28836-G01
OWNER’S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED UTILITY VEHICLE
ISSUED APRIL 2005
SAFETY
Read and understand all labels located on the vehicle. For any questions on any of the information, contact a representative for clarification.
Always replace any damaged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed
on level ground. (See vehicle specification.) Limit speed by applying the service brake.
Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of
situations that could result in an unsafe condition.
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
BATTERIES
CONTAIN LEAD
AND RELATED PARTS
!
< 14˚ 25%
DO NOT
DRIVE ACROSS
SLOPES IN
EXCESS OF 14˚
WASH HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
Be sure that this manual remains as part of the permanent service record should the vehicle be re-sold.
NOTES, CAUTIONS AND WARNINGS
Throughout this guide NOTE, CAUTION and WARNING
will be used.
A NOTE indicates a condition that should be
observed.
A CAUTION indicates a condition that
may result in damage to the vehicle.
!
!
A WARNING indicates a
hazardous condition that
could result in severe
injury or death.
Please observe these NOTES, CAUTIONS and WARNINGS; be aware that servicing a vehicle requires
mechanical skill and a regard for conditions that could be
hazardous. Improper service or repair may damage the
vehicle or render it unsafe.
Engine exhaust from this
product contains chemicals known, in certain
quantities, to cause cancer, birth defects, or other reproductive harm.
!
!
The exhaust emissions of this vehicles’ engine
is regulated by the Federal EPA. 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.
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleur
du Canada.
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
OWNER’S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED
UTILITY VEHICLE
JACOBSEN 4800
Starting Model Year 2004
Jacobsen Turf, Commercial and Specialty Equipment reserves the right to make design changes without obligation to make these changes on units previously
sold and the information contained in this manual is subject to change without notice.
Jacobsen Turf, Commercial and Specialty Equipment is not liable for errors in this manual or for incidental or consequential damages that result from the use of
the material in this manual.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175
INTERNATIONAL:
PHONE: 010-1-706-798-4311, FAX: 010-1-706-771-4609
JACOBSEN TURF, COMMERCIAL AND SPECIALTY EQUIPMENT
1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852
Owner’s Manual and Service Guide
Page i
NOTES
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local
distributor, authorized Branch or the Warranty Department with vehicle serial number and
manufacturer’s code.
The use of non Original Equipment Manufacturer (OEM) parts 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 Sates of America Federal and State
emission certification applicable at the time of manufacture.
BATTERY PROLONGED STORAGE
Page ii
Owner’s Manual and Service Guide
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75° F (-60° C).
Owner’s Manual and Service Guide
Page iii
NOTES
Page iv
Owner’s Manual and Service Guide
TABLE OF CONTENTS
SAFETY ................................................................................................................. Inside Covers
NOTES .........................................................................................................................................ii
SAFETY INFORMATION ...........................................................................................................vii
OPERATION AND SERVICE INFORMATION ........................................................................... 1
BEFORE INITIAL USE ............................................................................................................... 1
Fig. 2 Initial Service Chart .........................................................................................................2
TERRAIN .................................................................................................................................... 1
VEHICLE CAPACITY ................................................................................................................. 1
Fig. 1 Safety and Operation Label ............................................................................................2
MODIFICATIONS TO VEHICLE ................................................................................................ 2
LOAD BED ................................................................................................................................. 2
Fig. 3 Load Bed Warning Label ................................................................................................3
TOP AND WINDSHIELD (IF EQUIPPED) .................................................................................. 3
COMMON SENSE OPERATION ............................................................................................... 4
ENVIRONMENTAL CONCERNS ............................................................................................... 4
OPTIONAL WINCH .................................................................................................................... 4
Operation of the Winch ........................................................................................................................................4
Fig. 4 Winch Mounted to Vehicle ..............................................................................................4
Fig. 6 Winch Clutch Knob .........................................................................................................5
Winch Applications ..............................................................................................................................................5
Fig. 5 Winch Remote Control ....................................................................................................5
Fig. 7 Never Operate Winch with Less Than Five Turns Around Drum ....................................6
Fig. 8 Do Not Hook Cable to Itself ............................................................................................6
Fig. 9 Use a Nylon Sling and Install a Damper when Winching ................................................6
Fig. 10 Do Not Pull at Angle .....................................................................................................7
TOWING A TRAILER ................................................................................................................. 7
POWER CONSUMPTION .......................................................................................................... 7
SERIAL NUMBER PLATE LOCATION ...................................................................................... 8
Fig. 11 Serial Number Plate Location .......................................................................................8
PREPARATION OF SEATS FOR SERVICE ............................................................................. 8
CONTROLS AND INDICATORS ................................................................................................ 8
Key/Light Switch ..................................................................................................................................................8
Fig. 12 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge ..........................................8
Low Oil Pressure Light .........................................................................................................................................8
Fuel Gauge ..........................................................................................................................................................8
Direction Selector ................................................................................................................................................8
Fig. 13 Console Controls ..........................................................................................................9
Parking Brake ......................................................................................................................................................9
Differential Lock ...................................................................................................................................................9
Choke ..................................................................................................................................................................9
Accelerator Pedal ................................................................................................................................................9
Fig. 14 Accelerator, Brake and Horn ........................................................................................9
Service Brake Pedal ............................................................................................................................................9
Horn .....................................................................................................................................................................9
12 Volt Power Outlet ............................................................................................................................................9
Fig. 15 12V Power Outlet ........................................................................................................10
Electric Lift .........................................................................................................................................................10
Fig. 16 Electric Lift Toggle Switch ...........................................................................................10
BEFORE ENTERING VEHICLE ............................................................................................... 10
Break-In .............................................................................................................................................................10
