OWNER’S GUIDE
GAS SHUTTLE 2+2
ISSUED JAN 2015
642586-C
REVISED JULY 2017
WELCOME
Thank you for purchasing this vehicle. Before you drive the vehicle, read this Owner’s Guide. This guide contains maintenance and operation information. The illustrations can show items that are optional for your vehicle.
You can do most of the service procedures in this guide with common, automotive hand tools. If necessary, contact your
service representative for information about how to service the vehicle as shown in the Periodic Service Schedule.
Repair or replacement parts are available from your E-Z-GO dealer or E-Z-GO Service Parts Department.
When you contact E-Z-GO about service or parts for your vehicle, the information below is needed.
Vehicle Model: ___________________________________________________________
PIN, VIN or Serial Number: _________________________________________________
OWNER’S GUIDE
GAS POWERED VEHICLE
SHUTTLE 2+2
STARTING MODEL YEAR 2015
CALIFORNIA Proposition 65 Warning
WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known
to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive harm.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed
beyond the factory specifications. Such modifications can cause serious personal injury or death. E-Z-GO Division of Textron Inc. prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold previously.
The information contained in this manual may be revised periodically by E-Z-GO, and therefore is subject to change without notice.
E-Z-GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
These are the original instructions as defined by 2006/42/EC.
CONTACT US:
E-Z-GO Division of Textron Inc.
1451 Marvin Griffin Road.
Augusta, Georgia, USA 30906-3852
North America:
Technical Assistance & Warranty PHONE: 1-800-774-3946 FAX: 1-800-448-8124
Service Parts PHONE: 1-888-GET-EZGO (1-888-438-3946) FAX: 1-800-752-6175
International:
PHONE: 001-706-798-4311 FAX: 001-706-771-4609
i
FORWARD
This vehicle was designed and manufactured in the United States of America (USA). The
Standards and Specifications listed in the following text originate in the USA unless otherwise indicated.
Use Original Equipment Manufacturer (OEM) approved parts to keep the warranty effective.
Overfilling battery may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty.
When servicing engines, all adjustments and replacement components must be per original
vehicle specifications in order to maintain the United States of America Federal and State
emission certification applicable at the time of manufacture.
BATTERY PROLONGED STORAGE
The batteries discharge over time. The rate of discharge changes according to the ambient
temperature, the age and condition of the batteries.
Completely charged batteries will not freeze in winter temperatures unless the temperature
is less than -75°F (- 60°C).
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return discarded batteries to distributor, manufacturer
or lead smelter for recycling. For neutralized spills, put residue in acid-resistant containers
with absorbent material, sand or earth and discard according to local, state and federal regulations for acid and lead compounds. Contact local or state environmental authorized people for the disposal information.
ii
Owner’s Guide
TABLE OF CONTENTS
SAFETY
B
GENERAL ......................................................................................................................... 1
NOTICES, CAUTIONS, WARNINGS AND DANGERS .................................................... 1
GENERAL OPERATION................................................................................................... 3
MAINTENANCE ................................................................................................................ 4
VENTILATION................................................................................................................... 5
LABELS AND PICTOGRAMS........................................................................................... 6
LABELS AND PICTOGRAMS........................................................................................... 7
GENERAL SPECIFICATIONS
VEHICLE DIMENSIONS ................................................................................................. 10
TURNING DIAMETER AND INCLINE INFORMATION .................................................. 11
INTRODUCTION
FEATURES ..................................................................................................................... 13
General Information ........................................................................................... 13
Key and Light Switch .......................................................................................... 13
Fuel Gauge with Low Oil Pressure Indicator ...................................................... 13
12-Volt Power Outlet .......................................................................................... 13
Direction Selector ............................................................................................... 13
Choke ................................................................................................................. 14
Accelerator Pedal .............................................................................................. 14
Brake and Parking Brake Pedal ......................................................................... 14
Horn ................................................................................................................... 14
Turn Signal Switch ............................................................................................. 14
Front Seat .......................................................................................................... 14
Front Hip Restraint ............................................................................................. 14
Glove Box Doors (if equipped) ........................................................................... 14
Cup Holder ......................................................................................................... 14
Steering Wheel................................................................................................... 14
Brake Light and Turn Signal............................................................................... 15
Rear Seat and Cargo Platform .......................................................................... 15
Rear Hand Rail................................................................................................... 15
Rear Handle ....................................................................................................... 15
Weather Enclosure (if equipped)........................................................................ 15
Rear View Mirror (if equipped) ........................................................................... 15
Owner’s Guide
iii
TABLE OF CONTENTS
OPERATING PROCEDURES
B
SERIAL NUMBER LOCATION ........................................................................................ 17
BEFORE INITIAL USE..................................................................................................... 18
HOW TO OPERATE THE VEHICLE ............................................................................... 18
Key and Headlight Switch Operation .................................................................19
Direction Selector Operation ..............................................................................20
Accelerator Pedal Operation ...............................................................................20
Brake and Parking Brake Operation ...................................................................20
Horn Operation ...................................................................................................20
Rear Seat and Cargo Platform Operation ..........................................................21
12-Volt Power Outlet ...........................................................................................21
STARTING AND DRIVING .............................................................................................. 22
Run-In .................................................................................................................22
Starting Vehicle On A Hill ....................................................................................23
Coasting ..............................................................................................................24
FUEL................................................................................................................................ 24
FUEL TANK ..................................................................................................................... 24
Early Production Fuel Tank .................................................................................24
Late Production Fuel Tank ..................................................................................25
BATTERY ........................................................................................................................ 25
LABELS AND PICTOGRAMS.......................................................................................... 25
SUN TOP AND WINDSHIELD (IF EQUIPPED)............................................................... 26
MAINTENANCE
VEHICLE CLEANING AND CARE................................................................................... 27
ENVIRONMENTAL CONCERNS .................................................................................... 27
Battery Disposal ..................................................................................................27
LIFTING THE VEHICLE................................................................................................... 28
WHEELS AND TIRES...................................................................................................... 29
Tire Repair ..........................................................................................................29
Wheel Installation ................................................................................................30
LIGHT BULB REPLACEMENT ........................................................................................ 31
Headlight .............................................................................................................31
Taillight ................................................................................................................31
FUSE REPLACEMENT ................................................................................................... 31
VEHICLE WITH A DISCHARGED BATTERY ................................................................. 32
iv
Owner’s Guide
TABLE OF CONTENTS
TRANSPORTING VEHICLE ........................................................................................... 32
B
Towing ................................................................................................................ 32
Neutral Lock ....................................................................................................... 32
Hauling ............................................................................................................... 33
SERVICE AND MAINTENANCE..................................................................................... 33
ROUTINE MAINTENANCE............................................................................................. 34
Four Cycle Engine .............................................................................................. 34
Checking the Oil Level ....................................................................................... 34
Changing the Oil ................................................................................................ 35
Starter Generator Belt Tension .......................................................................... 37
Adjusting the Belt ............................................................................................... 38
Battery Cleaning ................................................................................................. 38
TIRE INSPECTION ......................................................................................................... 39
BRAKES ......................................................................................................................... 39
Periodic Brake Test ............................................................................................ 40
LUBRICATION ................................................................................................................ 40
CAPACITIES AND REPLACEMENT PARTS ................................................................. 41
HARDWARE ................................................................................................................... 41
AIR INTAKE AND COOLING FINS ................................................................................. 42
REAR AXLE ................................................................................................................... 42
Checking the Lubricant Level ............................................................................. 42
Cleaning the Air Filter Element .......................................................................... 43
LUBRICATION ................................................................................................................ 43
SPARK PLUGS............................................................................................................... 43
PERIODIC SERVICE SCHEDULE
PERIODIC SERVICE SCHEDULE ................................................................................. 45
APPENDIX A
DECLARATION OF CONFORMITY ................................................................................. A
Owner’s Guide
v
TABLE OF CONTENTS
B
vi
Owner’s Guide
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
SAFETY
GENERAL
For any questions about material in this manual, contact an authorized representative.
Read and understand all labels on the vehicle. Always replace any damaged or missing labels.
Steep hills allow the vehicle to move at faster speeds than speeds on a flat surface. To prevent the loss of vehicle control
and possible injury, speeds must be controlled to the maximum level ground speed indicated in the GENERAL SPECIFICATIONS section. Apply the brake to control the speed.
If you operate the vehicle above the maximum specified speed, you can damage the drivetrain components. The damage caused by speeds more than the maximum specified can cause a loss of vehicle control, is abusive, and will not be
covered under the warranty.
Use caution when you tow the vehicle. Towing the vehicle at above the recommended speed can cause personal injury
or damage to the vehicle and other property.
If the vehicle is used in a commercial environment, signs must be in position to inform of possible conditions that can be
dangerous. Examples shown below.
.
NOTICES, CAUTIONS, WARNINGS AND DANGERS
Read the NOTICES, CAUTIONS, WARNINGS and DANGERS. The person who services a vehicle needs the mechanical skill and experience to see possible hazardous conditions. Incorrect service or repairs can cause damage to the vehicle or make the vehicle dangerous to operate.
A NOTICE indicates and describes information not related to personal injury.
A CAUTION indicates a dangerous condition that can cause injury that is not life threatening.
A WARNING indicates a dangerous condition that can cause death or serious injury.
A DANGER indicates a dangerous condition that will cause death or serious injury.
Owner’s Guide
1
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm.
The exhaust emissions of this vehicles engine complies with regulations set forth by the Environmental Protection
Agency (EPA) of the United States of America (USA) at time of manufacture. Significant fines could result from modifications or tampering with the engine, fuel, ignition or air intake systems.
Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands
after handling.
This spark ignition system meets all requirements of the Canadian Interference-Causing Equipment Regulations.
This manual contains recommended maintenance procedures from the manufacturer. Follow these procedures and fault
isolation information to get the best service from the product. To decrease the risk of personal injury or property damage,
obey all the information in this manual.
