Interceptor OPERATORS MANUAL BT-57

Interceptor OPERATORS MANUAL BT-57
TABLE OF CONTENTS
Title
Page
GENERAL INFORMATION
SAFETY
CONTROLS AND GUAGES
OPERATION
SERVICE AND MAINTENANCE
SPECIFICATIONS
INDEX
2
4
7
20
31
73
78
The description and specifications contained in the operators manual were in affect at the time the manual
was approved for printing. Westward Industries Ltd has the rights to discontinue models at any time, or
change specifications or design, without notice and without incurring obligation.
GENERAL INFORMATION
The Westward Industries GO-4 is powered by a 1323cc 4-cylinder water cooled engine. The engine power
is transferred to the drive wheels by a three speed automatic transmission.
Vehicle Identification Number
The decal is located on the front left hand side of dash.
V.I.N.#
General Information – cont’d
Engine Number
It is located just below the oil filler cap on the engine block.
Engine No.
Vehicle Emission Control Information Decal
It is located on engine electrical rail right above coolant recovery bottle.
SAFETY
The Safety Alert Symbol means
ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
CAUTIONS and WARNINGS
Throughout the operators manual, you will find Cautions and Warnings.
Warnings remind you to be especially careful to avoid personal injury.
Cautions are given to prevent you from making an error, which could damage the vehicle and possibly
cause personal injury.
Safety Reminders
1. Make sure the GO-4 operator has read the manual and understands it
2. Do not let children operate vehicle.
3. This vehicle is to carry one person ONLY. No riders!
4. Use a seat belt for optimum safety.
5. Keep both hands on steering wheel whenever possible.
6. Keep legs and arms in the vehicle when it is in motion.
7. Always shut off engine when vehicle is refueling.
Why is SAFETY important to you?
Safety – cont’d
8. Never smoke when refueling or servicing vehicle.
9. Always dim headlights when approaching people or other vehicles.
10. Never make sudden turns or stops when not necessary.
NOTE: The cornering ability of three-wheeled vehicles is not as great as that of similar
4 – wheeled units.
11. Always keep within load limits and never overload it.
12. Always run the vehicle in open areas with plenty of fresh air to prevent carbon monoxide poisoning.
13. Always slow down before you turn and when travelling over rough areas.
14. Always signal lane changes and turns.
15. Always wear a helmet where law states such as required.
NOTE: The GO-4 is classed as a motorcycle.
Safety – cont’d
Operating Precautions for the Catalytic Converter
1. Use only unleaded fuel in your vehicle.
2. Do not park the vehicle near or over flammable objects such as dry glass.
3. Do not operate engine at high idle speeds for long periods of time while in “P” or “N”
4. Do not allow your vehicle to run empty of fuel.
5. Do not operate the vehicle when there are signs of engine malfunctions, such as misfire or noticeable
loss of power to the engine.
6. Do not coast with engine off.
7. Do not go down steep grades in gear with ignition off.
8. Do not modify or tamper with emission control system. Let a qualified technician do the adjustments.
CONTROLS AND GUAGES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Fan Speed
Heater Control
Vent Control
Speedometer/ Tachometer
Hourmeter
Fuel Gauge
Voltmeter
Governor
Park Brake/ Brake Warning Light
High Beam Indicator Light
Turn Signal Lights (L, R)
Panel Light Switch
Coolant Temperature Light
Oil Pressure Light
Service Indicator Light
Ignition Switch
Auxiliary Switches (three)
Signal/Light Control Stalk
Wiper Control
Vents
Controls and Gauges – cont’d
All controls and gauges are located on the dash.
Ignition Switch (4 position)
a. Accessory Position: Allows use of various instruments and accessories without the engine running. Ie
wipers.
b.
Off Position: Prevents all electrical powered accessories and engine from running except hazard
warning flasher and allows key to be removed
c. On Position: This allows all accessories and engine to be run.
The key is automatically returned to this position after starting the GO-4
d. Start Position: Hold key in start to engage starter, upon engine starting release key.
Important: Do not turn key to “start” position with engine running.
Severe damage can result to to starter drive and flywheel teeth.
Note: If GO-4 does not start within 15 seconds, turn key to Off position, then try again in 30 seconds.
Damage may to occur to starter.
Controls and Gauges – cont’d
Note: The GO-4 will start only when the transmission is in Park or Neutral.
Gear Selector
The gear selector is located to the left and on the seat box. When shifting from Park or Neutral to any gear,
hold foot on brake while engaging the transaxle. Use the thumb button on the side of gear selector to
release from “P” or “R”. When the trnsaxle is in Park, the push button will pop out automatically, latching
the lever in the Park position. In this position the gear selector cannot be moved unless the button is pushed
in.
Note: A back up alarm (if equipped) will sound when the transmission is in “R”.
Controls and Gauges – cont’d
“P” (Park) position: use only when the vehicle has come to a complete stop.
WARNING: When the above is not followed, extreme damage to
transmission can occur. “P” is not used as a brake.
“R” (Reverse) position: Use for backing up vehicle from a stop.
“N” (Neutral) position: For standing (brakes applied).
“D” (Drive) position: For normal driving this transmission will shift automatically through the three
forward gear sequence.
“2” position: manually select when power is needed to go up steep hills, a braking assist when going down
hills. Also for better control when starting off on slick surfaces.
“1” position: Manually select when climbing up or down very steep hills. For even better control on slick
surfaces.
Parking Brake
Pull up to engage. Push down to release parking brake. Brake light on dash will come on when parking
brake is engaged.
Controls and Gauges – cont’d
Foot Throttle
Push pedal down to open throttle. Idle position is when pedal returns to the top.
Note: The GO-4’s engine high idle comes automatically as engine reaches normal temperature the high idle
device will come off.
Brake Pedal
When pedal is depressed, the vehicle’s brakes are applied and vehicle will slow down to a stop.
Doors
The doors slide on tracks to ease opening and closing. The window can be opened separately from inside
(eg. To provide ventilation) without affecting door operation and safety.
Door: Open door by pulling on red handle and slide door back on its tracks. Close door by pushing on black
handle and allowing door to travel forward until click is heard.
Controls and Gauges – cont’d
Window: Pull back handle and slide window back to first notch (vent position) or back until it locks in the
fully open position.
Speedometer/Odometer
The speedometer indicates the forward speed of the vehicle.
This is shown in the MPH by large number and km/h (kilometers per hour) by the small numbers. The
odometer indicates the total distance (in miles) the vehicle has driven.
Hourmeter
Records the number of hours that the vehicle has run and is important if your vehicle operates at slow
speeds and idles a good portion of its daily operation. It is a better indicator when maintenance items
should be carried out, eg oil and filter changes.
Fuel Gauge
Records the fuel level in the tank. Tank capacity is 7.0 US gal,
26.5 liters.
Controls and Gauges – cont’d
Voltmeter
The voltmeter indicates the normal voltage output of 13-14 volts to the battery while the engine is running.
Warning and Indicator Lights
Governor: Red indicator light comes on when vehicle exceeds the governed speed of 45 MPH (55 km/h).
The engine will run on two cylinders to drop the governed speed.
Brake System Warning Light: Red warning light has two functions:
1. Park brake warning light. This indicates when the parking brake is applied when the engine is started.
Release the parking brake fully before moving vehicle.
The light should go off when the parking brake is released.
2. Brake fluid level warning light. This warning light is still on even when the parking brake is
completely released. It may indicate low brake fluid level in the reservoir.
Controls and Gauges – cont’d
If the warning light stays on:
1. Make sure parking brake is full released.
2. Carefully stop your vehicle. Put in “P” Park and apply emergency brake.
3. With engine stopped, check fluid level and flow. Check all brake components for leaks.
4. If any leaks are found, if warning light continues to stay on, or the brakes do not operate properly do
not drive vehicle.