Fig. 17 Check Oil Level on Dipstick ........................................................................................10
Owner’s Manual and Service Guide
Page iii
TABLE OF CONTENTS
OPERATING THE VEHICLE ....................................................................................................10
Cold Starting ...................................................................................................................................................... 12
Starting the Vehicle on a Hill ............................................................................................................................. 12
Starting the Vehicle with a Discharged Battery .................................................................................................. 12
COASTING ...............................................................................................................................12
FUEL .........................................................................................................................................12
Fig. 18 Fuel Tank Location .....................................................................................................13
TOWING ...................................................................................................................................13
SERVICING THE VEHICLE ......................................................................................................13
Neutral Lock ...................................................................................................................................................... 14
Fig. 19 Neutral Lock ................................................................................................................ 14
Lifting the Vehicle .............................................................................................................................................. 14
Fig. 20 Lifting the Vehicle ....................................................................................................... 15
Routine Maintenance ......................................................................................................................................... 15
POWERTRAIN MAINTENANCE ..............................................................................................15
Fig. 21 Lubrication Points ....................................................................................................... 15
Removing Debris ............................................................................................................................................... 16
Fig. 22 Cleaning Cooling Fins and Air Intake ......................................................................... 16
Replacing the Fuel Filter .................................................................................................................................... 16
Oil Capacity ....................................................................................................................................................... 16
Oil Recommendations ....................................................................................................................................... 16
Fig. 23 Oil Viscosity Chart ...................................................................................................... 16
Checking the Oil Level ....................................................................................................................................... 16
Fig. 24 Oil Fill Cap, Dipstick and Fuel Filter ............................................................................ 17
Fig. 25 Clean Entire Dipstick .................................................................................................. 17
Fig. 26 Check Oil Level on Dipstick ........................................................................................ 17
Changing the Oil ................................................................................................................................................ 17
Changing the Oil Filter ....................................................................................................................................... 18
AIR CLEANER MAINTENANCE ...............................................................................................18
Fig. 27 Oil Drain and Filter ...................................................................................................... 18
Fig. 28 Air Cleaner .................................................................................................................. 18
Pre-Cleaner Service .......................................................................................................................................... 18
Cartridge Service ............................................................................................................................................... 18
REAR AXLE ..............................................................................................................................19
Checking the Lubricant Level ............................................................................................................................ 19
Fig. 29 Add, Check and Drain Rear Axle Lubricant ................................................................ 19
STARTER/GENERATOR BELT TENSION ..............................................................................19
Fig. 30 Check Belt Tension with Gauge ................................................................................. 19
Fig. 31 Check Belt Tension with Finger .................................................................................. 19
Adjusting the Belt ............................................................................................................................................... 19
Fig. 32 Adjust Belt Tension .....................................................................................................20
SPARK PLUGS .........................................................................................................................20
Fig. 33 Gap Spark Plugs ......................................................................................................... 20
BRAKES ...................................................................................................................................20
DAILY BRAKE TEST ................................................................................................................20
TIRES .......................................................................................................................................21
Wheel and Tire Service ..................................................................................................................................... 21
Fig. 34 Wheel Installation ....................................................................................................... 22
LIGHT BULB AND FUSE REPLACEMENT ..............................................................................22
Fig. 35 Headlight Replacement .............................................................................................. 22
PROLONGED STORAGE ........................................................................................................22
CARE AND CLEANING OF THE VEHICLE .............................................................................23
TRANSPORTING VEHICLE .....................................................................................................23
HARDWARE .............................................................................................................................24
Page iv
Owner’s Manual and Service Guide
TABLE OF CONTENTS
Fig. 36 Bolt Grades .................................................................................................................24
TORQUE SPECIFICATIONS ................................................................................................... 24
Fig. 37 Torque Specifications .................................................................................................24
PERIODIC SERVICE SCHEDULE ........................................................................................... 25
Fig. 38 Periodic Service Schedule ..........................................................................................25
GENERAL SPECIFICATIONS.................................................................................................. 29
Fig. 39 Vehicle Dimensions and Incline Specifications..........................................................................31
Fig. 40 Vehicle Turning Clearance Diameter.........................................................................................32
LIMITED WARRANTY .............................................................................................................. 33
Owner’s Manual and Service Guide
Page v
TABLE OF CONTENTS
Page vi
Owner’s Manual and Service Guide
SAFETY INFORMATION
This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures
developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible
service from the product. To reduce the chance of personal injury and/or property damage, the following instructions
must be carefully observed:
Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-ZGO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z-GO-manufactured
vehicle is modified an any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER
FERERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of
Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer
MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for
LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the
requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applicable in the
places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final
Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.