Certain replacement parts can be used independently and/or in combination with other accessories to modify
an E-Z-GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph. When an E-Z-GOmanufactured vehicle is modified in any way by the Distributor, Dealer or customer to operate at or in excess
of 20mph, UNDER FEDERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to
Federal law the Distributor or Dealer MUST equip the product with headlights, rear lights, turn signals, seat
belts, top, horn and all other modifications for LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the requirements of FMVSS 571.565. Pursuant to FMVSS
571.500, and in accordance with the State laws applicable in the places of sale and use of the product, the
Distributor, Dealer or customer modifying the vehicle also will be the Final Vehicle Manufacturer for the LSV,
and required to title or register the vehicle as mandated by State law.
E-Z-GO will NOT approve Distributor, Dealer or customer changes that change an E-Z-GO product into a Low Speed
Vehicle (LSV).
Anyone who operates this vehicle must be A LICENSED DRIVER AND OPERATE THE VEHICLE ACCORDING TO
APPLICABLE STATE REQUIREMENTS. This rule is important to the SAFE USE AND OPERATION of the product. All
customers must obey this SAFETY RULE.
Information on FMVSS 571.500 is found at Title 49 of the Code of Federal Regulations, section 571.500. For information
online, go to www.ecfr.gov.
Vehicles are used for different purposes, so it is not possible to know and inform of every possible occurrence. Be careful
when you drive to prevent avoidable personal injury or damage to the vehicle. All users must read and obey this manual.
Make sure you give special attention to the CAUTIONS, WARNINGS and DANGERS.
For questions about this vehicle, contact your E-Z-GO/CUSHMAN dealer or write to the address on the back cover of this
publication, Attention: Customer Care Department.
2
Owner’s Guide
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
E-Z-GO has the right to change the design of the vehicle. There is no responsibility to make the changes on units purchased before changes were made. The information in this manual can change without notice.
B
E-Z-GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL. E-Z-GO IS NOT LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL.
This vehicle meets the current applicable standard for safety and performance requirements.
These vehicles are for off-road use. They DO NOT meet the federal Motor Vehicle Safety Standards of the United States
of America (USA) and are not for operation on the public streets. Some areas allow the operation of the vehicles on their
streets according to local codes.
Refer to GENERAL SPECIFICATIONS for capacity of the vehicle.
Do not change the vehicle in any manner that changes the weight distribution, decreases stability,
increases speed or extends the necessary distance to stop more than the factory specification.
Such changes can cause personal injury or death.
Do not change the vehicle in any manner that changes the weight distribution, decreases stability, increases speed or
extends the necessary distance to stop more than the factory specification. E-Z-GO is not responsible for changes that
cause the vehicle to be dangerous.
Do not let anyone below the height of 59 inches (150 cm) operate the vehicle.
GENERAL OPERATION
Read the following warnings before attempting to operate the vehicle.
When you leave the vehicle, turn the key to the OFF position and remove the key from the vehicle.
Drive the vehicle only as fast as terrain and conditions allow. Consider the terrain and traffic conditions. Consider environmental conditions that change the terrain and your ability to control the
vehicle.
Do not drive fast downhill. Sudden stops or change of direction can cause a loss of control. Use
the brake to control the speed of the vehicle when you drive down a slope.
When possible, stay in approved areas and do not drive on steep slopes.
Always keep feet, legs, hands and arms inside vehicle.
Do not drive on rough terrain.
Before you drive in the reverse direction, make sure the area behind the vehicle is clear.
Make sure the direction selector is in the correct position before you press the accelerator pedal.
Decrease speed before and during turns.
Make sure you completely stop the vehicle before you move the direction selector.
See GENERAL SPECIFICATIONS for the vehicle load and seat capacity.
Owner’s Guide
3
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Read the following text and warnings before you service the vehicle.
Normal use, age, wear or abuse can cause some components on the vehicle to fail. The manufacturer can not know all
possible component failures or the methods that failures can occur.
A vehicle in need of repair does not operate correctly and can be dangerous.
Be careful when you service the vehicle. Be aware of your safety and the safety of other people in the area.
Some components are heavy, spring loaded, corrosive, explosive, can cause high amperage or get hot. Battery acid and
hydrogen gas can cause injury. Do not put your hands, face, feet or body in a location that can expose them to injury if an
unexpected situation occurs.
Always use the correct tools shown in the tool list and wear safety equipment.
Remove all jewelry before you service the vehicle.
Do not allow loose clothing or hair to contact the moving parts.
Do not touch hot objects.
When you service the vehicle, always wear eye protection. Be careful
when you do work around batteries or you use solvents or compressed
air.
ALWAYS:
•
Use the vehicle with responsibility and keep the vehicle in safe condition for operation.
•
Read and obey all warnings and operation instruction labels on the vehicle.
•
Follow all safety rules in the area where the vehicle is operated.
•
When there is a risk of lightning, leave the vehicle and look for a safe location to wait until the lightning has stopped.
•
Drive the vehicle only as fast as terrain and conditions allow.
•
Apply service brake to control the speed on steep grades.
•
Keep enough distance between vehicles.
•
Decrease speed in wet areas.
•
Be careful when you make sharp turns, or turns you are not familiar with.
•
Be careful when you drive on loose terrain.
•
Be careful when you operate the vehicle around people.
MAINTENANCE
ALWAYS:
•
Replace damaged or missing warning, caution or information labels.
•
Service the vehicle according to the periodic service schedule in this manual.
•
Make sure that approved and qualified personnel do all repairs.
4
Owner’s Guide
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
•
•
•
•
•
•
•
•
•
•
Follow the manufacturers maintenance procedures.
Use insulated tools within the battery area to prevent sparks or battery explosion.
Use specified replacement parts, DO NOT use replacement parts of less quality.
Use recommended tools.
Make sure that tools and procedures not specified by the manufacturer will not be a safety risk to personnel or operation of the vehicle.
Support the vehicle with wheel chocks and jack stands. NEVER get below a vehicle that is supported by a jack. Lift
the vehicle according to the manufacturers instructions.
Make sure you service the vehicle in an area away from open flame or sparks.
Know that a vehicle in need of repair does not operate correctly and can be dangerous to operate.
After you do the repairs or maintenance, test the vehicle in a safe area that is without vehicle and person traffic.
Make sure you record and keep all of the maintenance history of the vehicle.
Vehicles are used for different purposes, so it is not possible to know and inform of every possible occurrence. Be careful
when you drive to prevent avoidable personal injury or damage to the vehicle. All users must read and obey this manual.
Make sure you give special attention to the CAUTIONS, WARNINGS and DANGERS.
People who do maintenance or repairs on the vehicle must have skill and experience to identify and prevent conditions
that can cause personal injury or death and damage to the vehicle.
VENTILATION
Always store gasoline vehicles in an area with good ventilation. Good ventilation prevents the accumulation of gasoline
fumes within an enclosed area.
Never put fuel in a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
water heaters and furnaces.
Never work around or operate a vehicle in an environment that does not allow ventilation of exhaust gases from the area.
Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.
Owner’s Guide
5
B
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
LABELS AND PICTOGRAMS
WARNING
READ THE MANUAL
HIGH CENTER
OF GRAVITY MAY
CAUSE TIP OVER
H
SECURE LOAD
MAX BED WEIGHT
250 LBS or 110 KG
OFF
MAX CENTER OF
GRAVITY HEIGHT
4” OR 10 CM
ABOVE FLOOR
MAX SIDE
SLOPE 14°
REMAIN SEATED
AND HOLD ON
TO HAND RAIL
DO NOT RIDE
ON LOAD BED
610631
ORN
ON
608527
71131-G01
71131G01
LOCATED ON GOVERNOR COVER
NO TAMPERING
KEEP HANDS
OUT
DO NOT
EXPOSE
TO FLAME
GROUND
FUEL
PUMP
NEGATIVE
GROUND
BATTERY
SHORTING BATTERY
TERMINALS MAY
CAUSE EXPLOSION
PP
74093G01
6
DO NOT SPILL
FUEL ON HOT
ENGINE
3
2
1
PP
PP
H2O
74093-G01
CLEAN GASOLINE SPILLS WITH WATER
BEFORE STARTING ENGINE
Owner’s Guide
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
LABELS AND PICTOGRAMS
FOR INFORMATION
REFER TO OWNERS
MANUAL OR
WEBSITE
NO PUBLIC
ROAD USE
DO NOT OPERATE
UNDER DRUG/ALCOHOL
INFLUENCE
OPERATOR MUST
BE MIN 150 CM
REMAIN SEATED
KEEP ARMS / LEGS
WITHIN VEHICLE
I
ON
R
F
cm
FOR INFORMATION
REFER TO OWNERS
MANUAL
I
ON
F
O
OFF
R
I
ON
R
O
OFF
F
O
OFF
MIN 150
OBEY LOCAL
RULES AND
REGULATIONS
USE CAUTION IN
INCLEMENT
WEATHER
B
TO OPERATE VEHICLE:
- TURN KEY TO ON
- MOVE DIRECTION SELECTOR TO
FORWARD OR REVERSE
- PRESS ACCELERATOR
< 14° 25%
I
ON
< 14° 25%
F
O
OFF
I
ON
O
OFF
F
I
ON
O
OFF
R
614121
614121
LEAVE VEHICLE
IN THREAT OF
LIGHTNING
MAX SIDE
SLOPE 14°
READ MANUAL
FOR MAX LOAD
BED CAPACITY.
MAX INCLINE 14°
OPERATE FROM
DRIVERS SIDE
ONLY
READ MANUAL
FOR MAX LOAD
BED CAPACITY.