5. Have your vehicle towed to an authorized dealer for a full brake examination. Let them do the
necessary repairs.
WARNING: Driving your vehicle with improperly operating brakes can cause severe damage to you and
your vehicle.
Check bulb operation: the warning light glows when the ignition key is in start position and should go out
when the brake is released and engine is started.
Headlight High Beam Indicator Light: The blue indicator light comes on when the headlights are on and in
the high beam position.
Turn Signal Indicators: Green lights when a left or right turn is being made.
Controls and Gauges – cont’d
Panel Light: Pull switch on instrument panel to display gauges at night. It will operate when the lights are
on. Push switch to shut off panel lights.
Coolant Temperature Warning Light: When engine coolant temperature becomes extreme, the red warning
light will come on. Shut down vehicle to avoid damage.
Oil Pressure Warning Light: The red oil pressure light indicates the low oil pressure in the engine.
Service: The red indicator light shows there is a problem in the fuel injection system. Have the vehicle
checked when this occurs.
Auxiliary Switches
The illuminated rocker switches (top to bottom) operate the following options:
Top Switch: Roof-mounted work light(s). Equipped with a 50-amp relay for heavy-duty use.
Bottom Switch: Air conditioning system. Push to operate. Make sure the heater shutoff valve is closed
when using the air conditioning.
Controls and Gauges – cont’d
Heater Controls
Fan Speed: The two-speed heater control switch is located on the left side of the dash. Turn clockwise to
adjust fan speed.
Note: To keep the operators compartment cooler in temperatures above 80 F, turn on heater, but direct air
flow down to your feet.
Heat/Cold: Temperature is controlled by pulling control for more heat. Push in to reduce heat.
Defrost/Vent: Air can be directed to defrost the front window or to heat the compartment by pulling or
pushing this control.
Heater Valve Shutoff: Use with the air conditioning. Pull control to shut off the control valve and prevent
heat from entering the compartment. Use with the bottom auxiliary switch when operating the air
conditioner. Note: Some models have this control located after the fan speed control.
Controls and Gauges – cont’d
Steering Column Controls
Light Switch/Turn Signal: The multifunction lever is on the left hand side of the steering wheel.
Turn Signals: Pull lever down until it latches to signal a left turn and push it up for a right turn. The
indicator lights on the instrument panel will indicate a left or right turn. When the turn is complete the
steering wheel will cancel the turn signal. If the turn signal continues to flash, pull the turn signal switch
back to OFF position.
Dimmer Switch: To change your headlamp from low to high beam, push the lever away from you, until it
latches and release. The blue high beam indicator on the dash glows when the headlamps are on high beam.
To change your headlamp from high to low beam, pull the lever toward you and release.
Flash to Pass: Pull the lever toward you and hold to momentarily turn on the high beam.
Lights: Rotate the knob on the end of lever to the first position. This activated the clearance, parking,
license, and taillights. Turn knob to second position to activate headlights, license, and taillights.
Controls and Gauges – cont’d
Tilt Adjustment: Loosen two bolts with brass colored washers on each side of the column and adjust wheel
to desired height. Tighten bolts.
Wiper Control
Located on the right hand side of the steering column. Move stalk down to select wiper speed. When the
wiper is on the INT (intermittent) setting, rotate knob on end of stalk to select desired intermittent setting.
Dome Light
Located on right hand rear part of ceiling in compartment. Push switch on dome light to light it. Push again
to shut it off.
Controls and Gauges – cont’d
Seat
Adjust seat-moving lever to the right. Push or pull on seat until desired position obtained. Release lever.
Seat Belt
The lap/shoulder belt is used. To fasten seat belt:
1. Grasp the buckle end and tongue plate.
2. Slowly pull out the tongue plate section.
3. Insert the tongue plate into the open end of the buckle.
A noticeable click will indicate the seat belt is securely locked.
Unfasten seat belt:
4. Push button on buckle end to release.
5. The tongue end will automatically return to resting position along side seat.
Note: To help decrease the possibility or severity of injury in sudden stops and accidents, buckle up at all
times when using your vehicle. Position the belt, low on the hips and make sure it always is snug. Use the
seat belt at all times when the vehicle is in operations.
OPERATION
WARNING: Do not exceed payload capacity given on vehicle nameplate or permit passengers any place on
the vehicle.
• Cornering ability of a three-wheeled vehicle is not as great as a four-wheeled vehicle.
• Place heavy loads forward of rear axles. Unbalanced or top heavy loads can cause vehicle upset.
• Wear a helmet.
• Do not start your vehicle in a closed garage or other enclosed areas. Exhaust fumes can be toxic.
Always open the garage door before you start the engine.
Before you start your vehicle, do the following:
1. Make sure you buckle your safety belt. See Seat Belt in the Controls and Gauges section of the manual
for more details.
2.
Make sure the gearshift selector is in Park and the parking brake is set before you turn the key.
Starting the Vehicle: Further information on engine starting is provided in this section.
1. Adjust the seat for easy access to switches and controls.
2. Adjust mirrors for a clear rear view both right and left mirrors.
3. Fasten seat belt.
4. Put key in ignition.
5. Turn key to start vehicle.
Operation – cont’d.
6.
7.
8.
9.
Use accelerator after vehicle has started.
Step on brake pedal.
Place gear selector into desired gear.
Release parking brake.
Note: Vehicle will not start if the transmission is not in “P” or “N”.
Stopping and Leaving Vehicle:
1. Stop unit fully with brake pedal.
2. Place gear selector lever in “P”.
3. Apply parking brake.
4. Turn ignition switch to OFF position and remove key.
Note: When leaving the vehicle on an uphill or downhill, the vehicle should be “curbed” (see diagram).
Operation – cont’d.
Starting the Engine
When starting the fuel-injected engine, avoid pressing down on the accelerator. Use the accelerator when
you have problems getting your vehicle started. See Starting a Cold Engine for details about when to use
the accelerator while you start your vehicle.
IMPORTANT: Do not park, idle or operate your vehicle in tall, dry grass or other dry ground areas. The
high heat generated by engine and emissions components (eg catalytic converter) could start a ground fire.
1.
Turn the key to the ON position. All the warning lights, except the Brake Warning Light, should light
up. If any of them do not light up, have the bulb and circuit checked. When the engine starts, the lights
should go out.
2.
The key must be in the START position, which cranks the engine, to test the Brake Warning Light. If
the Brake Warning Light does not light up, have the bulb and circuit checked.
3.
When you release the parking brake, the Brake Warning Light should go off.
Starting A Cold Engine
During extremely cold weather, let the engine idle for about one minute after starting. By doing this, you
will allow the engine to begin to warm.
Operation – cont’d.
WARNING: Do not let your vehicle idle to long. If it idles for more than 10 minutes, the high temperatures
in the exhaust system can cause damage especially if your vehicle idles at high speeds.
1.
Turn the key to START until the engine starts. Do not use the accelerator until the engine is running.
Do not hold the key in the START position for more than 15 seconds at a time or you could damage
the starter.
2.
Release the key as soon as the engine starts. Do not hold the key in START position after the engine
starts because you could damage the starter.
3.
If the engine does not start on your first try, turn the key to OFF. Wait 10 to 12 seconds so that you do
not flood the engine. Then begin again.
4.
If the engine does not start after two tries, press the accelerator about ¼ of the way to the floor. Then
try again.
5.
If the engine still does not start, push the accelerator to the floor and hold it while you turn the key.
Turn the key to START and hold it for up to 15 seconds. Then if the engine does not start, turn the key
to OFF and wait two minutes before you try again.
Operation – cont’d
NOTE: If you consistently start your vehicle in subzero temperatures, park your vehicle in a garage or use
the engine block heater (if so equipped). Your dealer can provide information on block heater installation.
Starting a Warm Engine
1. Follow the steps under “Starting”
2.
Turn the key to START until the engine starts. Do not use the accelerator until the engine is running.