E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.
The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE OPERATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE
REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-ZGO, I am directing that E-Z-GO Branch personnel, Distributors and Dealers advise all customers to adhere to this
SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has reason to believe may be operated in personal transportation applications.
Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or
through the Internet at the website for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
GENERAL
Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the
place of good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. The manufacturer strongly suggests that the owner-operator read this entire manual paying
particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employees
and other operators be encouraged to do the same.
If you have any questions, contact your closest representative or write to the address on the back cover of this publication, Attention: Product Service Department.
E-Z-GO Division of Textron Inc., reserves the right to make design changes without obligation to make these changes
on units previously sold and the information contained in this manual is subject to change without notice.
E-Z-GO Division of Textron Inc., is not liable for errors in this manual or for incidental or consequential damages that
Owner’s Manual and Service Guide
Page vii
SAFETY INFORMATION
result from the use of the material in this manual.
This vehicle conforms to the current applicable standard for safety and performance requirements.
These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety
Standards and are not equipped for operation on public streets. Some communities may permit these vehicles to be
operated on their streets on a limited basis and in accordance with local ordinances.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may
reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and
disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the
vehicle.
Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when
used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions,
terrain and common sense.
GENERAL OPERATION
Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
Always read and observe all warnings and operation instruction labels affixed to the vehicle.
Always follow all safety rules established in the area where the vehicle is being operated.
Always reduce speed to compensate for poor terrain or conditions.
Always apply service brake to control speed on steep grades.
Always maintain adequate distance between vehicles.
Always reduce speed in wet areas.
Always use extreme caution when approaching sharp or blind turns.
Always use extreme caution when driving over loose terrain.
Always use extreme caution in areas where pedestrians are present.
MAINTENANCE
Always maintain your vehicle in accordance with the manufacturer’s periodic service schedule.
Always ensure that mechanics performing repairs are trained and qualified to do so.
Always follow the manufacturer’s directions if you do any maintenance on your vehicle. Be sure to disable the vehicle
before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery
wire.
Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material.
Page viii
Owner’s Manual and Service Guide
SAFETY INFORMATION
Always use specified replacement parts. Never use replacement parts of lesser quality.
Always use recommended tools.
Always determine that tools and procedures not specifically recommended by the manufacturer will not compromise
the safety of personnel nor jeopardize the safe operation of the vehicle.
Always support the vehicle using wheel chocks and jack stands. Never get under a vehicle that is supported by a jack.
Lift the vehicle in accordance with the manufacturer’s instructions.
Always empty the fuel tank or plug fuel hoses to prevent fuel leakage.
Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.
Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the skill and experience to recognize and protect themselves from potential situations that could result in severe
personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury,
refer the repair or maintenance to a qualified mechanic.
Always test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of
both vehicular and pedestrian traffic.
Always replace damaged or missing warning, caution or information labels.
Always keep complete records of the maintenance history of the vehicle.
VENTILATION
Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating.
Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane gas
water heaters and furnaces.
Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Carbon
monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.
Owner’s Manual and Service Guide
Page ix
SAFETY INFORMATION
Notes:
Page x
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
\
Thank you for purchasing a Jacobsen 4800 Light Duty
Utility Vehicle. This vehicle is equipped with a 480 cc twin
cylinder, overhead valve, 4 cycle, air-cooled engine.
Before driving the vehicle, we ask you to spend some
time reading this Owner’s Manual and Service Guide and
the Operating and Maintenance Instructions manual provided by the engine manufacturer. These manuals contain the information that will assist you in the safe
operation of the vehicle. They will also assist you in
maintaining this highly reliable vehicle. Some illustrations
show items that may be optional for your vehicle.
Most of the service procedures in this guide can be
accomplished by an individual using common automotive
hand tools. If you prefer to have service procedures performed on your vehicle, contact the Service Manager.
To facilitate maintenance, a Service Parts Manual, a
Technician’s Repair and Service Manual and an engine
Repair Manual is available from a local distributor, an
authorized Branch or the Service Parts Department.
When ordering parts or requesting information for your
vehicle, provide vehicle model, serial number and manufacture date code.
BEFORE INITIAL USE
Plan carefully before using the vehicle to go significant distances over questionable terrain. Remember
that a one hour drive may take many hours to walk
out should you run out of fuel or be stranded by
becoming stuck on unsuitable terrain.
Hydrogen gas is generated as a natural part of the
lead acid battery charging process. A 4% concentration of hydrogen gas is explosive and could cause
severe injury or death. Charging must take place in an
area that is adequately ventilated (minimum of 5 air
exchanges per hour).
To reduce the chance of battery explosion that could
result in severe injury or death, never smoke around
or charge batteries in an area that has open flame or
electrical equipment that could cause an electrical
arc.