MAX INCLINE 14°
DO NOT OPERATE
UNDER DRUG/ALCOHOL
INFLUENCE
TO PARK VEHICLE:
- TURN KEY TO OFF
- MOVE DIRECTION SELECTOR
TO FORWARD
- ENGAGE PARKING BRAKE
TO OPERATE VEHICLE:
- TURN KEY TO ON
- MOVE DIRECTION SELECTOR
TO F OR R
- PRESS ACCELERATOR
REMAIN SEATED
KEEP ARMS / LEGS
WITHIN VEHICLE
NO PUBLIC
ROAD USE
P
F
< 14° 25%
WARNING
READ OWNERS
MANUAL OR
WEBSITE
MAX SIDE
SLOPE 14°
N
R
PP
F
601781
601781
OPERATE FROM
DRIVERS SIDE
ONLY
TO PARK VEHICLE:
- TURN KEY TO OFF
- MOVE DIRECTION SELECTOR
TO FORWARD
- ENGAGE PARKING BRAKE
608822
27653G01
H
USE CAUTION IN
INCLEMENT WEATHER
< 14° 25%
ORN
EGWHL14
AUTHORIZED REPRESENTATIVE IN EC IS:
RANSOMES JACOBSEN LTD.
WEST ROAD, IPSWICH,
SUFFOLK, IP3 9TT, UK
614068
614068
Owner’s Guide
7
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
8
Owner’s Guide
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
GENERAL SPECIFICATIONS
MODEL: CUSHMAN SHUTTLE 2+2 G
TYPE: GASOLINE POWERED PERSONNEL CARRIER
MODEL YEAR: 2015
Part No:. 641356
PRODUCT SPECIFICATION
CONFIGURATION HIGHLIGHTS
Engine: 13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki
z Fuel System: Fixed float bowl with remote pulse fuel pump
z Valve Train: Overhead valve
Electronic spark/magneto
z Ignition:
z Lubrication: Pressurized oil system, spin-on oil filter
Internal counter rotating balance shaft
Replaceable dry cartridge
z Air Cleaner:
z Balancer:
Electrical:
Drive Train:
Brakes:
Transaxle:
Capacity:
Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve)
Automatic, continuously variable transmission (CVT)
Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with self-compensating system
Differential with helical gears, ground speed governor, forward/reverse
Seating for 4 persons. Rear Seat converts to Load Deck
PRODUCT OVERVIEW
Dimensions
Overall Length
Overall Width
Overall Height (No Canopy)
Overall Height (w/ Canopy)
Wheel Base
Front Wheel Track
Rear Wheel Track
Gnd Clearance @ Differential
Load Bed Width
Load Bed Length
Vehicle Power
Power Source
Valve Train
Horsepower (kW)
Electrical System
Batteries (Qty, Type)
Key or Pedal Start
Air Cleaner
Lubrication
Oil Filter
Cooling System
Fuel Capacity (Early Prod.)
Fuel Capacity (Late Prod.)
Drive Train
Transaxle
Gear Selection
Rear Axle Ratio
Performance
Seating Capacity
4 Persons
Dry Weight
861 lb (391 kg)
Curb Weight
896 lb (406 kg)
Load Capacity (Load Deck) 250 lb (110 kg)
Load Capacity (Vehicle)
800 lb (360 kg)
Outside Clearance Circle 19 ft (5.8 m)
Intersecting Aisle Clearance N/A
Speed (Level Ground)
14 mph ± 0.5 mph (22.5 kph ± 0.8 kph)
Towing Capacity
N/A
Steering & Suspension
Steering
Self-compensating rack and pinion
4 Cycle 24.5 cu in (401 cc). Low E
Front Suspension
Leaf springs with hydraulic shock absorbers
Single Cylinder OHV
Rear Suspension
Leaf springs with hydraulic shock absorbers
13.5 hp (10.1 kW) Exceeds SAE J1940 Std. Service Brake
Rear wheel mechanical self-adjusting drum
Starter/Generator. Solid State Regulator
Parking Brake
Self-compensating, single point engagement
One, 12 Volt Maintenance Free
Front Tires
Pair of 18 x 8.50 - 8 (4 Ply Rated)
Pedal
Rear Tires
Pair of 18 x 8.50 - 8 (4 Ply Rated)
Replaceable Dry Cartridge
Pressurized Oil System
Body & Chassis
Spin-On
Frame
Welded steel with DuraShield™ powder coat
Air Cooled
Front Body & Finish
Injection molded TPO
6.0 Gallon (22.7 L) tank
Rear Body & Finish
Injection molded TPO
5.6 Gallon (21.4 L) tank
Patriot Blue
Continuously variable transmission (CVT) Standard Color
Differential with helical gears
Forward - Reverse
11.42:1 (Forward) 15.78:1 (Reverse)
108.5 in (276 cm)
48.5 in (123 cm)
46.5 in (118 cm) (Top of steering wheel)
77.0 in (196 cm) (Top of Sun Canopy)
65.5 in (166 cm)
38.0 in (96 cm)
38.5 in (97 cm)
4.5 in (11 cm)
40.0 in (102 cm)
32.0 in (81 cm)
Some items shown may be optional equipment
Owner’s Guide
9
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
VEHICLE DIMENSIONS
46.5 in
(118 cm)
4.5 in
(11 cm)
77 in.
(196 cm)
65.5 in (166 cm)
108.5 in (276 cm)
Front
38 in. (97 cm)
48.5 in
(123 cm)
Rear
38.5 in. (98 cm)
RECOMMENDED MAX RAMP GRADE
25% or 14 o MAX
RECOMMENDED MAX SIDE TILT
25% or 14o MAX
10
Owner’s Guide
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
TURNING DIAMETER AND INCLINE INFORMATION
B
TURNING CLEARANCE DIAMETER
19 ft (5.8 m)
Owner’s Guide
11
GENERAL SPECIFICATIONS
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
12
Owner’s Guide
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
INTRODUCTION
FEATURES
General Information
If the vehicle has accessories that were installed at the factory, some accessories continue to operate with the key
switch in the OFF position.
1. Key and Light Switch
2
1
To decrease the risk of component damage, stop the vehicle before you
move the key switch or the direction selector.
OFF ON
F
E
FUEL
The key and light switch is found on the dash panel. The switch controls the
basic electrical system of the vehicle and the lights. To prevent accidental operation of an unattended vehicle, turn the key to the OFF position and remove from
the switch.
3
If the vehicle has accessories that were installed at the factory, some accessories continue to operate with the key switch in the OFF position.
2. Fuel Gauge with Low Oil Pressure Indicator
The fuel gauge indicates the amount of gasoline in the fuel tank. ‘F’ indicates a full tank and ‘E’ indicates an empty fuel
tank. The fuel gauge has a low oil pressure indicator. A low engine oil pressure condition is shown with a red indicator
light.
The low oil pressure indicator light on early model vehicles is located beside the fuel gauge on the dash, and not part
of the fuel gauge.
3. 12-Volt Power Outlet
A 12-volt power outlet, with a rating of 15 amps, is found to the left of the key and light switch. The outlet supplies
continuous power for any accessories that have a 12-volt plug.
4. Direction Selector
4
To reduce the possibility of component damage, the vehicle must be
completely stopped before moving the direction selector.
The direction selector is found on the seat panel and allows the operator to
select F (forward) or R (reverse). Vehicle should be left in F when unattended.
Reverse
When you leave the vehicle, put the direction selector in the F position,
engage the parking brake, turn the key to OFF position and remove the key.
Forward
5
When the direction selector is moved to the R position, a reverse warning buzzer activates.
Owner’s Guide
13
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
5. Choke
The choke is found on the seat panel below the driver seat. The choke helps start the vehicle when the engine is cold.
Refer to the COLD-START section for operation instructions.
6. Accelerator Pedal
Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause
severe injury or death.
With the key switch in the ON position, press the accelerator pedal to start the engine. When the pedal is released, the
engine will stop. To stop the vehicle immediately, press the brake pedal.
7. Brake and Parking Brake Pedal
The foot operated parking brake is the top part of the brake pedal. To engage
the parking brake, press on the upper section of the pedal until it locks in position. Press the lower part of the brake pedal to release the parking brake.
A parking brake that is engaged releases when you press the accelerator
pedal. This is a feature to make sure the vehicle is not driven with the parking brake engaged. Pressing the accelerator pedal is not the recommended
method to release the parking brake.
8
7
8. Horn
The horn button is found on the driver side of the floorboard. Press the button to activate the horn.
9. Turn Signal Switch
The turn signal switch is on steering wheel and
controls the operation of the right and left turn
signals.
14
10. Front Seat
12
9
The front seat is for two people, one person on
each side of the seat.
H
11. Front Hip Restraint
O RN
The front hip restraints help people stay in position if the vehicle changes position suddenly.
12. Glove Box Doors (if equipped)
The glove box doors have locks and are found
on each side of the instrument panel.
13. Cup Holder
The vehicle has a cup holder for the benefit of
both the driver and passenger.
13
14. Steering Wheel
11
10
The steering wheel controls the direction of vehicle travel.
14
15
Owner’s Guide
6
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
15. Brake Light and Turn Signal
B
The brake light and turn signal assemblies are one unit. They are found on the rear fenders.
16. Rear Seat and Cargo Platform
Rear passengers must stay in the seat and hold both the
hand rail and rear handle while the vehicle is in motion.
Do not allow passengers to ride on the cargo platform. A
sudden move or stop can cause severe injury or death to
passengers on the cargo platform.
The vehicle has a feature that functions as a rear seat or a cargo platform.
When in the upright position, it is a rear seat for two passengers. Fold the
seat flat for a cargo platform.
REAR SEAT FOLDED UP
16
17. Rear Hand Rail
17
There is a hand rail on each side of the rear seat to help passengers stay
in position when the vehicle is in motion. The passengers must hold the
rear hand rail whenever the vehicle is in motion.
18
18. Rear Handle
The rear handle is found at the far end of the vehicle in the center of the
rear seat. The handle helps the passengers stay in position when the vehicle is in motion. The passengers must hold the handle when the vehicle is
in motion.