Do not hold the key in the START position for more than four seconds at a time so that you do not
flood the engine.
3.
If the engine does not start within four seconds, turn the key to the OFF position. Wait 10 or 12
seconds so that you do not flood the engine. Then begin again.
4.
If the engine still does not start:
a. Press the accelerator all the way to floor. Hold it. Do not pump the pedal.
b. Turn the key to START.
c. Release the key when the engine starts.
d. Release the accelerator gradually as the engine starts.
Operation – cont’d
Engine Cranks but Does Not Start
WARNING: If you smell gas, do not reset the fuel pump shut-off switch or try to start your vehicle. You
could injure yourself or others. Get out of your vehicle and call a towing service or the local fire
department.
If the engine cranks but does not start or does not start after a collision, the fuel pump shut-off switch may
have been triggered. The fuel pump shut-off switch automatically stops the fuel flow to the engine when
your vehicle has been hit or you are involved in a collision. The impact does not have to be great for the
switch to be triggered. Minor parking lot bumping and severe road impacts (eg potholes) may trigger the
switch even when there is no apparent body damage. In many instances, you might not even know that the
switch has been triggered.
Operation – cont’d
Once the fuel shut-off switch is triggered, you must reset the switch by hand before you can start your car.
The fuel pump shut-off switch is located in the center and under electrical component rail in the engine
compartment. Push the red button to reset.
Exhaust Fumes
Carbon monoxide is colorless and odorless. It is present in exhaust fumes. Take precautions to avoid its
dangerous effects.
WARNING: Never idle the engine in closed areas. Never sit in parked or stopped vehicle for more than a
short period of time. Exhaust gases, particularly carbon monoxide, may build up. These gases are harmful
and could kill you.
If you smell exhaust fumes of any kind inside your vehicle, have your dealer inspect and fix your vehicle
immediately. Do not drive the vehicle if you smell exhaust fumes.
Operation – cont’d
Refueling
WARNING: Use only unleaded fuel, damage to the pollution control system and catalytic converter will
occur if leaded fuel is used. Do not use fuel system cleaning agents.
Shut off engine and no smoking while refueling. A fire or explosion may occur.
Filler Cap
To remove cap, turn counterclockwise.
To install cap, turn clockwise until a click(s) is heard.
Fuel Type
Use only a minimum of 87 octane rating for best performance. If your vehicle doesn’t perform well switch
to another fuel. If this doesn’t cure the problem see your GO-4 dealer or agent service technician. If your
vehicle is damaged because of wrong fuel, your warranties may not apply.
NOTE: Higher-octane fuel is allowed. If a lower octane fuel is used it can cause a persistent and heavy
knocking, which can cause severe damage to engine.
Operation – cont’d
Your vehicle may knock slightly when driving up steep hills or when you accelerate. See your GO-4 dealer
if your vehicle:
1. Still knocks heavily under all driving conditions.
2. Vehicle knocks lightly while you are driving at cruising speed on level ground.
Running Out of Gas: If your vehicle runs out of gas, try to stop on level ground. Add at least two gallons to
start again. On an uneven surface, you may need to as much as five (5) gallons. You may need to turn the
ignition to START (not more than 15 seconds) for a long time before the fuel system starts to pump gas
from the tank to the engine.
Engine Block Heater (optional)
This dealer installed accessory is strongly recommended if you live in a region where temperatures reach
0F (-18 C) or below consistently during the winter months. An engine block heater warms the engine
coolant, which improves starting, warms up the engine faster, and allows the heater -defrost system to
respond quickly.
To operate the block heater, simply plug it into a ground 110-volt outlet. It is recommended that you use a
Ground Fault Circuit Interrupter on your 110-volt circuit.
WARNING: Do not use your block heater with ungrounded electrical systems or two-pronged (cheater)
adapters. You can be injured by an electrical shock from an ungrounded connection.
Operation – cont’d
For best results, plug the heater in at least three hours before you start your vehicle. Using the heater for
longer than three hours will not damage the engine, so you can plug it in at night to start your vehicle the
following morning. Use a timer to conserve energy.
Tire Gauge Decal
Shows proper tire inflation rates’ depending on load for your GO-4. The decal is located inside the cargo
space at rear.
The tire inflation pressure for front is 28psi and for the rear is 30 psi.
Operation – cont’d
Towing
Tow the vehicle only on dollies or on decks of trucks or trailers.
IMPORTANT: Failure to follow towing procedures may cause severe damage to critical vehicle parts. Turn
slowly and carefully.
SERVICE AND MAINTENANCE
Engine Service
Routine service can be done by opening the rear cargo box lid using the latch. At front and inside the cargo
box is an access cover for checking fluid levels; coolant, engine oil and transaxle.
Better access to the engine/transaxle is done by removing the rear cargo box.
1. Open box lid by unlocking rear latch.
2. Unscrew fastener and remove bracket that holds the cargo box to frame.
3. You and another person lift cargo box slightly, and slide backward, and remove.
Install cargo box opposite of disassembly. Apply a little grease on sides of box to keep your box sliding
easy.
Service and Maintenance – cont’d
Air Cleaner Element
The air cleaner element is a dry type air cleaner. It is chemically treated, pleated paper-air-filtering element
which permits air flow through the air induction system, filtering out unwanted dust, dirt, and debris.
Replace air filter every 10,000 miles (16,000 km).replace more often every 5,000 miles (8,000 km) under
severe operating conditions.
Access to air filter is done by:
1. Remove panel on right hand side of vehicle between rear wheel and door.
2. Release four latches on air cleaner housing cover.
3. Lift the air cleaner housing cover and air cleaner element.
4. Remove the air cleaner element.
5. To install, reverse the removal procedure.
Service and Maintenance - cont’d
Engine Oil
Proper amount of oil in the engine is important for safe operation. Check every time you add fuel to your
vehicle. For accurate reading make sure the vehicle is on a level surface and the oil is warm.
Check oil
1. Turn off engine after the oil is warm (2-3 minutes of running is fine).
2. Locate the dipstick, behind the right side panel, the handle end is yellow and rounded.
3. Pull out dipstick, wipe clean and replace.
4. Pull out dipstick out once again and read it. If the oil level is below the letter “F” or reads at 0.8L, add
oil until it reads at the line below “F”.
Adding Oil
1. Find the yellow filler cap on engine. Remove it.
2. Add desired amount of oil.
Service and Maintenance – cont’d
3.
Let it sit a couple of minutes and pull dipstick to insure proper level.
4.
Replace filler cap.
Choosing the Right Viscosity Grade
You must consider the temperature in which you drive your GO-4. If you regularly drive in temperatures
that are below 100 F (38 C), use a SAE 5W-30 SG oil. If you drive regularly at temperatures above 100 F
(38 C), use a SAE 10W30 oil. If you regularly drive in temperatures that are below 20 F (-10 C), use SAE
5W20 oil.
Service and Maintenance – cont’d
Oil and Filter Change Intervals
The engine oil and engine oil filter in the GO-4 should be changed every 5,000 miles (8,000 km) or every
650 hours, under the Normal Maintenance Schedule.
However, if the use of the GO-4 includes:
1. Extended periods of idling or low speed driving.
2. Operation industry conditions.
3. Majority of operation is in stop and go city traffic, or short trips (less than 10 minutes).
4. Operation in sub-freezing temperatures.
Then engine oil and filter should be changed every 3,000 miles (5,000 km) or 200 hours, whichever occurs
first.
Oil Change
1. Drain oil by removing the oil filler cap and drain plug while the engine is warm.
2. Replace the drain plug tightly after the oil has been thoroughly drained.
Service and Maintenance – cont’d
3.
4.
Refill the engine with new oil to the “F” level marked on the dipstick.
Refit the oil filler cap securely.