Read, understand and follow the SAFETY AND OPERATION label located on the center of the instrument panel
above the drink holders (Ref Fig. 1 on page 2).
Be sure you understand the vehicle, its equipment and
how to use it safely. Although the vehicle has been
designed to provide safe and reliable operation, maintaining good performance depends, to a large extent, on
the operator.
Before a new vehicle is put into operation, it is recommended that the items shown in the INITIAL SERVICE
CHART be performed (Ref Fig. 2 on page 2).
TERRAIN
The vehicle is designed for use on improved roads (but
not on public highways). The vehicle may also be used
on established trails or open terrain that is free from
stumps, large rocks or holes.
The vehicle should not be used to cross water.
Record the four digit key number and store in a
safe place. Individual keys can only be
replaced if the key number is known. Without a
key number, the entire ignition switch will have to be replaced if
keys are lost.
Improper use of this
!
! vehicle could result in
severe injury or death.
The vehicle is a light
duty utility vehicle. It is NOT an all terrain vehicle
(ATV).
This vehicle is not a toy and using it while engaging in
horseplay is dangerous.
VEHICLE CAPACITY
Due to the variety of
!
! ways the vehicle may be
used, it is important that
the operator consider
any potential hazards before use to prevent serious
injury or death.
The vehicle may be used to transport a maximum of
two people within the operator/passenger compartment and cargo in the load bed. Never carry passengers in the load bed. The total payload is 800 lbs. (363
kg).
Owner’s Manual and Service Guide
Page 1
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
!
!
P
R
F
!
WARNING
Read Owner's
Manual before
operating
vehicle
< 14˚ 25%
< 14˚ 25%
WARNING
Use caution
when operating
in poor weather
WARNING
Do not drink
or use drugs
when operating
vehicle
WARNING
Do not drive
across slopes
in excess of 14˚
WARNING
Do not drive up slopes
in excess of 14˚
F
WARNING
Operate vehicle
from drivers
seat only
WARNING
Keep seated and
keep arms and
legs inside
vehicle
Ref Csl 2
To go forward,
turn key ON,
put Direction
Selector in
FORWARD and
push accelerator
pedal
To go in reverse,
turn key ON,
put Direction
Selector in
REVERSE and
push accelerator
pedal
To park, set
parking brake,
turn key OFF,
put Direction
Selector in
FORWARD
35962-G01
WARNING
Vehicle is not
intended for
use on
highways
Fig. 1 Safety and Operation Label
ITEM
SERVICE OPERATION
Battery
Charge battery
Seats
Remove protective plastic covering
Brakes
Check operation and adjust if necessary
Check hydraulic brake fluid level
Establish new vehicle braking distance
Tires
Check pressure
Fuel
Fill tank with correct fuel
Engine
Check oil level (Initial change after 5 - 8 hours)
Keys
Record key number and store in safe location
Ref Isc 3
fertilizer, sod, etc. can be handled with complete safety.
The same load when wet will grossly overload the vehicle and increase the potential for roll over and damage to
the vehicle.
MODIFICATIONS TO VEHICLE
Changes to the weight
distribution or the center
of gravity may make it
unstable or prone to roll
over which could result in injury or death to the operator or passenger.
!
!
Do not modify the vehicle in any manner that will change
the weight distribution of the vehicle. Changes to the
weight distribution or the center of gravity may make it
unstable or prone to roll over which could result in injury
or death to the operator or passenger.
Fig. 2 Initial Service Chart
The weight of the driver and passenger plus any options
or accessories must be deducted from the total payload
rating to determine the load bed capacity. Remember
that towing a trailer will reduce the payload of the vehicle
itself.
LOAD BED
Remember that volume of your load can be misleading.
Loading the vehicle to its rated capacity with dry sand,
This label must be understood and observed at all times
for safe operation of the vehicle. The bed is limited to a
Page 2
Be careful when loading the vehicle. Secure loads to prevent shifting. Do not overload vehicle. A load bed warning label is affixed to the inside of the bed on the front
panel (Ref Fig. 3 on page 3).
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Fig. 3 Load Bed Warning Label
maximum load of 500 lbs (228 kg). The load must be
positioned in the bed as far forward as possible, its center of gravity must not be higher than 5" (12 cm) above
the bed floor, and securely fastened down. Failure to follow these instructions could cause personal injury, damage to the vehicle and/or cause the vehicle to tip over.
Operate the vehicle with awareness of the load.
Do not drive the vehicle with the load bed raised or with
the tailgate unsupported.
When using the electric lift, be sure to avoid backing up
to the edge of a drop off, such as a loading dock or
ravine. A misjudgment of distance or an unstable surface
could result in the vehicle falling backwards.
Always insure that no one is behind or close to the load
bed while the electric lift mechanism is being operated.
Passengers should nev!
! er be allowed to ride in
the load bed. Severe
injury or death could
result if they should fall out or the vehicle is involved
in an accident or sudden maneuver.
TOP AND WINDSHIELD (IF EQUIPPED)
The top does not pro!
! vide protection from roll
over or falling objects.
The windshield does not provide protection from tree
limbs or flying objects.