19. Weather Enclosure (if equipped)
A weather enclosure supplies protection from strong weather conditions.
20. Rear View Mirror (if equipped)
REAR SEAT FOLDED DOWN
The rear view mirror is adjustable for use during the day or night.
Owner’s Guide
15
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
16
Owner’s Guide
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
OPERATING PROCEDURES
SERIAL NUMBER LOCATION
The vehicle has two serial number and manufacture date code plates. PART C label is found on the body panel below the
driver seat. PART D is found on the frame tube below the floorboard. The other (PARTS A and B) is found on the frame
crossmember below the front seat. Lift the seat and the flap to access PARTS A and B
Design changes occur continuously. When you order service parts, the PIN number, manufacture date code or serial
number must be available.
PART B
PART A
V
PART C/D
V
Lift Flap on Access Panel
Part A
Part B
Serial Number
Labels
Part D
Part C
Owner’s Guide
17
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
BEFORE INITIAL USE
Read, understand and follow the safety label on the instrument panel. Make sure you understand how to safely operate
the vehicle and its equipment.
Reckless use of this vehicle can cause severe injury or death. This vehicle is a light-duty vehicle,
NOT an All Terrain Vehicle (ATV).
Do not engage in rough or reckless operation of this vehicle.
If you do not know the terrain, make sure you prepare for unexpected occurrences. If the vehicle
gets stuck or the batteries discharge, a one-hour drive can take many hours on foot.
To prevent battery explosion, keep all flammable materials, open flame or sparks away from the
battery.
Never charge a vehicle near flammable materials, open flame or sparks. Never charge a vehicle near gas water heaters
and furnaces.
Before a new vehicle is put into operation, do the items shown in the INITIAL SERVICE CHART.
INITIAL SERVICE CHART
Item
Service Operation
Seats
Remove the protective plastic cover.
Brakes
Check the operation.
Calculate the distance necessary to stop the vehicle for the brake
performance test.
Tires
Check air pressure (18-22 psi).
Fuel
Fill tank with correct fuel.
Engine
Check oil level.
General
Check for possible leaks that may have developed during shipment.
HOW TO OPERATE THE VEHICLE
Incorrect use of the vehicle or lack of maintenance can cause damage or decreased
performance.
Read the following warnings before you operate the vehicle.
Make sure you know the terrain and traffic conditions. Make sure you know environmental conditions that change the terrain and your ability to control the vehicle. Drive the vehicle only as fast
as terrain and conditions allow.
When possible, stay in approved areas and do not drive on steep slopes.
18
Owner’s Guide
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Do not drive fast downhill. Sudden stops or change of direction can cause a loss of control. Use
the brake to control the speed of the vehicle when you drive down a slope.
To prevent loss of control, do not move the direction selector while the vehicle is in motion. If you
move the selector, the speed will immediately decrease and a warning device activates.
Decrease speed before and during turns.
Do not drive the vehicle up, down, or across a slope that is more than 14° (25% grade).
See GENERAL SPECIFICATIONS for the vehicle load and seat capacity.
When the accelerator pedal is pressed, the foot-operated parking brake releases and can cause
accidental or sudden vehicle movement. When the vehicle is parked, make sure the key is in the
OFF position.
When you leave the vehicle, turn the key to the OFF position and remove from the switch to prevent accidental operation.
Make sure the direction selector is in correct position before you press the accelerator pedal.
Make sure you completely stop the vehicle before you move the direction selector to a different
position.
Do not take vehicle out of gear while in motion.
Before you drive in the reverse direction, make sure the area behind the vehicle is clear.
Driver and passengers must stay in their seats while the vehicle is in motion.
Always keep feet, legs, hands and arms inside vehicle while in motion.
Key and Headlight Switch Operation
Key and Headlight Switch
When you leave the vehicle, turn the key to the OFF position
and remove from the switch to prevent accidental operation.
OFF ON
F
E
FUEL
To prevent possible damage to the components, stop the vehicle before you move the key switch or the direction selector to a different position.
Turn the key to the right to enable the electrical system of the vehicle. The first stop is ON and supplies power that allows
you to drive the vehicle. The second stop has a light icon and activates the lights.
When you leave the vehicle, turn the key to the OFF position and remove the key from the switch.
If the vehicle has accessories that were installed at the factory, some accessories continue to operate with the key
switch in the OFF position.
Owner’s Guide
19
B
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Direction Selector Operation
B
Direction
Selector
To prevent loss of control, do not move the direction selector to a
different position while the vehicle is in motion. If you move the
selector, the speed will immediately decrease and a warning
device activates.
Reverse
Forward
Move the direction selector to F to move in the forward direction.
Move the direction selector to R to move in the reverse direction. A reverse warning buzzer activates when the direction selector is moved to the R position.
The position between F and R is the neutral position.
When you leave the vehicle, put the direction selector in the forward position, engage the parking brake and remove the
key from the switch.
Accelerator Pedal Operation
Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause
severe injury or death.
An engaged parking brake will release when the accelerator pedal is pressed and cause the vehicle to move suddenly. When the vehicle is parked, make sure the key is in the OFF position so
that the electrical system is disabled.
When the key switch is in the ON position, press the accelerator pedal start the engine and move the vehicle. Release
the pedal to stop the engine.
Press the brake pedal to stop the vehicle quickly.
If the key switch is in the ON position and the parking brake is
engaged, the brake releases when you press the accelerator
pedal and can cause the vehicle to move suddenly. This is a feature to make sure the vehicle is not driven with the parking brake
engaged. Pressing the accelerator pedal is not the recommended method of to release the parking brake.
Parking
Brake Pedal
Accelerator Pedal
Brake and Parking Brake Operation
The function of the lower part of the brake pedal is to control
speed. Press the lower part of the pedal to decrease speed or
stop the vehicle.
To engage the parking brake, press the upper section of the pedal
until it locks into position. Press the lower part of the pedal to
release the parking brake.
Horn Operation
Press the horn button to activate the horn.
20
Owner’s Guide
Horn
Brake Pedal
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Rear Seat and Cargo Platform Operation
B
To prevent damage to the rear seat, move any accessories that are
installed on the hand rail, when you fold the seat.
Fold the seat to the flat position to access the cargo platform.
Secure the loads on the platform to prevent movement.
Put the load on the platform as far forward as possible.
REAR SEAT FOLDED UP
The center of gravity of the load must be less than 4 inches
(10 cm) above the platform.
Do not put more than the specified capacity on the platform.
Increased loads can change drive properties of the vehicle.
Do not allow passengers to ride on the cargo platform.
When you put cargo on the platform, make sure you follow information
below to decrease the risk of injury, damage to the vehicle or cause the
vehicle to tilt over.
•
•
•
•
Put the load on the platform as far forward as possible.
Secure the loads on the platform to prevent movement.
The center of gravity of the load must be less than 4 inches (10 cm)
REAR SEAT FOLDED DOWN
above the platform.
The load capacity of the cargo platform is a maximum of 250 lbs. (115 kg). Do not put more than the specified capacity on the platform.
Increased loads can change the drive properties of the vehicle.
12-Volt Power Outlet
Power Outlet
Overuse of accessories can drain the battery and leave insufficient charge to
start the vehicle.
Excessive use of accessories that are connected to the outlet can drain the
battery.
Lift the cover and insert the 12-volt accessory plug.
Owner’s Guide
21
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
STARTING AND DRIVING
To decrease the risk of roll-back, do not release the service brake until the engine has started.
To operate the vehicle:
•
•
•
•
•
Apply the service brake, put the key in the key switch and turn to the ON position.
Move the direction selector to the correct direction.
Press the service brake to release the parking brake.
Slowly press the accelerator pedal to start the engine. Release service brake when the engine starts.
When the accelerator pedal is released, the ignition circuit is de-energizes and the engine stops. To stop the
vehicle quickly, press the service brake pedal.
When the direction selector is in the reverse position, a warning signal activates to indicate that the vehicle is ready to
run in the reverse direction.
Run-In
Check for possible leaks that may have developed during shipment.
Avoid full throttle starts and fast acceleration until the engine has reached operating temperature.
All engines use more oil than normal during the first hours of operation. As internal moving parts are run-in, oil use will
gradually decrease until the rate of use stabilizes.
Check the oil level according to the Periodic Service Schedule. Add oil if the level on the dipstick indicates that oil is in the
add oil range.
Do not overfill engine. Too much oil can cause smoke or
allow oil to enter the air filter enclosure.
Fill Cold Engine
To This Point
Add Oil
The oil dipstick and fill cap must be in position before engine
operation starts. Failure to install the dipstick and fill cap will
cause oil becoming contaminated and/or being discharged into
the engine compartment.
Safe
Operating Range
Hot Engine
Oil dipsticks are unique to this model vehicle. Do not use a dipstick from another engine.
22
Owner’s Guide
Maximum Oil Level
For Hot Engine
Do Not Overfill
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Change the oil according to the Periodic Service Schedule while
the engine is warm..
B
See the Repair and Service Manual for procedures to check the
oil level and change the oil.
Cold-Start
The use of a choke may be necessary to start a cold engine.
Press the accelerator 1 inch (2.5 cm) or until the starter starts to operate.
Pull the choke out if needed. Press the accelerator slowly and push the
choke in completely when the engine is running smoothly.
Do not allow the starter to operate continuously for more than 10
seconds. Allow 30 seconds between starting tries. If the vehicle does
not start on the third try, turn the key to the OFF position, set the
parking brake and find the cause of the problem.
Choke
If the vehicle had been running and the engine does not start within 10 seconds, use the choke.
Starting Vehicle On A Hill
To decrease the risk of roll-back, do not release the service brake until the engine has started.
Do not use the accelerator and engine to hold the vehicle on a hill. Doing so will cause early and excessive
wear to the drive train components.
To decrease the risk of permanent damage to the drive train, do not allow roll-back when you start the vehicle
on a hill.