Oil Filter
1. Remove the engine oil filter with a suitable wrench.
2. Use a clean rag to wipe off the mounting surface on the engine.
3. Apply a small amount of new engine oil on to the rubber seal of the new oil filter.
4. Install the oil filter and hand tighten. Do not use a wrench.
5. Start the engine and inspect around the oil filter seal for leaks. Check the oil level and fill to the “F”
mark if necessary.
Oil Capacity:
3.6 US qt (3.4 liters),
3.2 US qt (3.0 liters) without filter
Service and Maintenance – cont’d
Cooling System
The vehicle’s cooling system protects your engine from overheating in hot temperatures and freezing in
below freezing temperatures. Check the level at least once a month in the coolant recovery reservoir.
If the engine is cold, the coolant level in the coolant recovery reservoir should be between the low and full
mark. If the coolant level is low, add coolant to the FULL mark.
CAUTION: Your vehicle is equipped with an automatic cooling fan. It may come on at any time without
warning, even if ignition is OFF and key is out. If working around the fan, disconnect the negative battery
terminal to avoid injury.
Service and Maintenance – cont’d
Adding Coolant
DANGER: DO NOT REMOVE RADIATOR CAP WHEN VEHICLE IS RUNNING EXTREMELY HOT.
Before removing the radiator cap:
1. Turn the engine off and let it cool. Even when the engine is cool be careful when you remove the
radiator cap.
2. When the engine is cool, wrap a cloth around the cap and turn it slowly to the first stop.
3. Step back while the pressure releases. A hissing sound will be heard.
4. When you are sure that all the pressure has been released, use the cloth to press down on cap, turn it
and remove.
5. Stand back from the radiator opening as hot steam may blow out or hot water may splash out.
NOTE: Add engine coolant only to the coolant recovery reservoir NOT to the radiator. Add to the proper
level with not more than 50/50 mixture of antifreeze and water.
This will provide coolant protection to –40 F (-40 C).
Service and Maintenance - cont’d
NOTE: A mixture that has less than 40% engine antifreeze can cause the engine to rust and overheat. A
mixture that has more than 50% engine antifreeze can cause an engine to overheat in 80 F over weather.
IMPORTANT: Do not use an alcohol or methanol antifreeze. This will cause aluminum radiator and other
aluminum parts to corrode. Use a premium grade ethyl glycol antifreeze.
NOTE: See your dealer or agent to check your cooling systems for leaks if:
1. You add coolant more than once a month.
2. You have to add more than a pint at a time.
Brake Fluid
Under normal circumstances, your vehicle should not use brake fluid. However, expect the level of the
brake fluid to slowly fall as you put more mileage on your vehicle and as brake pads wear. Check the brake
fluid at least once a year. This is done by looking at the fluid level in the plastic see-through reservoir on
the master cylinder. This level should be at or near the maximum line.
IMPORTANT: If you use brake fluid that is not DOT 3, you will cause permanent damage to your brakes.
Never reuse brake fluid that has been drained from the system or that has been allowed to stand in an open
container for an extended period of time.
Service and Maintenance – cont’d
WARNING: Do not let the reservoir for the master cylinder run dry. This may cause the brakes to fail.
Adding Fluid
If the fluid is low:
1. Carefully clean and remove the cap from the reservoir.
2. Fill the reservoir to the maximum line with a DOT 3 brake fluid.
IMPORTANT: Do not fill the reservoir above the maximum line.
Transaxle
Make sure the transmission fluid level is just below the “F” mark. Do not overfill.
Service and Maintenance – cont’d
Checking Automatic Transaxle Fluid Level
1. Park the vehicle on level ground and set the parking brake firmly.
2. Start and run engine until it is at normal operating temperature.
3. Press brake pedal firmly and move the gear selector through all the gear positions.
4. Place the gear selector lever in PARK position.
5. Measure fluid using the oil indicator markings. Clean dipstick and reinsert fully.
6. With the engine still idling, pull the dipstick out again. If the fluid is low, add enough fluid so that the
oil level indicator is reading between “F” and “L” marks. Do not overfill.
Automatic Transmission Fluid: Motorcraft Mercon Automatic Transmission Fluid or similar.
Capacity:
5.8 US qts (5.7 liters) with torque converter drained
3.0 US qts (2.8 liters), transaxle only
Service and Maintenance – cont’d
Fuel Filter
The in line fuel filter is located in the engine compartment between the fuel tank and fuel injection supply
manifold. Service the fuel filter every 60,000 miles or 4,000 hours whichever comes first.
Removal
WARNING: DO NOT SMOKE OR CARRY LIT TOBACCO OR AN OPEN FLAME OF ANY TYPE
WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN PERSONAL
INJURY.
1.
Remove the cargo box from the vehicle.
2.
Relieve fuel pressure as follows:
- Start the engine.
- Disconnect the pump relay electrical connector.
- After the engine stalls, turn the ignition to the OFF position.
- Connect the fuel pump relay electrical connector.
3.
Loosen the clamp and disconnect the fuel supply line at the fuel filter inlet fitting. Plug the end to
prevent spillage and contamination.
4.
Loosen the clamp and disconnect the fuel return line at the fuel filter outlet opening.
5.
Remove the two fuel filter bracket nuts and the fuel filter bracket bolt.
6.
Remove the fuel filter from the fuel filter bracket.
Installation
1. Install fuel filter to the fuel filter bracket.
Service and Maintenance – cont’d
2.
Connect the fuel return line to fuel filter outlet fitting.
3.
Install the fuel filter bracket bolt and the two fuel filter bracket nuts. Tighten the fuel filter bracket to
71-97 lb/in.
4.
Connect the supply line to the fuel filter inlet fitting and install the clamp.
5.
Connect the fuel pump electrical connector.
6.
Start the engine and check for leaks.
Service and Maintenance – cont’d
Belt Tension
Alternator Belt
Apply moderate finger pressure (approximately 22 lbs or 10 kg) midway between pulleys and check the
deflection.
Deflection on alternator belt should be:
New: 86-103 lb (39-47 kg). Run engine for 10 minutes and readjust belt tension.
Used: 68-86 lb (31-39kg).
Tightening the Alternator Belt
1. Loosen the alternator mounting bolt and adjust bar bolt.
2. Move the alternator to obtain the proper belt tension.
3. Tighten the bolts and recheck the tension.
CAUTION: Do not try any adjustment while engine is running.
Service and Maintenance – cont’d
A/C Compressor Belt
Apply moderate finger pressure between pulleys and check the deflection.
Deflection on A/C compressor belt should be:
New: 110-132 lb (50-60kg). Run for 10 minutes and readjust A/C compressor belt tension as specified
above.
Used: 95-110 lb (43-50 kg). More than 10 minutes of running time.
Tightening the A/C compressor belt:
1. Loosen the drive belt idler pulley nut.
2. Loosen the fan belt idler pulley bolt.
3. Move the A/C compressor to obtain proper tension.
4. Tighten the fan belt idler pulley bolt and drive belt idler pulley nut. Recheck tension.
Service and Maintenance – cont’d
Drive Belt Removal/Installation
A/C Compressor Belt
1. Loosen the drive belt idler pulley nut.
2. Loosen the fan belt idler pulley bolt until there is enough slack to remove the A/C compressor drive
belt.
3. Remove the A/C compressor drive belt from the drive belt idler pulley, A/C clutch pulley, and the
crankshaft pulley.
4. Remove the A/C compressor drive belt from the vehicle.
Install:
1. Route the A/C compressor drive around the three pulleys.
2. Note: Ensure that the A/C compressor drive belt is seated properly on all the pulleys before the tension
is adjusted.
3. Adjust the A/C compressor belt to the proper tension.
Service and Maintenance – cont’d
Alternator Drive Belt (A/C equipped models)
1. On vehicles equipped with air conditioning, remove the A/C compressor drive belt.
2. Loosen the alternator adjustment bolt until there is enough slack to remove the alternator drive belt.
3. Loosen the alternator lower bolt.
4. Position the prybar against the area around the case bolt. Remove the alternator drive belt from the
water pump pulley, crankshaft pulley, and alternator pulley.