The top and windshield provide some protection from the
elements; however, they will not keep the operator and
passenger dry in a downpour. This vehicle is not
equipped with seat belts and has not been designed to
provide roll over protection.
Clean windshield with lots of water and a clean cloth.
Minor scratches may be removed using a commercial
plastic polish or Plexus plastic cleaner available from the
service parts department.
COMMON SENSE OPERATION
This vehicle is not a toy. If not operated properly and
responsibly, it can cause severe injury or death to the
operator, passenger or bystanders. All operators should
possess a valid driver’s license. Children should not be
Owner’s Manual and Service Guide
Page 3
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
permitted to operate the vehicle. Children may not have
the skill, judgement or strength to operate this or similar
vehicles.
Alcohol, drugs and many over the counter medications
reduce the ability of the driver to operate the vehicle
safely. Always review side effects of any medication with
a doctor or pharmacist before operating the vehicle.
Protective clothing and an approved motorcycle helmet are
recommended for operator and passengers when operating
vehicle in rough or densely wooded terrain.
When driving at full speed on a dirt road, loose surfaces
or wet grass, vehicle stopping distance will increase. If
the vehicle is fully loaded, it will take longer to stop than
with no load. When operating vehicle in wet weather conditions, remember that the brakes may need to be lightly
applied in order to provide enough friction to dry the
brake unit. If wet, the brakes will lose much of their effect.
Slow down when in unfamiliar terrain. Slow down when
cresting a hill in an area that you are unfamiliar with.
Some hills are too steep to climb. If you attempt to climb
a hill that is too steep or if you are unable to achieve adequate traction, do not attempt to turn around on the
hill. Slowly back straight down the hill using the service brake to control speed.
OPTIONAL WINCH
This vehicle may be equipped with an optional winch.
Read, understand and follow all of the following information on the operation and use of the winch before
attempting to operate it.
Operation of the Winch
The winch can be mounted at the front or rear of the
vehicle and moved to accommodate different situations.
At the front, it is mounted under the center of the front
cowl to a bracket attached to the front axle as shown (Ref
Fig. 4 on page 4). At the rear, the winch is mounted
upside down in the hitch receiver.
If mounting winch at rear of vehicle, the winch
must be mounted upside down.
Winch shown mounted at front of vehicle
Front Axle
Spring Pin
ENVIRONMENTAL CONCERNS
Clevis Pin
As a responsible user, practice respect for all wildlife and
their habitat. Respect private property and comply with
all local laws and regulations governing the use of light
duty utility vehicles. Do not tamper with the exhaust system or governor. The exhaust system has been tuned to
the engine for maximum performance. Removal or modification of the exhaust is annoying to other people and
will not improve the performance of the vehicle.
To prevent severe injury
or death while driving,
be aware of the following:
Environmental hazards such as steep slopes, overhanging limbs, etc.
Danger of fire when vehicle is operated over dry combustible organic material.
!
!
When driving, be aware of environmental hazards such
as steep slopes, overhanging limbs, etc. Be aware of the
danger of fire when the vehicle is operated over dry combustible organic material.
Ref Wmt 1
Fig. 4 Winch Mounted to Vehicle
Before moving the winch, unplug the winch connector
from the wire harness. To move the winch from one end
of the vehicle to the other, remove the spring pin, pull out
the clevis pin and remove the winch mount tube from the
receiver. Move to opposite end of vehicle and install by
inserting clevis pin and securing with spring pin. Plug the
winch connector into wire harness.
The winch remote control plugs into the receptacle on the
driver side of the seat support (Ref Fig. 5 on page 4).
Remote Control
Receptacle
Ref Wrc 1
Fig. 5 Winch Remote Control
Page 4
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
To unwind the cable, locate the clutch knob on the winch.
Pull out knob and rotate 90° to lock out. Using handsaver
bar, pull cable from winch drum. Leave at least five turns
of cable on drum. Re-engage drum by turning clutch
knob 90°, returning it to original position (Ref Fig. 6 on
page 5).
To wind cable, use handsaver bar to keep tension on the
cable while activating remote. When winding cable,
make sure the cable winds tightly and evenly onto the
drum leaving no gaps that could cause premature wear
to the cable. When using winch under a load, operate the
remote control from as far to the side of the vehicle as
possible. Do not operate winch while sitting in passenger
seat. Read the following section (Winch Applications)
before attempting to operate winch.
ENGAGED
LOCKED OUT
Pull out
Clutch Knob
Turn 90˚
Ref Wcn 1
Fig. 6 Winch Clutch Knob
Winch Applications
The optional winch may be used for a number of purposes, including pulling the vehicle if it loses traction on
unsuitable terrain.
Improper use of the
!
! winch could result in a
number of conditions
that could cause severe
injury or death to operator, occupants of vehicle or
bystander.
It is impossible to predict all conditions that the winch
could be used, therefore the following warnings should
not be considered as complete. Before operating the
winch, consider the possible dangers and take precautions to protect yourself, your passenger and any
bystanders.
