause audible vibration and squeal.
Tighten a new starter/generator belt to 90 - 110 lbs. (4150 kg) tension when a gauge is applied half way
between the two pulleys (Ref. Fig. 41 on page 25).
Fig. 40 Add Engine Oil
A new belt may be checked manually. A maximum
deflection of 3/8" (10 mm) is acceptable (Ref. Fig. 42 on
page 26). Tighten an existing belt to 75 - 80 lbs. (34 36 kg) tension using the same technique and inspect for
Repair and Service Manual
Page 25
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
BATTERY CLEANING
3/8" (1 cm) Maximum
Deflection (New Belt)
1/2" (1.3 cm) Maximum
Deflection (Existing Belt)
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 on Page 21).
Fig. 42 Check Belt Tension Manually
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.
Fig. 43 Adjust Belt Tension
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 (Ref. Fig. 43 on page
26).
Tighten the starter/generator pivot bolt.
Page 26
The correct cleaning technique is to spray the top and
sides of the battery with a solution of sodium bicarbonate (baking soda) and water. This solution is best
applied with a garden type sprayer equipped with a non
metallic spray wand or a plastic spray bottle. The
solution should consist of the amounts of sodium bicarbonate (baking soda) and clear water shown below (Ref.
Fig. 44 on page 27). 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 battery
to remove any residue that could contribute to the self
discharge of the battery. Rinse the entire area with low
pressure clear water. Do not use a pressure washer.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
BRAKES
Non-Metalic Wandr
1/4 Cup (60 ML)
Sodium Bicarbonate
(Baking Soda)
Dry, Level, Clean, Paved Surface
Accelerate To
Maximum Speed
Latch
Parking Brake
and Take Foot
Off Pedal
Line or Marker
Line or Marker
1 1/2 GAL (6 Liters) Water
2 GAL (8 Liters)
Gargen Sprayer
(1 1/2 GAL (6 Liters)
Baking Powder Solution
Acceptable
Stopping 4 ft. (1.2 m)
Distance
Fig. 44 Preparing Acid Neutralizing Solution
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
Fig. 45 Typical Brake Performance Test
To reduce the possibility of severe injury or
death, always evaluate pedal travel before
operating a vehicle to verify some braking
function is present.
All driving brake tests must be done in a
safe location with regard for the safety of
all personnel.
Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.
The Periodic Brake Performance Test should be performed regularly as an evaluation of braking system performance. It is useful as a method of identifying subtle
loss of performance over time.
Repair and Service Manual
Page 27
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
Periodic Brake Test For Mechanical Brakes
The purpose of this test is to compare the braking performance of the vehicle to the braking performance of
new or ‘known to be good’ vehicles or to an established
acceptable stopping distance. Actual stopping distances
will be influenced by weather conditions, terrain, road
surface condition, actual vehicle weight (accessories
installed) and vehicle speed. No specific braking distance can be reliably specified. The test is conducted by
latching the 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.
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.
Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.
Drive the vehicle at maximum speed on a flat, dry, clean,
paved surface (Ref. Fig. 45 on page 27). 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.
AIR INTAKE AND COOLING FINS
To prevent possible burns, engine parts should
be kept clean to reduce risk of overheating and
Page 28
Fig. 46 Cleaning Cooling System with Air
REAR AXLE
The rear axle is provided with a lubricant level check
plug located on the driver side at the rear of the housing
(Ref. Fig. 47 on page 29). Unless leakage of rear axle
lubricant is evident, an annual lubricant check is sufficient.
Checking The Lubricant Level
Tool List
Qty. Required
Socket, 13 mm, 3/8" drive............................................1
Ratchet, 3/8" drive .......................................................1
Funnel..........................................................................1
Clean the area around the check and fill plugs. Remove
the check plug. The correct lubricant level is just below
the bottom of the threaded hole (Ref. Fig. 47 on page
29). If lubricant is to be added, remove the fill plug and
add lubricant using a funnel. Add lubricant slowly until
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
Fill / Check Plug
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
Ref Air 2
Fig. 48 Air Cleaner
If the element is in acceptable condition, loose dirt may
be removed by tapping the filter lightly. Do not use oil on
the filter element or any part of the unit.