5. Remove alternator drive belt from the vehicle.
Install the alternator drive belt as follows:
1. Route the alternator drive belt around the three pulleys.
2. Ensure the alternator drive belt is seated properly on all the pulleys before the tension is adjusted.
3. Adjust the alternator drive belt to the proper tension.
4. Tighten the alternator bolt to 14-19 lb/ft (19-25 N.m.)
5. Tighten the alternator lower bolt to 27-38 lb/ft (37-52 N.m.)
Service and Maintenance – cont’d
6.
On vehicles equipped with air conditioning, install the A/C compressor drive belt. Refer to the
procedure in this section.
Jump Starting
Before jump starting the vehicle, be aware of the following:
WARNING: Hydrogen and Oxygen gases are produced during normal battery operation. This gas mixture
can explode if flames, sparks, or burning substances (cigarettes, etc.) are brought near the battery. When
charging or using a battery in an enclosed area (including the vehicle engine compartment) always provide
ventilation and shield your eyes. Keep children away from vehicle batteries. Batteries contain sulfuric acid.
Avoid contact with skin, eyes, or clothing. In case of acid contact with skin, eyes or clothing, flush
immediately wit clean water for a minimum of 15 minutes. If acid is accidentally swallowed, consult a
physician immediately. Give the person large quantities of milk or water, followed by milk of magnesia, a
beaten egg, or vegetable oil.
WARNING: To avoid any possibility of injury, extreme care should be exercised when connecting jumper
cables to a discharge battery.
Service and Maintenance – cont’d
When the starter motor will not crank, or does so very slowly, connect a 12-volt booster battery, following
these instructions and precautions. Make the connections in the numerical order shown. Disconnect the
connections in the reverse order shown.
CAUTION: Do not allow the vehicles to touch.
CAUTION: Do not disconnect the battery of the vehicle to be started. Doing so could damage the
operational vehicle’s electrical system while jump starting.
Note: Make connections in numerical order (disconnect in reverse order eg 4, 3, 2, 1).
1.
Position the vehicles so the jumper cables will easily reach both batteries and the engine block of the
vehicle to be started. Do not allow the vehicles to touch.
2.
Ensure all unnecessary electrical accessories on the disabled vehicle are turned off while jump starting.
Service and Maintenance – cont’d
3.
Turn on the blower motor of the operational vehicle to remove voltage surges.
4.
Shield your eyes using safety goggles or similar eye protection.
5.
Ensure jumper cables are not in the way of moving parts as you make the jumper cable connections
a. Connect one end of the first jumper cable to the positive (+) terminal of the discharged
battery.
b. Connect the other end of the first cable to the positive (+) terminal of the booster battery.
c. Connect one end of the second jumper cable to the negative (-) terminal of the booster battery.
d. WARNING: Making the final cable connection could cause an electrical arc which, if made at
or near the battery, could cause an explosion.
e. Connect the other end of the second cable to the engine block of the disabled vehicle. Do not
connect the cable to the negative terminal.
6.
Start the engine of the vehicle with the good battery and run the engine at a moderate speed.
7.
Start the engine of the vehicle with the discharged battery.
8.
Turn off all electrical components and reduce the engine speed to idle on both of the vehicles to
prevent possible damage to the vehicle electrical system.
Service and Maintenance – cont’d
9.
Remove the jumper cables in the exact reverse order from which they were connected. With the
jumper cables removed, the vehicle accessories can be used.
If the starter motor does not crank the engine sufficiently with the booster battery attached, further
diagnosis of the engine and starting is required.
Tires
When replacing tires, it is recommended to use tires of the same size, speed rating, load range and radial
construction as originally installed on the vehicle. Use of any other vehicle may seriously effect ride,
handling, speedometer/odometer calibration, vehicle ground clearance, and tire clearance to the body and
chassis. The GO-4 is equipped with P155/80R 13 radial (M + S) tires.
Tire Inflation
Maintain tire inflation of 28 psi – front; and 30 psi – rear. Check tire pressure each time you fill up with
fuel.
Service and Maintenance – cont’d
Tire Rotation
To equalize tire wear, tires may be rotated, but not until the cause of unusual or uneven tire wear is
determined and corrected.
Front and rear tires perform different jobs and can wear differently depending on the type of the vehicle
and driving habits. To equalize wear and extend tire life, rotate tire every 5,000 miles (8,000 km) or 325
hours.
Service and Maintenance – cont’d
Changing a Tire
WARNING:
1. Use the correct front and rear jacking points on the vehicle. Never use the bumpers or any other part of
vehicle for jack support.
2. Do not exceed the jack’s maximum permissible load, which is 1102 lbs (500 kg). The jack provided is
for emergency wheel and tire change only.
3. Never go beneath the vehicle while using the jack.
4. Do not stand or run the engine while the vehicle is jacked up.
5. Never attempt vehicle repairs in the traffic lanes of a public road or highway. Always move the vehicle
completely off the road and to the shoulder before trying to change a tire. If you cannot find a firm,
level place off the road, call a service truck.
6. Follow jacking instructions to reduce the possibility of personal injury.
7. When one rear wheel is lifted off the ground the transaxle in PARK position will not prevent the
vehicle from moving and possibly slipping off the jack, even if those positions are properly engaged.
To prevent inadvertent vehicle movement while changing a tire, always set the parking brake fully.
Block up the other two wheels at front and rear.
Service and Maintenance – cont’d
Front Tire
1. Park on a level surface.
2. Block rear wheels and place transmission in PARK.
3. Place a jack as near as possible to the center of the GO-4 directly behind the front wheel.
4. Before jacking the vehicle, loosen the bolts on the front wheel and the bolts which hold the axle caps.
5. Jack the front off the ground.
6. Take the bolts out of the caliper.
7. Remove the axle caps.
8. Remove the wheel bolts.
9. Reassemble in reverse order.
10. Make sure all bolts are properly tightened.
TORQUE SPECIFICATIONS:
Axle Cap Bolts: 50-55 lbs/ft.
Wheel Bolts: 70-80 lbs/ft.
Service and Maintenance – cont’d
Rear Tire
1. Park on a level surface and set the parking brake firmly.
2. Position the gear selector in PARK position.
3. Place the jack close to rear wheel.
4. Raise rear wheel.
5. Remove the four wheel bolts.
6. Reassemble in the reverse order of the above.
7. Tighten all wheel bolts. Torque them to 70-80 lbs/ft.
Service and Maintenance – cont’d
Fuses
All fuses are 15 amp, except for engine and computer memory, which are 10 amp.
WARNING: Replace the fuse with one of the same amps.
1.
2.
3.
Open access door on right hand side of instrument panel by removing two screws.
Remove fuse by grasping each side of it and pull.
Replace fuse by pushing gently in the center of fuse until it stops.
FUSE LAYOUT:
Top Row (left to right)
1. Engine – 10A
2. Radio
3. Hazard and Beacon Lights
4. Stop Lights, Horn, Dome
Middle Row (left to right)
1. Auxiliary
2. A/C (option)
3. Heater
4. Turn, Running, Dash Lights
Bottom Row (left to right)
1. Computer Memory – 10A
2. Engine Fan
3. Rear Wiper (option)
4. Front Wiper
Vehicle Appearance
NOTE: When using any polish or chemical cleaner always read and follow the directions, warnings and
cautions on the label.
Washing and Polishing
1. To remove tree sap, insects and road tar; wash with a mild soap solution. Rinse immediately with clean
clear water. The longer the time the above objects are on the vehicle, the tougher they are to remove.
2. Wash your vehicle often to prevent dirt, salt, chemicals and other material from damaging the paint
and other finishes. This applies to areas where chemicals and salt are used on roads.