To prevent severe injury
or death to operator,
occupants or bystanders, select the object to
which the cable is attached with the following considerations:
!
!
Make sure the object cannot be pulled over or otherwise damaged.
The object the winch cable is attached to could fall on
the vehicle and it’s occupants.
If attaching the winch to a dead tree, a section could
fall.
When pulling vehicle with winch, pull straight only. Do
not permit the cable to contact the side of the drum.
Do not pull vehicle at
!
! angle. If the vehicle is
pulled at an angle, it
could turn over causing
severe injury or death to anyone in the area. The
winch cable could also become overstressed and
break causing severe injury or death to anyone struck
by the cable.
The rear drive axle is equipped with a manually operated
locking differential. With the differential unlocked, if one
drive wheel looses traction, all available power is transferred to that wheel until it regains traction. In normal
driving this is not a problem. However, if the vehicle
becomes ‘hung up’ on an object, the vehicle will stop.
With the differential locked, power is distributed to both
drive wheels at all times. If both drive wheels lose traction as a result of the vehicle becoming ‘hung up’ on an
object, the vehicle will stop. If the vehicle cannot be
pushed off the obstruction, it will have to be pulled off
using the winch.
Depending on the location of the obstruction, the vehicle
may need to be pulled either forward or backward.
The winch may be installed in either the front or rear
receiver and held in place with the locking pin provided.
!
!
To prevent severe
injury or death, read
and understand the
following before
attempting to use the winch:
The winch is not intended to be used in any hoisting operation.
The rolling load capacity of the winch decreases
with the steepness of the slope.
The winch is designed for intermittent duty only.
The electric motor should not be allowed to
become excessively hot. If the motor becomes
uncomfortably hot to the touch, stop winching
and allow the motor to cool.
Owner’s Manual and Service Guide
Page 5
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Always wear thick leather gloves when handling
the wire cable.
Replace frayed wire cable with a direct factory
replacement only.
Never operate the winch with less than five (5) full
turns of cable around the drum (Ref Fig. 7 on
page 6).
Ref Wca 2
Fig. 8 Do Not Hook Cable to Itself
Ref Wdt 1
Fig. 7 Never Operate Winch with Less Than
Five Turns Around Drum
If the winch motor stalls from overloading, do not
continue to activate the winch remote control. The
wire cable may become overstressed.
Do not attempt to pull loads exceeding 1500 lbs.
(680 kg).
To pull out the cable, the free spool clutch knob
must be used. Pull out and rotate the knob. If the
cable is under any load the clutch may not release
easily. Jog out some of the cable to release the
tension and operate clutch. Pull out the desired
amount of cable and secure. Engage the drum by
rotating the knob until it snaps in place. Never
operate the winch unless the clutch is engaged.
Have all persons and pets leave the area while
operating winch. Never allow anyone to remain in
the vehicle.
To prevent damage to the wire cable, never hook
the cable to itself. Always use a nylon sling (Ref
Fig. 8 on page 6) (Ref Fig. 9 on page 6).
Stay clear of the winch, the cable and the cable
hook. Place a heavy cloth, jacket or blanket over
the cable to act as a damper should the cable
break when operating the winch (Ref Fig. 9 on
page 6).
Page 6
Damper
Nylon
Sling
Ref Wcd 2
Fig. 9 Use a Nylon Sling and Install a Damper when
Winching
Remember that the winch operation will drain the
battery and may leave insufficient power to start
the vehicle.
When operating the winch, keep the entire area in
view.
Never release the free spool clutch while the
cable is under load.
Never work around the winch drum or the winch
cable while it is under tension.
Unplug the winch switch before working on the
winch drum in order to prevent inadvertent operation.
When operating winch, take up slack slowly. Stop
winch before cable becomes tight and inspect all
winching connections. Check winch attachment,
hook attachment, nylon sling (if required) and
load attachment.
Do not pull at an angle. This will cause the wire
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
cable to pile up on one end of the winch. This may
jam the winch causing damage to the cable and/or
the winch. Pulling the vehicle at an angle can
cause damage to the front suspension and may
cause the vehicle to overturn. When pulling vehicle, pull straight only (Ref Fig. 10 on page 7).
Correct
performance characteristics of the vehicle and result in
unsafe handling, possible roll over or vehicle damage.
POWER CONSUMPTION
The vehicle uses a combination starter/generator to both
start the engine and charge the battery. The engine will
not idle; therefore, the battery cannot be charged while
the vehicle is stopped. Do not operate accessory items
(such as accessory lights, radios, winch etc.) excessively
while the vehicle is stopped.
Overuse of accessories may drain the
battery and leave insufficient reserve
to start the vehicle.
The generator is only capable of supplying 35 amps,
therefore, operation of all accessories could result in the
discharge of the battery even though the engine is running and the generator operating. Discharging the battery is known as deep cycling. The battery is not a deep
cycle model, but is a starting battery. Multiple deep
cycling of the battery will result in the premature failure of
the battery.
Incorrect
Ref Wps 2
Vehicle battery must be fully charged before initial use.