Put left foot on service brake and release the parking brake. Press the accelerator with right foot and release the service
brake.
Owner’s Guide
23
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Coasting
B
Do not allow the vehicle to coast at above recommended speeds. Control vehicle speed with the
service brake.
Steep hills allow the vehicle to move at faster speeds than speeds on a flat surface. To prevent the loss of vehicle control
and possible injury, speeds must be controlled to the maximum level ground speed indicated in the GENERAL SPECIFICATIONS section. Apply the brake to control the speed.
FUEL
To decrease the risk of severe injury or death from improper fuel handling:
Do not smoke near the fuel tank.
Do not add fuel near open flame or electrical items that can cause a spark.
Always handle gasoline in a well ventilated area.
Always wear eye protection to protect against splashed fuel and fuel vapors.
Inspect the fuel cap, tank and other components for leaks or damage that can cause a hazardous
condition.
Oxygenated or reformulated gasoline, is mixed with alcohols or ethers. Excessive amounts of these blends
can damage the fuel system or cause performance problems. If any operating problems occur, use gasoline
with a lower percentage of alcohol or ether.
Use clean regular grade unleaded fuel. The Ethanol blend fuel up to 10% is permitted.
Do not use gasoline that contains methanol.
High altitude or heavy use/load applications can benefit from higher octane gasoline.
FUEL TANK
The fuel tank is found below the seat on the passenger side of the vehicle. Fill the tank with clean, automotive grade gasoline.
Early Production Fuel Tank
Always allow enough space for the expansion of gasoline. Leave at least 1-inch (2.5 cm) of space
below bottom of filler neck.
24
Owner’s Guide
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Early production fuel tanks can be identified by the location of
the fuel cap which is located in the middle of the top of the
tank as shown.
B
Fuel
1" Min.
(2.5 cm)
Early production fuel tanks require enough space for the
expansion of the gasoline. Leave at least 1-inch (2.5 cm) of
space below the bottom of the filler neck.
Early Production Fuel Tank
Late Production Fuel Tank
Late production fuel tanks can be identified by the location of
the fuel cap which is located in the rear of the top of the tank
as shown.
Late production fuel tanks are designed to allow for fuel
expansion and do NOT require space below bottom of filler
neck.
Late Production Fuel Tank
BATTERY
Heavy use of accessories drains the battery which can leave insufficient reserve to start the vehicle.
The vehicle uses a starter/generator to start the engine and charge the battery. The engine will not idle; so the battery
does not charge while the vehicle is stopped. Do not operate lights and other accessory items excessively while the vehicle is stopped.
The generator can supply 35 amps; so operation of all accessories can cause the discharge of the battery even if the
engine is running and the generator is operating. Discharging the battery is known as deep cycling. The battery is not a
deep cycle model. It is a starting battery. Multiple deep cycling causes early failure of the battery.
If the battery has discharged, charge it with a 12-volt charger that is rated at 10 amps or less and according to instructions supplied by the manufacturer of the charger.
LABELS AND PICTOGRAMS
The vehicle can have labels with pictograms to supply information or warnings. Refer to the SAFETY section of this manual for the description of the labels.
Owner’s Guide
25
OPERATING PROCEDURES
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
SUN TOP AND WINDSHIELD (IF EQUIPPED)
The sun top does not supply protection from roll-over or falling objects.
The windshield does not supply protection from tree branches or moving objects.
The sun top and windshield supply some protection from the elements, but do not keep the operator and passenger dry
in heavy rain.
26
Owner’s Guide
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
MAINTENANCE
VEHICLE CLEANING AND CARE
Read and understand all instructions supplied by the manufacturer of the pressure washer before
use.
When you clean the outside of the vehicle with a pressure washer, do not use more than 700-psi pressure.
Keep a minimum distance of 12 inches from the spray nozzle to the painted surface. Do not clean the plastic
parts with abrasive solvents.
Make sure you use correct methods and cleaning materials to prevent risk of damage to the outside of the vehicle. The
use of more than 700-psi water pressure can cause injury to anyone in the area or damage to vehicle.
Clean the windshield with water and a clean cloth. Remove small scratches with a plastic polish or Plexus® plastic
cleaner, available from the service parts department.
Apply a soap and water solution with a sponge or soft brush to clean the vinyl seats and plastic or rubber trim. Dry with a
cloth.
Use a commercially available vinyl and rubber cleaner to remove oil, tar, asphalt, shoe polish, etc.
Wash the vehicle frequently with cool water and mild detergent to protect the painted surfaces.
Apply wax that is for clear coat automotive finishes to improve the appearance and protection of the painted surfaces. Do
not apply wax to matte finish surfaces.
Materials used as fertilizers or for dust control can collect on the bottom of the vehicle. These materials will cause corrosion of components, unless cleaned with water. Clean areas where mud or dirt can collect. Loosen the sediment that is
packed in closed areas to help with removal. Be careful not to damage the paint.
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.
Always be respectful of the environment.
Make sure you are permitted by property owners to operate the vehicle on their property.
There is a risk of fire when the vehicle is operated near combustible material.
Be careful of environmental hazards like steep slopes, tree branches, etc.
Battery Disposal
Return used batteries to the manufacturer or lead smelter for recycling purposes. For neutralized spills, put residue in
acid-resistant containers with absorbent material, sand or earth and discard according to state and federal regulations for
acid and lead compounds. Contact authorized environmental people for information about disposal.
Owner’s Guide
27
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
LIFTING THE VEHICLE
You must lift the front, the rear or the entire vehicle for some service and maintenance operations.
The vehicle is not stable during the lifting process.
Make sure the vehicle is on a hard and level surface.
Never get below a vehicle that is supported by a jack only.
Make sure a vehicle that is supported on jack stands is stable before you get below the vehicle.
Put wheel chocks in front and behind the wheels that remain on the ground.
Do not allow any person in or on the vehicle being lifted.
When you lift the vehicle, put the jacks and jack stands at the areas indicated only.
Tool List
Quantity
Floor Jack.................................................................... 1
Wheel Chocks ............................................................. 4
Tool List
Jack Stands................................................................. 4
Remove payload from vehicle before lifting. No person(s) should be in or on the vehicle while lifting.
How to lift the entire vehicle:
1.
2.
3.
4.
5.
6.
7.
Install the wheel chocks in front and behind each front wheel.
Put the jack below the center of the rear frame crossmember.
Lift the vehicle enough to put jack stands below the outer ends of the rear axle as shown.
Lower the jack and test the stability of the vehicle on the two jack stands.
Put the jack at the center of the front axle.
Lift the vehicle enough to put two jack stands below the front frame crossmember as shown.
Lower the jack and test the stability of the vehicle on all four jack stands.
How to lift the rear of the vehicle only:
1.
2.
3.
4.
Put the wheel chocks in front and behind each front wheel.
Put the jack below the center of the rear frame crossmember.
Lift the vehicle enough to put a jack stand below the outer ends of the rear axle as shown.
Lower the jack and test the stability of the vehicle on the two jack stands.
How to lift the front of the vehicle only:
1.
2.
3.
4.
28
Quantity
Put the wheel chocks in front and behind each rear wheel.
Put the jack at the center of the front axle.
Lift the vehicle enough to put two jack stands below the front frame crossmember as shown.
Lower the jack and test the stability of the vehicle on the two jack stands.
Owner’s Guide
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Lower the vehicle:
1.
2.
B
Lift the vehicle enough to remove the jack stands.
Carefully lower the vehicle to the ground with the jack.
Flat Portion
of Frame
Center of
Front Axle
Outside End
of Rear Axle
View from Underside of Vehicle
WHEELS AND TIRES
Recommended tire inflation pressure: 18-22 psi
To decrease the risk of tire explosion, do not exceed the tire inflation pressure rating on the tire
sidewall.
To decrease the risk of tire explosion, inflate small amounts of air into the tire at intervals to seat
beads. Because of the low volume of the small tires, over inflation can occur in seconds. Never
exceed the tire inflation pressure rating on the tire sidewall when seating a bead. Protect the face
and eyes when you remove a valve core.
When you remove the wheels, use only sockets made for impact wrenches to decrease the risk of
injury by a broken socket.
Do not use tires with low rated pressure. Do not use tires that have a recommended tire inflation
pressure less than the tire inflation pressure recommended in the owner’s guide.
Do not over inflate the tires. Excess pressure can cause the tire to separate from the wheel or
cause a tire explosion.
Tire Repair
Tool List
Quantity
Lug Wrench, 3/4”......................................................... 1
Impact Wrench ............................................................ 1
Tool List
Quantity
Impact Socket, 3/4” ..................................................... 1
Torque Wrench, ft. lbs. ................................................ 1
Owner’s Guide
29
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Use caution when you inflate the tires. Because of the low volume of the small tires, over inflation can occur in seconds.
Over inflation can cause the tire to separate from the wheel or cause a tire explosion.
The general recommended tire inflation pressure is 18-22 psi, but know that tire inflation pressure can change according
to the condition of the terrain.
For outdoor applications with primary use on areas with grass, consider the following:
•
•
Slightly higher tire inflation pressure is suitable on hard turf
A lower pressure decreases the risk of tires cutting into a soft turf
For hard surfaces or pavement, tire inflation pressure must be in the higher allowed range, but not more than recommended on the tire sidewall.
All four tires must have the same pressure for best control qualities. Always install the valve stem cap after you check or
inflate the tires.
The vehicle has low-pressure tubeless tires, installed on one-piece rims.
Use a tire plug to repair small holes in the tread part of the tire. For large holes and cuts, replace the tire.
Tire plug tools and plugs are available at automotive outlets. The tires do not have to be removed from the wheel to
install the tire plugs.
If the tire is flat, remove the wheel and inflate the tire to the recommended maximum pressure for the tire. Submerge the
tire in water to find the leak and mark with chalk. Install the tire plug according to manufacturers instructions.