3. Slow down the corrosion process by applying a semi-annual coat of wax or polish.
4. Do not direct high pressure water or solution from a close distance at the front wheel bearings or at the
rear wheel bearings. High pressure water at close distances ca bypass the seal and contaminate the
lubricant causing premature wheel bearing failure.
Important:
1. Wiping of dust or dirt with a dry cloth will scratch the finish and glass.
2. Don’t wash the vehicle in direct sun or when the surface is hot.
3. When cleaning plastic surfaces use plenty of water and soft cloths to prevent scratching.
4. Prevent caustic solutions such as perfume, cosmetic oil, etc., from coming in contact with plastic
covers on gauges that may cause damage or discoloration. If the above come in contact, wipe off
immediately.
5. Test brakes to make sure they were not affected by the water.
6. The vehicle should be washed and dried before applying wax or polish. Don’t use a polish with a large
amount of abrasives as these will damage surfaces.
Service and Maintenance – cont’d
MAINTENANCE SCHEDULES
Maintenance schedules are based on how the vehicle is driven.
Regularly Scheduled Maintenance Intervals
The normal maintenance schedule should be followed if, generally, the vehicle is driven on a daily basis for
more than 10 miles and NONE OF THE CONDITIONS IN THE SEVERE MAINTENANCE SCHEDULE
APPLY TO THE DRIVING HABITS.
The Severe Maintenance Schedule should be followed if the vehicle owner’s driving habits mainly include
one or more of the following:
1.
Short trips of less than 10 miles when outside temperatures remain below 0 F.
2.
Operating when outside temperatures remain below freezing.
3.
Operating during hot weather in stop-in-go “rush hour” traffic.
4.
Extensive idling, such as police or door-to-door service.
5.
Operating in extremely humid climates.
6.
Driving in severe dust conditions.
7.
Driving in areas where road salt or other corrosives are used.
8.
Driving on rough and/or muddy roads.
Owner Maintenance Checks
The following list of vehicle checks and inspections should be performed at the intervals indicated.
Service and Maintenance – cont’d
Whenever You Stop For Fuel
1. Check the engine oil level.
2.
Look for under-inflated tires.
At Least Monthly
1. Check tire pressure. Check the tires when cold, not after a long drive.
2.
Check the coolant in the radiator coolant recovery reservoir.
3.
Check the operation of all exterior lamps including the brake lamps, turn signals, and hazard warning
flashers.
At Least Twice A Year
1. Check windshield wiper operation.
2.
Check and replace worn windshield wiper blades.
3.
Check for worn tires and loose wheel hub bolts.
4.
Check pressure in spare tire (option).
5.
Check headlamp alignment.
6.
Check the muffler, exhaust pipe, catalytic converter, and clamps for damage.
7.
Check the lap shoulder belt for wear and function.
8.
Check the radiator, heater, and air conditioning hoses for leaks or damage.
9.
Check the rear driveshaft joint boots for cuts or leakage.
Service and Maintenance – cont’d
At Least Once A Year
1. Lubricate all hinges, checks, latches, rollers, and all outside key locks.
2.
Lubricate the door rubber weatherstrips.
3.
Check air conditioning system (if so equipped) before the warm weather season.
4.
Clean door guide rails.
5.
Check brake fluid level.
6.
Clean battery connections.
7.
Lubricate the transaxle controls and linkage.
8.
Inspect the refrigerant amount.
9.
Inspect the A/C compressor operation.
Severe Maintenance Schedule
The Severe Maintenance Schedule should be followed if the vehicle owner’s driving habits include one or
more of the following:
1. Short trips of less than 10 miles (16 km).
2.
Operating when outside temperatures remain below freezing.
3.
Operating during hot weather in stop-in-go “ rush hour” traffic.
4.
Extensive idling, such as police or door-to-door service.
5.
Operating in extremely humid climates.
6.
Driving in severe dust conditions.
7.
Driving in areas where road salt or other corrosives are used.
Service and Maintenance – cont’d
8.
Driving on rough and/or muddy roads.
For items marked with a number in brackets (1), see footnotes at end of this section.
3,000 miles (200 hours)
• Change engine oil and replace oil filter (4).
6,000 miles (400 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
9,000 miles (600 hours)
• Change engine oil and replace oil filter (4).
12,000 miles (800 hours)
• Change engine oil and replace oil filter (4).
15,000 miles (1,000 hours)
• Change engine oil and replace oil filter (4).
• Inspect air cleaner element (1) (4).
• Inspect front and rear disc brake pads and rotors.
• Inspect bolts and nuts on chassis and body.
• Rotate tires and adjust air pressure.
18,000 miles (1,200 hours)
• Change engine oil and replace oil filter (4).
21,000 miles (1,400 hours)
• Change engine oil and replace oil filter (4).
• Change automatic transmission fluid (2).
24,000 miles (1,600 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
27,000 miles (1,800 hours)
• Change engine oil and replace oil filter (4).
30,000 miles (2,000 hours)
• Change engine oil and replace oil filter (4).
Service and Maintenance – cont’d
•
•
•
•
•
•
•
•
•
•
•
•
•
Replace spark plugs (4).
Replace air cleaner element (4).
Inspect alternator and A/C compressor belts (4).
Check idle speed (3) (4).
Change engine coolant every 30,000 miles (2,000 hours) or 36 months (4).
Inspect engine cooling system, hoses, clamps: and check coolant strength every 30,000 miles (2,000
hours) (4).
Inspect fuel lines and hoses (1) (4).
Inspect exhaust heat shield.
Inspect rear wheel driveshaft joint boots.
Inspect front and rear brakes.
Inspect brake lines, hoses and connections.
Inspect front fork assembly.
Inspect steering operation and linkage.
33,000 miles (2,200 hours)
• Change engine oil and replace oil filter.
• Rotate tires and adjust air pressure.
36,000 miles (2,400 hours)
• Change engine oil and replace oil filter,
39,000 miles (2,600 hours)
• Change engine oil and replace oil filter.
42,000 miles (2,800)
• Change engine oil and replace oil filter.
• Rotate tires and adjust air pressure.
• Change automatic transmission fluid (2).
45,000 miles (3,000 hours)
• Change engine oil and replace oil filter.
• Inspect air cleaner element (1) (4).
• Inspect front and rear disc brake pads and front and rear disc rotors.
• Inspect bolts and nuts on chassis and body.
48,000 miles (3,200 hours)
• Change oil and replace oil filter (4).
Service and Maintenance – cont’d
51,000 miles (3,400 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
54,000 miles (3,600 hours)
• Change engine oil and replace oil filter (4),
57,000 miles (3,8600 hours)
• Change engine oil and replace oil filter (4).
60,000 miles (4,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor belts (4).
• Replace air cleaner element (4).
• Inspect ignition timing (1) (4).
• Check idle speed (3) (4).
• Change engine coolant every 30,000 miles (2,000 hours) or 36 months (4).
• Inspect engine cooling system, hoses, clamps: and check coolant strength every 30,000 miles (2,000
hours) (4).
• Replace fuel filter (3) (4).
• Inspect fuel lines and hoses (1) (4).
• Inspect fuel hoses and tubes for emissions (1) (4).
• Inspect exhaust heat shield.
• Inspect rear wheel driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect front fork assembly.
• Inspect steering operation and linkage.
• Repack front and rear wheel bearings.
• Rotate tires and adjust air pressure.
• Replace timing chain/belt. Failure to replace timing chain/belt may result in damage to engine (3) (4).
• Inspect timing chain/belt (3) (4).
Service and Maintenance – cont’d
63,000 miles (4,200 hours)
• Change engine oil and replace oil filter (4).
• Change automatic transmission fluid (2).
66,000 miles (4,400 hours)
• Change engine oil and replace oil filter (4).
69,000 miles (4,600 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
72,000 miles (4,800 hours)
• Change engine oil and replace oil filter (4),
75,000 miles (5,000 hours)
• Change engine oil and replace oil filter (4).