Fig. 10 Do Not Pull at Angle
If the vehicle is being used as an anchor to winch
a load, it should have the parking brake set and
chocks installed on all wheels.
Never use the winch to lift people or other overhead loads.
Do not use the winch to secure loads. Use a tie
down designed for the job.
Do not apply shock loads to the winch.
Do not attempt to modify or weld the winch.
TOWING A TRAILER
Hydrogen gas is gener!
! ated as a natural part of
the lead acid battery
charging process. A 4%
concentration of hydrogen gas is explosive and could
cause severe injury or death. Charging must take
place in an area that is adequately ventilated (minimum of 5 air exchanges per hour).
To reduce the chance of battery explosion that could
result in severe injury or death, never smoke around
or charge batteries in an area that has open flame or
electrical equipment that could cause an electrical
arc.
The vehicle is equipped with a receiver that can be fitted
with a standard 1 7/8" or 2" ball. The trailer and its load
must not exceed 500 lbs (227 kg) and no more than 50
lbs (23 kg) tongue weight may be attached to the hitch.
Remember that the overall capacity of the vehicle, operator, passenger, contents of load bed and accessories
must be reduced to compensate for the trailer and load.
The range of motion of the trailer is limited by the ball and
hitch. The trailer should not be used on rough trails or
over objects such as logs, large rocks, holes, etc.
Never install non-approved baskets or extensions using
the hitch receivers (front or rear). Such items will change
Owner’s Manual and Service Guide
Page 7
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
SERIAL NUMBER PLATE LOCATION
Two serial number and manufacture date code plates are
on the vehicle. One is placed on the body below the
front, driver side of the seat. The other is located on the
chassis between the seat back supports. (Ref Fig. 11 on
page 8). Design changes take place on an ongoing
basis. In order to obtain correct components for the vehicle, the manufacture date code, serial number and vehicle model must be provided when ordering service parts.
turning the key. The lights will illuminate only when the
key is moved to the light icon (Ref Fig. 12 on page 8).
When the vehicle is left unattended, the key should be
removed to prevent inadvertent operation of the vehicle.
If the vehicle is equipped with custom accessories, some accessories may remain operational
with the key switch in the ‘OFF’ position.
OFF ON
Serial Number
Labels
F
E
FUEL
Ref Kes 3
Fig. 12 Key/Light Switch, Low Oil Pressure Light and
Fuel Gauge
Fig. 11 Serial Number Plate Location
PREPARATION OF SEATS FOR SERVICE
Remove the protective plastic coverings from the seats
before placing the vehicle in service. The only function of
the plastic covering is to protect the seat bottom and
back rest during shipping. If the plastic covering is left on
the seat and becomes torn, dirt may get under the plastic
covering and be ground into the cover material. Water
getting under the plastic covering can become trapped
and eventually will damage the seat assembly.
CONTROLS AND INDICATORS
Vehicle controls and indicators consist of:
• key/light switch
• low oil pressure light
• fuel gauge
• direction selector
• parking brake
• differential lock
• choke
• accelerator pedal
• service brake pedal
• horn
• electric lift switch for operation of the dump bed
• 12 volt power outlet
Key/Light Switch
Low Oil Pressure Light
A low oil pressure light is located to the right side of the
key/light switch (Ref Fig. 12 on page 8). If oil pressure
drops below 1 - 4 psi (.1 - .2 kg/cm2), the oil pressure
switch will activate the light. Check oil level (Refer to
page 16). If oil level is between ADD and FULL mark on
dipstick, a mechanical problem exists within the engine
and the vehicle must not be driven. Contact a local distributor or authorized Branch.
To prevent engine damage, do not
operate engine until oil pressure is
corrected.
If oil level is below ADD mark on dipstick, add oil to bring
level to FULL mark (Refer to page 16). Drive vehicle a
short distance and check oil pressure. If oil pressure light
does not come on, continue to use vehicle.
Fuel Gauge
An electric fuel gauge is located to the right side of the
key/light switch. It indicates the amount of fuel in the tank
(Ref Fig. 12 on page 8).
Direction Selector
Located on the console between the seats, this lever permits the selection of either forward or reverse (Ref Fig.
13 on page 9). Neutral is the straight up position between
forward and reverse. The vehicle should be left in forward when unattended.
Located on the dash panel, this switch enables the basic
electrical system of the vehicle to be turned on and off by
Page 8
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
To prevent component damage, the
vehicle must be completely stopped
before moving the direction selector.
Parking
Brake
Choke
Direction
Selector
Differential
Locked
Differential
Lock Lever
(Stop Vehicle
Before Moving
Lever)
Differential
Unlocked
To disengage the differential lock, stop the vehicle and
push the differential lock lever backward towards the
green ‘unlocked’ symbol. After unlocking, the differential
may remain locked if driving is resumed in a straight line.
This is a normal occurrence caused by pressure remaining against the gears and not allowing the locking mechanism to release. To avoid this, simply turn the vehicle as
acceleration begins or accelerate in reverse.
Choke
Located on the console between the front seats (Ref Fig.