Wheel Installation
To decrease the risk of component damage, do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.
Always follow the cross-sequence pattern when you install the lug nuts to make sure the wheel is evenly seated
against the hub.
With the valve stem to the outside of the wheel, install the wheel
on the hub with lug nuts.
Tighten the lug nuts (1) with your fingers in the cross-sequence
pattern shown.
Valve Stem Cap
Tighten the lug nuts to 50 to 85 ft. lbs. (68 to 115 Nm) torque in
20 ft. lbs. (27 Nm) increments.
1
Continue to follow the cross-sequence pattern until the correct
torque is reached.
Tire style may vary
30
Owner’s Guide
Cross Sequence
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
LIGHT BULB REPLACEMENT
B
To decrease the risk of premature bulb failure, do not allow your fingers to contact new bulbs. Use clean, dry
paper or paper towels to touch the glass part of the bulb.
Headlight
To prevent the bulb from accidentally disconnecting and possibly melting or igniting plastic components, the
locking ring MUST be installed again after installation of replacement bulb.
Inside of Cowl
Rotate the bulb socket a quarter turn to the left to unlock.
Remove the bulb and socket. Install new bulb and rotate
the socket a quarter turn to the right to secure.
Headlight Housing
Replacement bulbs are available from a local Distributor, an authorized Branch or the Service Parts Department.
Screw
Headlight Bulb
Taillight
Remove two Phillips head screws that secure the lens.
Rear Fender
Pull the lens from the housing to access the taillight bulb.
Taillight Lens
Remove the light bulb and install a new bulb. Make sure the bulb contacts the socket correctly.
Replace the lens and install the Phillips head screws.
Replacement bulbs are available from a local Distributor, an authorized
Branch or the Service Parts Department.
Taillight Bulb
FUSE REPLACEMENT
The fuse block is found below the driver seat. Lift the seat bottom to access the fuses.
Remove the old fuse and replace with a new fuse of the same type and size.
Fuses are available from a local Distributor, an authorized Branch or the Service Parts Department.
Owner’s Guide
31
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
VEHICLE WITH A DISCHARGED BATTERY
To decrease the risk of severe injury or death from accidental movement, do not use a jumper
cable to start a vehicle.
The vehicle has a starter/generator and does not idle. When you start the engine, the starter/generator functions as a
starter and with the engine running, it functions as a generator.
The generator can keep the battery charged with the short run times with this type of vehicle. The generator will not
charge a discharged battery.
When the engine starts, the clutches engage and cause the vehicle to move making ‘jump starting’ both dangerous and
impractical.
If the battery has discharged, charge it with a 12-volt charger that is rated at 10 amps or less and according to instructions supplied by the manufacturer of the charger.
TRANSPORTING VEHICLE
Towing
Do not ride or allow other people on the vehicle being towed.
Do not try to tow the vehicle with ropes, chains or any device different from a tow bar approved by
the factory.
Do not tow the vehicle on highways.
Do not tow the vehicle at speeds more than 12 mph (19 kph).
Neutral Lock
To prevent the driven clutch from turning the rear wheels during service
operations, a neutral lock is located on the direction selector.
To operate:
2
Turn key switch to ‘OFF’ and lift seat. Pull out and rotate the neutral lock
pin handle so that the pointed portion of the handle is to the side of the
direction selector cam. Move direction selector towards the area between
‘F’ and ‘R’. During that motion the pin will snap into the hole in the direction selector mounting bracket preventing any movement.
When in this position, the direction selector remains locked in the neutral
position. To unlock the direction selector, pull the neutral lock pin handle
out and rotate until the pointed portion of the handle fits into the hole in
the direction selector cam.
32
Owner’s Guide
Hole in Direction
Selector Cam
1
Unlocked
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Hauling
B
Make sure you secure the vehicle and all items before you move a vehicle on a trailer.
Do not allow any people on a vehicle being moved on a trailer.
Remove the windshield before you move a vehicle on a trailer.
Maximum speed with sun top installed is 50 mph (80 kph).
If you move the vehicle on a trailer at highway speeds, the sun top must be removed and the seat bottom secured.
When you move the vehicle on a trailer below highway speeds, check for tight hardware and cracks in sun top at the
mounting points.
The rated capacity of the trailer or truck must be more than the weight of the vehicle and load plus 1000 lbs. (454 kg).
See GENERAL SPECIFICATIONS for the weight of the vehicle.
Secure the vehicle to the trailer with ratchet tie downs.
SERVICE AND MAINTENANCE
Read all notices, cautions and warnings before any type of service operations.
The drive wheels must be lifted and supported on jack stands before you do any service to the
powertrain when the engine is in operation.
To decrease the risk of engine damage, do not operate the vehicle at full throttle for more than 5
seconds with the drive wheels lifted off the ground.
Disconnect the negative battery terminal before you service the vehicle to prevent accidental
operation.
Wear eye protection when you service the vehicle. Be careful when you do
work around batteries, use solvents or compressed air.
To decrease the risk of electrical arc, which can cause a battery explosion, disable all electrical loads from the battery before you remove the battery wires.
Use wrenches with insulation to decrease the risk of a wrench that falls on a battery to cause a
short-circuit. A battery short-circuit can cause an explosion.
The electrolyte in a battery is an acid solution which can cause burns to the skin and eyes. Completely clean all electrolyte spills that contact the body and eyes with clear water. Contact a physician immediately.
Neutralize electrolyte spills with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking
soda) mixed in 1 quart (1 liter) of water. Clean with water.
Be careful when you use the aerosol containers near battery terminals. Use a metal container that
has insulation to prevent an explosion.
Owner’s Guide
33
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
The vehicle owner and service technician must carefully follow the procedures recommended in this manual. The preventative maintenance, applied at recommended intervals, keeps the vehicle dependable and decreases the costs for
the repairs. Refer to the Periodic Service Schedule for service and intervals. Refer to Lubrication Points for correct lubrication locations.
ROUTINE MAINTENANCE
To increase the life of a vehicle that is used in strong conditions, some maintenance must be done more
often than recommended in the Periodic Service Schedule. For example: high or low temperatures, high dust
and dirt conditions, high use with maximum load.
To access the powertrain for normal maintenance, lift or remove the seat and remove the rear access panel. For major
repairs, refer to the applicable Technician’s Repair and Service Manual.
Some service procedures make it necessary to lift the vehicle. Refer to LIFTING THE VEHICLE for correct lift procedure
and safety information.
Four Cycle Engine
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.
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
Checking the Oil Level
Do not overfill engine. Too much oil may cause engine to
smoke or cause spark plug fouling.
Do not overfill engine. Too much oil may cause smoking or
allow oil to enter the air filter enclosure.
The oil should be checked with the engine warm. The vehicle
should be on a level surface with the parking 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.
Insert the dipstick fully into the dipstick hole and remove. Examine the level of the oil on the dipstick.
34
Owner’s Guide
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
The engine can be operated safely as long as oil is within the safe
operating range as indicated on the dip stick. Do not operate vehicle if oil level is below the safe area indicated on the dipstick.
Oil should be added to bring the level into the safe operating range.
Remember that oil expands as it gets hot, Do not overfill. Check
that the oil cap is firmly in place.
Add Oil
When adding oil between oil changes, do not mix brands and viscosity grades of oil.
B
Maximum Oil Level
For Hot Engine
Do Not Overfill
Fill Cold Engine
To This Point
Safe
Operating Range
Hot Engine
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
Quantity
Socket, 19 mm ............................................................ 1
Ratchet ........................................................................ 1
Extension, 8" ............................................................... 1
Tool List
Quantity
Oil Filter Wrench ......................................................... 1
Oil Drain Pan............................................................... 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.
HEAVY DUTY WORK
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.
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 to remove any moisture that has accumulated during storage.
10W-40
10W-30
LIGHT DUTY WORK
10W-30
F
0
C
0
-20
-30
0
-20
20
40
60
-10
0
10
20
(AIR TEMPERATURE)
80
100
30
40
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.
Owner’s Guide
35
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Place a drain pan under engine. Wipe top of the engine clean with a cloth.
Remove the oil fill cap.
Oil Fill Cap
Be careful of hot oil when drained. It may be hot
enough to burn you severely
Place the oil drain pan under the oil drain plug (1) found at the
rear of the engine base. Remove the drain plug (1), allow the
oil to drain into the pan. 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. Before installing the drain plug, clean the area
around the drain hole with a lint free cloth and inspect the
drain plug (1) for damage; replace if necessary. If the O-ring
(2) on the drain plug is damaged replace it with a new one.
Tighten the drain plug to 62 in. lbs (7 Nm) torque.
2
1
Clean the area around filter. Use a filter wrench (3) to remove
the filter (4) from the engine and allow the oil to drain.
3
4
The O-ring (5) may have remained on engine (6) or filter (7). If
the O-ring (5) remained on the engine surface (6), remove it
and discard with the filter (7).
Inspect the new oil filter for any defects, apply engine oil to the
oil filter O-ring (5) 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 41.
36
Owner’s Guide
5
7
6
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Oil capacity is 1 1/3 quarts (1.3 liters). Add slightly less than 1
1/3 quarts (1.3 liters) to allow for possible residual oil left in
engine. The oil must be high quality oil that meets or exceeds
API SF, SG, CC standards. Check oil level on dipstick. Oil
should be slightly below ‘H’ to allow for expansion. If necessary, continue to add oil slowly and allow time for oil to flow
down into engine. Check oil level on dipstick. Do not overfill.
B
Do not overfill engine. Too much oil may cause smoking
or allow oil to enter the air filter enclosure.
Both the oil dipstick and fill cap must be in place before
operating the engine. Failure to install the dipstick and fill
cap will result in oil being discharged into the engine compartment
As a final check, check the oil level again with the vehicle on level ground. Like all liquids, oil increases in volume when
warm. The full ‘H’ mark on the dipstick is calibrated for an engine at operating temperature. When the engine is cold, the
oil will be below the full mark. The engine can be operated safely as long as the oil is within the safe operating range as
indicated on the dipstick. Do not operate vehicle if oil level is below the safe area indicated on the dipstick.