• Inspect air cleaner element (1) (4).
• Inspect front and rear disc brake pads and rotors.
• Inspect bolts and nuts on chassis and body.
78,000 miles (5,200 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
81,000 miles (5,400 hours)
• Change engine oil and replace oil filter (4),
84,000 miles (5,600 hours)
• Change engine oil and replace oil filter (4).
• Change automatic transmission fluid (2).
87,000 miles (5,800 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
90,000 miles (6,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor drive belts (4).
• Replace air cleaner element (4).
• Inspect ignition timing (1) (4).
• Check idle speed (3) (4).
Service and Maintenance – cont’d
•
•
•
•
•
•
•
•
•
•
•
Change engine coolant every 30,000 miles (2,000 hours) or 36 months (4).
Inspect engine cooling system, hoses, clamps: and check coolant strength every 30,000 miles (2,000
hours) (4).
Replace fuel filter (3) (4).
Inspect fuel lines and hoses (1) (4).
Inspect fuel hoses and tubes for emissions (1) (4).
Inspect exhaust heat shield.
Inspect rear wheel driveshaft joint boots.
Inspect front and rear brakes.
Inspect brake lines, hoses and connections.
Inspect front fork assembly.
Inspect steering operation and linkage.
93,000 miles (6,200 hours)
• Change engine oil and replace oil filter (4).
96,000 miles (6,400 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
99,000 miles (6,600 hours)
• Change engine oil and replace oil filter (4),
102,000 miles (6,800 hours)
• Change engine oil and replace oil filter (4),
105,000 miles (7,000 hours)
• Change engine oil and replace oil filter (4).
• Inspect air cleaner element (1) (4).
• Replace timing chain/belt (4)
• Inspect fuel hoses (4).
• Inspect front and rear disc brake pads and front and rear disc rotors.
• Inspect bolts and nuts on chassis and body.
• Change engine oil and replace oil filter (4).
• Change automatic transmission fluid (2).
108,000 miles (7,200 hours)
• Change engine oil and replace oil filter (4).
Service and Maintenance – cont’d
111,000 miles (7,400 hours)
• Change engine oil and replace oil filter (4),
114,000 miles (7,600 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
117,000 miles (7,800 hours)
• Change engine oil and replace oil filter (4),
120,000 miles (8,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor belts (4).
• Replace air cleaner element (4).
• Inspect ignition timing (1) (4).
• Check idle speed (3) (4).
• Change engine coolant every 30,000 miles (2,000 hours) or 36 months (4).
• Inspect engine cooling system, hoses, clamps: and check coolant strength every 30,000 miles (2,000
hours) (4).
• Replace fuel filter (3) (4).
• Inspect fuel lines and hoses (1) (4).
• Inspect fuel hoses and tubes for emissions (4).
• Inspect exhaust heat shield.
• Inspect rear wheel driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect bolts and nuts on chassis and body.
• Inspect front fork assembly.
• Inspect steering operation and linkage.
• Repack front and rear wheel bearings.
• Rotate tires and adjust air pressure.
• Replace timing chain/belt. Failure to replace timing chain/belt may result in damage to engine (4) (5).
Service and Maintenance – cont’d
FOOTNOTES:
1. This item is not required to be performed, however Westward Industries recommends that you perform
maintenance on this item in order to achieve best vehicle operation.
2.
Change automatic transmission fluid if your driving habits frequently include one or more of the
following conditions:
- Operation during hot weather (above 90 F, 32 C), carrying heavy loads or driving in hilly
terrain.
- Police or door-to-door delivery service.
3.
This item is required for all states.
4.
These items are for emissions control.
5.
Required for all states except California.
Normal Maintenance Schedule
The Normal Maintenance Schedule should be followed if the vehicle is generally driven on a daily basis for
more than 10 miles (16 km) and NONE OF THE CONDITIONS SHOWN IN THE SEVERE
MAINTENANCE SCHEDULE APPLY TO DRIVING HABITS.
For items marked with a number in brackets (1), see footnotes at end of this section.
5,000 miles (325 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
10,000 miles (650 hours)
• Change engine oil and replace oil filter (4).
15,000 miles (1,000 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
Service and Maintenance – cont’d
20,000 miles (1,325 hours)
• Change engine oil and replace oil filter (4).
25,000 miles (1,650 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
30,000 miles (2,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Replace air cleaner element (4).
• Inspect alternator and A/C compressor belts (4).
• Check idle speed (3) (4).
• Change engine coolant every 30,000 miles (2,000 hours) or 36 months (4).
• Inspect engine cooling system, hoses, clamps: and check coolant strength every 30,000 miles (2,000
hours) (4).
• Inspect fuel lines and hoses (1) (4).
• Inspect exhaust heat shield.
• Inspect rear wheel driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect front steering system.
• Inspect steering operation and linkage.
• Change automatic transmission fluid (2).
35,000 miles (2,325 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
40,000 miles (2,650 hours)
• Change engine oil and replace oil filter,
45,000 miles (3,000 hours)
• Change engine oil and replace oil filter.
• Rotate tires and adjust air pressure.
50,000 miles (3,325)
• Change engine oil and replace oil filter (4).
Service and Maintenance – cont’d
55,000 miles (3,650 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
60,000 miles (4,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor drive belts (4).
• Replace air cleaner element (4).
• Replace timing chain/belt (2) (4).
• Inspect ignition timing (1) (4).
• Check idle speed (3) (4).
• Change engine coolant every 30,000 miles (2,000 hours) or 36 months (4).
• Inspect engine cooling system, hoses, clamps: and check coolant strength every 30,000 miles (2,000
hours) (4).
• Replace fuel filter (2) (4).
• Inspect fuel lines and hoses (2) (4).
• Inspect fuel hoses and tubes for emissions (2) (4).
• Inspect exhaust heat shield.
• Inspect rear wheel driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect front steering assembly.
• Inspect bolts and nuts on chassis and body.
• Inspect steering operation and linkage.
• Repack front and rear wheel bearings.
• Change automatic transmission fluid.
65,000 miles (4,325 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
70,000 miles (4,650 hours)
• Change engine oil and replace oil filter (4).
75,000 miles (5,000 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
Service and Maintenance – cont’d
80,000 miles (5,325 hours)
• Change engine oil and replace oil filter (4),
85,000 miles (5,650 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
90,000 miles (6,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor drive belts (4).
• Replace air cleaner element (4).
• Check idle speed (3) (4).
• Change engine coolant every 30,000 miles (2,000 hours) or 36 months (4).
• Inspect engine cooling system, hoses, clamps: and check coolant strength every 30,000 miles (2,000
hours) (4).
• Inspect timing chain/belt (1) (4).
• Inspect fuel lines and hoses (1) (4).
• Inspect exhaust heat shield.
• Inspect rear wheel driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect steering assembly.
• Inspect bolts and nuts on chassis and body.
• Inspect steering operation and linkage.
• Change automatic transmission fluid.
95,000 miles (6,325 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
100,000 miles (6,600 hours)
• Change engine oil and replace oil filter (4),
105,000 miles (7,000 hours)
• Change engine oil and replace oil filter (4).
• Replace timing chain/belt (4)
• Inspect fuel hoses (4).
• Rotate tires and adjust air pressure.
Service and Maintenance – cont’d
110,000 miles (7,325 hours)
• Change engine oil and replace oil filter (4),
115,000 miles (7,650 hours)
• Change engine oil and replace oil filter (4).
• Rotate tires and adjust air pressure.
120,000 miles (8,000 hours)
• Change engine oil and replace oil filter (4).
• Replace spark plugs (4).
• Inspect alternator and A/C compressor belts (4).
• Replace air cleaner element (4).
• Inspect ignition timing (1) (4).
• Check idle speed (3) (4).