Drain Plug
LUBRICATION
Fig. 47 Add, Check and Drain Rear Axle Lubricant
lubricant starts to seep from the check plug hole. Install
the check plug / fill plug. In the event that the lubricant is
to be replaced, a drain plug is provided at the bottom of
the differential housing.
AIR CLEANER 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.
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 (Ref. Fig. 49 on page 30).
SPARK PLUG
Tool List
Cleaning the Air Filter Element
Do not use compressed air to clean the air filter; doing so
will damage the filter which may result in damage to the
engine.
The air cleaner element is accessible by unsnapping the
clips on the air canister and removing the cover and air
filter element (Ref. Fig. 48 on page 29). Clean inside of
cover, canister and dust collector. Install the element
Qty. Required
Spark plug socket, 13/16", 1/2" drive ...........................1
Ratchet, 1/2" drive .......................................................1
Plug gauge, wire type ..................................................1
Anti-seize compound ................................................AR
Torque wrench, 1/2" drive, ft. lbs..................................1
Use care not to over-tighten the plug. Over-tightening can
cause damage to the aluminum cylinder head threads.
Repair and Service Manual
Page 29
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
tion or poor quality fuel could also contribute to the problem.
King Pin
King Pin
Rack
Ball
Joint
Ball Joint
on Rack
and Rod
To reduce the possibility of severe injury or
death resulting from a possible explosion:
View from Underside of Vehicle
King Pin
Idler Arm
PROLONGED STORAGE
King Pin
Steering
Unit
View From Underside Of Vehicle
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.
Fig. 49 Lubrication Points
Remove and inspect the spark plug at intervals indicated
in the Periodic Service Schedule (Ref. Fig. 32 on page
21). Spark plug should be properly gapped (Ref. Fig. 50
on page 30). Tighten to 16 ft. lbs. (22 Nm) torque.
Plug
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.
0.7 - 0.8 mm
(.028” - .031”)
Gap
Fig. 50 Gapping the Spark Plug
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 is in poor condi-
Page 30
• 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.
Repair and Service Manual
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
• with
Add a gasoline additive to the tank in accordance
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.
marks on the hexagonal head and grade 8 hardware is
identified by 6 marks on the head. Unmarked hardware
is Grade 2 (Ref. Fig. 52 on page 32).
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)
Headlight Sealed Beam
(P/N 20209-G3)
Turn Signal Bulb
(P/N 20574-G3)
Tail Light Bulb
#1157 (P/N 21759-G1)
Fig. 51 Capacities and Replacement Parts
HARDWARE
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref. Fig. 52 on
page 32).
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
Repair and Service Manual
Page 31
B
B
OPERATION AND SERVICE INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings.
B
ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)
Unless otherwise noted in text, tighten all hardware in accordance with this chart.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
BOLT SIZE
1/4"
5/16"
3/8"
7/16"
1/2"
9/16"
5/8"
3/4"
7/8"
1"
Grade 2
4
(5)
8
(11)
15
(20)
24
(33)
35
(47)
55
(75)
75
(102)
130
(176)
125
(169)
190
(258)
Grade 5
6
(8)
13
(18)
23
(31)
35
(47)
55
(75)
80
(108)
110
(149)
200
(271)
320
(434)
480
(651)
Grade 8
6
(8)
18
(24)
35
(47)
55
(75)
80
(108)
110
(149)
170
(230)
280
(380)
460
(624)
680
(922)
BOLT SIZE
M4
M5
M6
M8
M10
M12
M14
Class 5.8
(Grade 2)
5.8
1
(2)
2
(3)
4
(6)
10
(14)
20
(27)
35
(47)
55
(76.4)
Class 8.8
(Grade 5)
8.8
2
(3)
4
(6)
7
(10)
18
(24)
35
(47)
61
(83)
97
(131)
Class 10.9
(Grade 8) 10.9
3
(4)
6
(8)
10
(14)
25
(34)
49
(66)
86
(117)
136
(184)
Ref Tsp 1
Fig. 52 Torque Specifications and Bolt Grades
Page 32
Repair and Service Manual
Download PDF
Similar pages