Starter Generator Belt Tension
Tool List
Quantity
Belt Tension Gauge ..................................................... 1
Wrench, 3/4"................................................................ 1
Wrench, 9/16".............................................................. 2
Ratchet ........................................................................ 1
Socket, 3/4" ................................................................. 1
The starter/generator belt tension should be checked after the first 15 - 20 hours and set to 75 - 80 lbs. (34 - 36 kg).
At no time during installation of belt, should the belt tension exceed 160 lbs (73 kg).
At the time of installation, the belt must not be rolled over the installed edges of the starter/generator or drive
clutch pulleys. Excessive stretch in belt may cause cord failure.
A loose belt can cause audible vibration and squeal.
Owner’s Guide
37
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Tighten a new starter/generator belt to 110 - 130 lbs. (50 - 59 kg) tension when a gauge is applied half way between the two pulleys.
A new belt may be checked manually. A maximum deflection of
3/8" (10 mm) is acceptable. Tighten an existing belt to 75 - 80
lbs. (34 - 36 kg) tension using the same technique and inspect
for cracking or wear. A maximum deflection of 1/2" (13 mm) is
acceptable.
3/8" (1 cm) Maximum
Deflection (New Belt)
1/2" (1.3 cm) Maximum
Deflection (Existing Belt)
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.
Tighten the starter/generator pivot bolt.
Battery Cleaning
To decrease the risk of damage to vehicle or floor, neutralize acid before you spray the battery with water.
To decrease the risk of damage to the electrical components while cleaning, do not use a pressure washer.
Clean the battery according to the Periodic Service Schedule.
When you clean the battery cases and terminals, do not use a water hose without neutralizing any acid deposits first. The
water hose moves the acid from the top of the battery to another area of the vehicle or storage facility, where it can cause
damage. After spraying the battery, a conductive residue remains on the battery and contributes to the discharge of the
battery
38
Owner’s Guide
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Preparing Acid Neutralizing Solution
B
2 teaspoons (10 ml)
1 quart (1 liter)
Sodium Bicabonate
Plastic Spray
Clear Water
(Baking Soda)
Bottle
The correct cleaning method is to spray the top and sides of the battery with a solution of baking soda and water. Apply
this solution with a plastic spray bottle. The solution is 2 teaspoons (10 ml) sodium bicarbonate (baking soda) mixed with
1 quart (1 liter) of water. Spray the solution on all metal components near the battery also.
Allow the solution to set a minimum of three minutes. Use a soft bristle brush or cloth to clean the top of the battery to
remove residue that can cause the discharge of the battery. Clean the area with low pressure clear water.
Be careful when you use the aerosol containers near battery terminals. Use a metal container that
has insulation to prevent an explosion.
Clean one time a month or more often in harsh conditions. After the battery is clean and dry, apply a commercially available protectant to the terminals.
TIRE INSPECTION
Inspect the tire condition according to the Periodic Service Schedule. Tire inflation pressures must be checked when the
tires are cool. Always install the valve dust cap after you check or inflate the tires.
BRAKES
Dry, Level, Clean, Paved Surface
Accelerate to
maximum speed.
Always inspect the pedal travel before you operate a
vehicle to confirm some brake function is found.
Make sure you do all brake tests in a safe location
with regard to the safety of all personnel.
Latch park
brake and take
foot off pedal.
Line or Marker
Line or Marker
A subtle loss of performance can occur over time; 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.
Owner’s Guide
Acceptable
Stopping 4 ft. (1.2 m)
Distance
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.
39
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Periodic Brake Test
This test compares the brake performance of the vehicle to the brake performance of new or ‘known to be good’ vehicles
or to an established acceptable stopping distance. Actual stopping distances are 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. Several vehicles should be tested when new and the range of stopping locations or distances recorded.
Over time, a subtle loss of performance may occur; therefore, it is important to establish the standard with a new vehicle.
Drive the vehicle at maximum speed on a flat, dry, clean, paved surface.
Quickly press the brake pedal to lock the parking brake at the line or marker in the test area and remove foot from pedal.
The vehicle must stop fast. 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
locked. The vehicle must 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 must be tested again.
If the vehicle fails the second test, it must 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.
LUBRICATION
Lubrication Points
Do not use more than three (3) pumps of grease in any grease
fitting at any one time. Excess grease may cause grease seals
to fail or grease migration into areas that could damage components.
Putting more than three pumps of grease in a grease fitting could
damage grease seals and cause premature bearing failure.
Rack Ball Joint
View from Underside of Vehicle
40
Owner’s Guide
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
CAPACITIES AND REPLACEMENT PARTS
B
Fuel (Early Production)
6.0 gal. (22.7 liters)
Fuel (Late Production)
5.6 gal. (21.4 liters)
Rear Axle Oil
12 oz (1.2 liters) 30 WT Engine Oil
Fuse (15 amp)
P/N 18392-G1
Headlight Bulb
P/N 619100
Turn Signal Bulb
P/N 619102
Tail Light Bulb
P/N 21759-G1
HARDWARE
Normally, three classes of standard hardware and three classes of metric hardware are used in the vehicle. Grade 5
hardware is identified by the three marks on the hexagonal head; grade 8 hardware is identified by six marks on the
head; grade 2 hardware is not marked. The class specification is marked on metric hardware.
Inspect the vehicle for loose fasteners periodically. The fasteners must be tightened carefully and according to the
Torque Specifications table or as specified in the Repair and Service Manual.
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)
Torque Specifications and Bolt Grades
Owner’s Guide
41
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
AIR INTAKE AND COOLING FINS
To prevent possible burns, engine parts should be
kept clean to reduce risk of overheating and ignition
of accumulated debris. After every off road use,
allow to cool and then check for a build up of dirt and
debris in the air intake and cooling fins. Dirt and
debris may clog the engine’s air cooling system.
Clean areas shown to prevent engine damage. Keep
linkages, springs and controls clean. Keep area
around muffler free of any combustible material.
At least once a year, (or more often under adverse conditions)
the cooling system should be cleaned. Cleaning will assure an adequate supply of air to the cooling fins. Compressed air
may be used for routine cooling system maintenance.
REAR AXLE
Fill / Check Plug
The rear axle is provided with a lubricant level check plug located
on the driver side at the rear of the housing. Unless leakage of
rear axle lubricant is evident, an annual lubricant check is sufficient.
Checking the Lubricant Level
Tool List
Quantity
Socket, 13 mm ............................................................ 1
Ratchet ........................................................................ 1
Funnel ......................................................................... 1
For vehicles with LSD axle, add 2 ounces of friction modifier
during refill.
Clean the area around the check and fill plugs. Remove the
check plug. The correct lubricant level is just below the bottom of
the threaded hole. If lubricant is to be added, remove the fill plug
and add lubricant using a funnel. Add lubricant slowly until lubricant starts to seep from the check plug hole. Install the check
plug and the fill plug. In the event that the lubricant is to be
replaced, a drain plug is provided at the bottom of the differential
housing.
Drain Plug
AIR CLEANER INSPECTION AND REPLACEMENT
The air cleaner unit on the vehicle is a dry unit. Do not use oil on the filter element or any part of the unit.
42
Owner’s Guide
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Cleaning the Air Filter Element
Air Filter Element
Air Cleaner
Canister
Do not use compressed air to clean the air filter; doing so
will damage the filter which may result in damage to the
engine.
B
Air Cleaner
Cover
Dust Collector
The air cleaner element is accessible by unsnapping the clips
on the air canister and removing the cover and air filter element.
Clean inside of cover, canister and dust collector. Install the element and cover the same way they were removed. Be sure the
positioning arrow on cover is pointing upward and all clips are fastened securely.
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.
LUBRICATION
Lubrication Points
Do not use more than three (3) pumps of grease in any grease
fitting at any one time. Excess grease may cause grease seals
to fail or grease migration into areas that could damage components.
Putting more than three pumps of grease in a grease fitting could
damage grease seals and cause premature bearing failure.
Rack Ball Joint
View from Underside of Vehicle
SPARK PLUGS
Tool List
Quantity
Spark Plug Socket, 13/16" .......................................... 1
Ratchet ........................................................................ 1
Plug Gauge, Wire Type ............................................... 1
Tool List
Quantity
Anti-Seize Compound .............................................. AR
Torque Wrench, ft. lbs. ................................................ 1
Use care not to over-tighten the plug. Over-tightening can cause damage to the aluminum cylinder head
threads.
Remove and inspect the spark plug at intervals indicated in the Periodic Service Schedule. Spark plug should
be properly gapped. Tighten to 16 ft. lbs. (22 Nm) torque
Remove and inspect the spark plug at intervals indicated in the Periodic Service Schedule. Spark plug should be
properly gapped. Tighten to 16 ft. lbs. (22 Nm) torque.
Fouled spark plug is indicated by a wet, black appearance. This could be caused by a dirty air filter element or other
restrictions in the air intake system. Incorrectly adjusted valves, spark plug wire which are in poor condition or poor quality fuel could also contribute to the problem
Owner’s Guide
43
MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
PROLONGED STORAGE
Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or
refuel near open flame or electrical items which could produce a spark.
Store vehicle in a clean, dry area. Do not store in same area as a stove, furnace, water heater, or
other appliance that uses a pilot light or has a device that can create a spark.
When refueling, inspect the fuel cap for leaks or breaks that could result in fuel spillage.
Always wear safety glasses while refueling to prevent possible eye injury from gasoline or gasoline vapor.
Keep hands, clothing and jewelry away from moving parts. Use care not to contact hot objects.
Raise the rear of the vehicle and support on jack stands before attempting to run the engine.
Preparing the engine for a prolonged storage period (30 days or more) calls for a few simple steps to prevent a build up
of varnish and gum in the carburetor and corrosion in the engine.