• Change engine coolant every 30,000 miles (2,000 hours) or 36 months (4).
• Inspect engine cooling system, hoses, clamps: and check coolant strength every 30,000 miles (2,000
hours) (4).
• Replace fuel filter (3) (4).
• Inspect fuel lines and hoses (2) (4).
• Inspect fuel hoses and tubes for emissions (1) (4).
• Inspect exhaust heat shield.
• Inspect rear wheel driveshaft joint boots.
• Inspect front and rear brakes.
• Inspect brake lines, hoses and connections.
• Inspect bolts and nuts on chassis and body.
• Inspect front fork assembly.
• Inspect steering operation and linkage.
• Repack front and rear wheel bearings.
• Replace timing chain/belt. (3) (4).
• Change automatic transmission fluid.
FOOTNOTES:
1. This item is not required to be performed, however Westward Industries recommends that you perform
maintenance on this item in order to achieve best vehicle operation.
2.
This item is required for all states.
Service and Maintenance – cont’d
3.
Required for all states except California.
4.
These items are for emissions control.
SPECIFICATIONS
Engine Compression Ratio: 9.7:1
No. of Cylinder and Arrangement: 4-cylinder inline.
Firing Order: 1-3-4-2
Bore and Stroke: 2.78 x 3.29 in. (71 x 83.6mm)
Idle Speed: 850 RPM with transmission in PARK.
Ignition Timing: At idle 10 degrees BDTC. Adjust alignment mark at crankshaft pulley to timing indicator
at idle.
Oil Capacity: 3.6 US qts (3.4 liters) w/filter.
3.2 US qts (3.0 liters) w/o filter.
Engine Oil Type: SAE 5W30 SG
Spark Plug Type: Motocraft AD532C
Spark Plug Gap: .039-.043 in (1.0-1.1mm)
Cooling System
Capacity: 6.3 US qts (6.0L)
Pressure – radiator: 15 psi
Coolant Mixture: 50/50 provides –40 F (-40 C) is recommended.
Transaxle: 3 speeds forward, one reverse. It combines an automatic transmission and differential into one
component.
Fluid Capacity: 6.0 US qts (5.7 liters)
Brakes: Disc (one at front and two at rear.
Fuel Tank Capacity: 7.0 US gal. (26.5 liters)
WARRANTY SERVICE
To make a claim under warranty, contact the authorized GO-4 dealer or agent within 30 days upon
realizing a problem with your vehicle. We recommend having all warranty work done by the Go-4 dealer
or agent that sold you the vehicle. If not available, any authorized GO-4 agent or dealer. Remember your
GO-4 vehicle must be delivered to an authorized GO-4 dealer or agent within the warranty period, and all
warranty work must be done by an authorized GO-4 dealer or agent. A proof of purchase will be needed by
the dealer or agent to follow up any warranty claim.
Items Not Covered By Warranty
1. Vehicles subject to misuse, neglect, negligence or accident.
2.
Vehicles that have been modified or altered so as to adversely affect their operation, performance, or
durability or to change their intended use. Normal service work and above the repair and replacement
of defective parts.
3.
Normal service requirements arising during the warranty period such as fuel injection or ignition
adjustment and wear of brake shoes.
4.
Any expense when your vehicle has warranty done on it such as towing charges to and from your GO4 dealer or agent.
5.
Normal cleaning, adjusting or replacing if items such as filters, spark plugs and fuses.
6.
Vehicles that were not maintained or operated as listed in the GO-4 operator’s manual.
7.
Periodic checking of fluid levels or adding of lubricants.
8.
Check-up service, tune-up or diagnosis.
Owners’ Obligation and Responsibilities
Normal maintenance and replacement of service items are the responsibility of the owner and as such are
not considered defects in material and workmanship within the terms of the warranty. The need for service
maintenance will depend on the user of the vehicle. See your GO-4 dealer or agent for proper maintenance
and care of your vehicle. Proper maintenance and care will keep your operating cost to a minimum. To
assure a warranty claim, it is the owner’s responsibility to maintain all components in proper adjustment
and to service the vehicle as per GO-4 operator’s manual. Also proper lubrication of all components and
only the right fuel. Also, the correct battery level and the correct air pressure in the tires.
FOR OWNERS/OPERATORS ONLY
To comply with National Traffic and Motor Vehicle Safety Act of 1966, Williams Steiger Equipment
Safety and Health Act of 1970 and the Consumer Product Safety Act changes in address and/or ownership
are to be reported to the manufacturer.
If the name of the owner of the vehicle or the owner’s address changes, see your GO-4 dealer who had
vehicle registration change forms. These should be filled out and:
1.
Returned to the manufacturer.
2.
keep one copy for dealer records.
To find your local GO-4 dealer, inquire to:
Westward Industries Ltd.
2401 Saskatchewan Avenue, West
P.O Box 1288,
Portage la Prairie, Manitoba
Canada, R1N 3L5
Telephone: 1-204-857-8109
Fax: 1-204-239-5061
U.S. Distributors
Personal Information
Name _______________________________________
Address _____________________________________
_____________________________________
Telephone ___________________________________
Fax _________________________________________
Local GO-4 Dealer
Name _______________________________________
Address _____________________________________
Service Manager ______________________________
Telephone ___________________________________
Fax ________________________________________
GO-4 Information
VIN # ______________________________________
Engine # ____________________________________
INDEX
A
Air Cleaner Element
Automatic Transmission Fluid
Auxiliary Switches
B
Belts
32
41
18
Alternator belt, w/o a/c
With a/c
A/C compressor belt
Deflection, alternator
Deflection, a/c belt
Drive belt removal/install
Block Heater
Brake Fluid
Adding fluid
Brake Pedal
44
44
47
45
44
45
46
28
40
41
11
C
Controls and Gauges
Cooling System
Adding coolant
7
37
38
D
Decal
Emission Control Decal
Tire Gauge
Defrost/ Vent
Dimmer Switch
Dome Light
Doors
3
29
16
17
18
11
E
Engine Block Heater
Engine Number
Engine Oil
Adding oil
Capacity
Change Intervals
Check oil level
Filter
Viscosity
Engine Starting
Cold Engine
Cranks but does not start
Jump Starting
Warm Engine
Engine Service
Exhaust Fumes
28
3
33
33
36
35
33
36
34
22-25
22
25
48
24
31
26
F
Fan Speed
Filler Cap
Flash to Pass
Foot Throttle
Fuel Filter
Installation
Removal
Fuel Gauge
Fuel Type
Fuses
15
27
17
11
42
42
42
12
27
56
G
General Information
Gear Selector
2
9
H
Hazard Warning Switch
Heater Controls
Heater Valve Shutoff
Hourmeter
17
15
16
12
I
Ignition Switch
8
J
Jump Starting
48
L
Lights
Light Switch/Turn Signal
17
16
M
Maintenance Schedule
Maintenance Checks
Normal Maintenance Schedule
Severe Maintenance Schedule
58
58
67
60
O
Operation
20
P
Parking Brake
9
R
Refueling
Running out of gas
27
28
S
Safety
4
Operating Precautions for
the Catalytic Converter
Seat
Seat Belt
Service and Maintenance
Specifications
Starting a Cold Engine
Starting a Warm Engine
Starting the Vehicle
Stopping and Leaving Vehicle
6
19
19
31
73
22
24
22
21
T
Tilt Adjustment
Tires
Changing a tire
Front
Rear
Inflation
Rotation
Towing
Transaxle
Automatic transmission fluid
Capacity
Checking fluid level
17
51
53
54
55
51
52
30
41
41
41
41
V
Vehicle Appearances
Vehicle Emission Control Information
Vehicle Identification Number
57
3
2
W
Warning Lights
Brake System
Coolant Temperature
Governor
High Beam
Oil Pressure
Panel Light
Service
Turn Signal
Warranty Service
Wiper Control
13
13
15
13
14
15
15
15
14
74
18
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