•
•
•
•
•
•
•
•
•
•
•
•
•
44
Turn the Key Switch to OFF position, and leave the Forward/Reverse switch in the NEUTRAL position during storage.
Perform all required routine maintenance per the Periodic Service Schedule.
Properly inflate the tires to recommended pressure (psi) stated on sidewall of tires.
Place the Forward/Reverse handle in the NEUTRAL position engage the neutral lock, see page 5 - 11.
Turn the fuel shut-off valve to the closed (OFF) position.
Fuel Shut-off
With proper ventilation, run engine until the remaining fuel in
Valve
carburetor and fuel lines is depleted and the engine stalls.
Turn to “OFF”
Return the neutral lock to the OPERATE position
Position
Loosen, but do not remove the carburetor drain screw. Drain
any fuel remaining in bowl into an approved container and
pour the fuel collected into the vehicle fuel tank. Add Sea
Foam (4 oz. for a full tank of fuel) to stabilize fuel and install
the tank cap securely.
Tighten the carburetor drain screw.
Remove spark plug and pour about 1/2 oz. (15 ml) of SAE 10
- 30 weight oil or Fogging oil into the cylinder. Rotate the crankshaft by hand several times, then install the spark
plug.
Do not engage the park brake, but secure the car from rolling
While engine is still warm, change oil.
Clean body, chassis and engine of debris, mud, chaff or grass.
Owner’s Guide
PERIODIC SERVICE SCHEDULE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
PERIODIC SERVICE SCHEDULE
PERIODIC SERVICE SCHEDULE
*
*
*
*
*
*
*
*
*
*
*
*
*
*
C&A
*
*
*
*
*
*
*
*
*
C&A
*
*
*
*
*
*
*
*
*
C&A
*
*
*
*
*
*
*
*
*
C&A
*
*
*
*
*
*
*
*
*
C&A
*
*
C&A
*
*
*
C&A
C&A
*
*
*
*
C&A
*
*
C&A
*
*
*
C&A
C&A
*
*
*
*
*
*
C&A
*
*
*
C&A
*
*
C&A
*
*
*
C&A
C&A
*
*
*
*
*
*
C&A
*
*
*
C&A
*
*
C&A
*
*
*
C&A
C&A
*
*
*
*
*
*
C&A
*
*
*
*
*
*
*
*
*
*
500 hrs
5 YEARS
250 - 300 hrs
ANNUAL
Front Wheel Alignment - Check for unusual tire wear; align if required
*
*
*
*
*
*
*
125 hrs
SEMI-ANNUAL
Tires - Check pressure and inspect condition of tires & rims.
Hardware - Check for loose or missing.
Reverse Warning Indicator
Brake Pedal - Check for smooth operation
Parking Brake - Check for correct hold capability.
Accelerator - Check for smooth operation.
Overall Vehicle Condition
Tires - Examine for cuts, wear and pressure.
Wheels - Check for bent rims, missing or loose lug nuts.
Cooling Fan - Check for build-up of dirt inside blower housing and fins; clean if
necessary
Engine Oil - Check and add if required - DO NOT OVERFILL
Starter/Generator Belt
Parking Brake - Conduct brake performance test; adjust if required.
Controller - Check controller braking force for correct operation.
Wiring - Inspect for loose connections, broken or missing insulation.
Direction Selector - Inspect attachment and mechanism.
Steering Assembly - Check for excess play, loose or missing hardware.
Tie Rods - Check for excess play, bent rods, loose or missing hardware.
Choke Cable - Check for smooth movement
Carburetor Linkage - Check attachment; adjust as required.
Direction Selector - Check attachment; adjust as required.
Engine - Check for unusual noise, vibration, acceleration, oil leaks
Rear Axle - Check for leakage; add SAE 30 oil as required
Throttle/Governor Linkage - Check operation and governed speed
Fuel System - Check for leaks at tank, cap, lines, filters, pump, carburetor
Front Axle - Check for damage to axle, loose or missing hardware.
Parking Brake - Inspect linkage rods, latch arm and catch bracket.
Parking Brake - Lubricate with light oil. Do not lubricate cables or brake latch.
Engine Electrical System - Check coil/spark plug wires for cracks/loose connections
Rear Suspension - Inspect for shock oil leakage, worn bushings, loose or
missing hardware.
Front Suspension - Inspect for strut oil leakage, excessive play in hubs or
kingpins, worn bushings, loose or missing hardware.
50 hrs
QUARTERLY
REMARKS
R - REPLACE
20 hrs
MONTHLY
CL - CLEAN
WEEKLY
C&A - CHECK & ADJUST
Before each use
DAILY
* - CHECK
*NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.
Owner’s Guide
45
PERIODIC SERVICE SCHEDULE
C&A
*
*
*
R
R
C&A
*
*
*
R
R
*
C&A
*
C&A
*
*
*
*
*
*
C&A
500 hrs
5 YEARS
250 - 300 hrs
ANNUAL
50 hrs
QUARTERLY
C&A
125 hrs
SEMI-ANNUAL
Front Wheel Alignment - Inspect for unusual tire wear.
King Pins - Check for excessive play and tightness of retaining nuts.
Rear Axle - Check for unusual noise and loose/missing mounting hardware.
Air Filter Element - Check filter element; clean/replace as required.
Oil Filter - Replace (at oil change)
Engine Oil - Replace with SAE 10W-30 or 10W-40 that meets or exceeds SF,
SG, CC oil. DO NOT OVERFILL
Drive Belt - Check for cracks, fraying and excessive wear
Direction Selector - Check for wear and smooth movement; lubricate shaft
with light oil if required.
Steering Assembly - Inspect bellows and pinion seal for damage and leakage.
Rack End Ball Joint - Check for noise and loose or missing hardware.
Battery - Clean battery and terminals
Front Wheel Bearings - Check and adjust as required. See Repair and Service Manual for procedure.
Rear Axle - Check lubricant level; add lubricant if required.
Brakes - Clean and adjust. See Repair and Service Manual for procedure.
Brakes - Check brake shoe linings. See Repair and Service Manual for procedure.
Fuel Filter - Replace
Spark Plug - Replace and gap new plug.
Muffler/Exhaust - Check mounting hardware. Check for leaks at head and
muffler gaskets.
Valves - Check cold (intake/exhaust). See Repair and Service Manual for procedure.
Carburetor - Clean
Cylinder Head and Piston - Remove carbon from cylinder head and piston.
Cylinder Head and Piston - Check valve seats for carbon buildup; clean if
required.
20 hrs
MONTHLY
REMARKS
WEEKLY
Before each use
DAILY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
*
C&A
*
R
R
*
*
CL
CL
CL
*NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.
46
Owner’s Guide
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
APPENDIX A
DECLARATION OF CONFORMITY
Owner’s Guide
A
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
B
Owner’s Guide
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Owner’s Guide
C
APPENDIX A
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Notes:
D
Owner’s Guide
Read the following warnings before operating vehicle:
When you leave the vehicle, turn the key to
the OFF position and remove the key from
the vehicle.
Drive the vehicle only as fast as terrain and
conditions allow. Consider the terrain and
traffic conditions. Consider environmental
conditions that change the terrain and your
ability to control the vehicle.
Do not drive fast downhill. Sudden stops or
change of direction can cause a loss of control. Use the brake to control the speed of the
vehicle when you drive down a slope.
When possible, stay in approved areas and
do not drive on steep slopes.
Always keep feet, legs, hands and arms
inside vehicle.
Do not drive on rough terrain.
Before you drive in the reverse direction,
make sure the area behind the vehicle is
clear.
Make sure the direction selector is in the correct position before you press the accelerator
pedal.
Decrease speed before and during turns.
Make sure you completely stop the vehicle
before you move the direction selector.
See GENERAL SPECIFICATIONS for the
vehicle load and seat capacity.
Read the following information and warnings before
operating vehicle:
In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.
Normal use, age, wear or abuse can cause some components
on the vehicle to fail. The manufacturer can not know all possible component failures or the methods that failures can occur.
A vehicle in need of repair does not operate correctly and can
be dangerous.
Be careful when you service the vehicle. Be aware of your
safety and the safety of other people in the area.
Some components are heavy, spring loaded, corrosive, explosive, can cause high amperage or get hot. Battery acid and
hydrogen gas can cause injury. Do not put your hands, face,
feet or body in a location that can expose them to injury if an
unexpected situation occurs.
Always use the correct tools shown in the tool list and wear
safety equipment.
Remove all jewelry before you service the
vehicle.
Do not allow loose clothing or hair to contact
the moving parts.
Do not touch hot objects.
The drive wheels must be lifted and supported on jack stands before you do any service to the powertrain when the motor is in
operation.
When you service the vehicle, always wear eye protection. Be careful when
you do work around batteries or you use solvents or
compressed air.
Use wrenches with insulation to decrease the
risk of a short-circuit if a wrench falls across
the battery terminals. A battery short-circuit
can cause an explosion.
To prevent the risk of battery explosion, keep
all flammable materials, open flames or
sparks away from the batteries.
Hydrogen gas is made as batteries are
charged. Do not charge batteries without
good ventilation.
E-Z-GO Division of Textron Inc.
1451 Marvin Griffin Road, Augusta, Georgia 30906-3852 USA
CONTACT US:
North America:
Technical Assistance & Warranty
Service Parts
Phone: 1-800-774-3946, FAX: 1-800-448-8124
Phone: 1-888-GETEZGO (1-888-438-3946), FAX: 1-800-752-6175
International:
Phone: 001-706-798-4311, FAX: 001-706-771-4609
Service Parts Manuals, as well as Repair and Service Manuals
are available from a local Distributor, an authorized Branch,
Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.
Copyrighted Material
This manual may not be reproduced in whole
or in part without the express permission of
E-Z-GO Division of Textron Inc.,
Technical Communications Department