13 on page 9), the choke is used to aid cold starting. See
‘Cold Starting’ (Refer to page 12) for instructions on using
the choke properly.
Accelerator Pedal
Depressing the accelerator pedal starts the engine.
When the pedal is released, the engine will stop (Ref Fig.
14 on page 9).
75694G01
Ref Coc 1
To engage the differential lock, stop vehicle and push the
lock lever forward towards the red ‘locked’ symbol (Ref
Fig. 13 on page 9).
Fig. 13 Console Controls
Parking Brake
Horn
H
The hand operated parking brake is located on the console between the front seats (Ref Fig. 13 on page 9). The
brake is engaged when the handle is raised and disengaged when the handle is parallel to the seat bottom.
When leaving the vehicle unattended, engage the parking brake by raising the handle until it locks in place. To
release the parking brake, depress the release button in
the end of the handle while slightly raising the handle,
then lower the parking brake handle.
Service
Brake
ORN
Accelerator
Ref Abh 2
Fig. 14 Accelerator, Brake and Horn
Differential Lock
The rear drive axle is equipped with a manually operated
locking differential. With the differential unlocked, if one
drive wheel looses traction, all available power is transferred to that wheel until it regains traction. With the differential locked, power is distributed to both drive wheels
at all times.
The differential lock should only be used when
additional traction is required. Continued use of
the differential lock may cause excessive wear
to the rear tires.
Service Brake Pedal
Depressing the foot operated service brake pedal activates the wheel brakes, slowing or stopping the vehicle
(Ref Fig. 14 on page 9).
Horn
The horn is an electric powered unit that is activated by a
push button located on the upper floorboard to the left of
the brake pedal (Ref Fig. 14 on page 9).
12 Volt Power Outlet
The vehicle must be completely
stopped before engaging or disengaging the differential lock. Failure to
stop will damage the differential.
Owner’s Manual and Service Guide
Overuse of accessories may drain the
battery and leave insufficient reserve
to start the vehicle.
Page 9
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
A 12 volt power outlet is located to the left side of the key/
light switch (Ref Fig. 15 on page 10). It provides constant
power for accessories equipped with a 12 volt plug.
OFF ON
F
E
FUEL
Ref Pow1
12V Power
Outlet
Break-In
Check for any oil or fuel leaks that could have developed
in shipment from the factory. As in normal driving, avoid
full throttle starts and rapid acceleration until the engine
has achieved operating temperature.
All engines consume more oil than normal during the first
hours of operation. As internal moving parts are run in, oil
consumption should gradually decrease until the rate of
consumption stabilizes. All engines use some oil even
when in perfect condition and properly broken in. During
the initial period, check the oil level at least every two (2)
operational hours (Refer to page 16). Add oil if the level
on dipstick indicates that oil is below safe operating
range (Ref Fig. 17 on page 10).
Fig. 15 12V Power Outlet
Maximum oil level
DO NOT OVERFILL
Electric Lift
Exercise caution while
!
! operating the electric lift
bed to insure clothing is
not snagged during lifting or lowering. Severe injury could result if body
parts are caught on or under bed while moving.
Do not back up to a drop off, such as a loading dock
or ravine. Misjudgment or an unstable surface could
result in the vehicle falling backwards into the drop
off.
The toggle switch is located on the driver side of the front
seat panel. Move the electric lift toggle switch up to raise
the dump bed and down to lower the dump bed (Ref Fig.
16 on page 10).
Rais
ADD
Ref Dsk 3
Fig. 17 Check Oil Level on Dipstick
Never overfill the engine with oil,
foaming may result and oil may enter
the breather system.
Both the oil dipstick and fill cap must be in place
before operating the engine. Failure to install
the dipstick and fill cap will result in oil becoming contaminated and/or oil being discharged into the engine
compartment.
The oil should be changed after the first five (5) to eight
(8) hours of operation and should be drained while the
engine is warm (Refer to page 16).
OPERATING THE VEHICLE
e
Improper use of vehicle or lack of
proper maintenance may result in
decreased performance or damage to
Low
er
vehicle.
Ref Lbs 1
Fig. 16 Electric Lift Toggle Switch
BEFORE ENTERING VEHICLE
1. Check for correct tire inflation. See GENERAL SPECIFICATIONS on page 4-1.
2. Inspect for fluid leaks.
3. Be sure everything is properly stored and secured.
Page 10
FULL
Read and understand the following warnings
before attempting to operate the vehicle.
To reduce the possibility
!
! of severe injury or death
resulting from loss of
vehicle control, the following warnings must be observed:
Drive the vehicle only as fast as terrain and safety
considerations allow. Consider the terrain, traffic
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
conditions and the environmental factors which
effect the terrain and the ability to control the
vehicle.
Use extra care and reduced speed when driving
on poor surfaces, such as loose dirt, wet grass,
gravel, etc.
Stay in areas suitable for a light duty utility vehicle. Avoid rough, unimproved trails, areas with
large rocks, stumps or holes and avoid steep
slopes.
Avoid driving fast downhill. A sudden stop or
change of direction may result in loss of control.
Use service brake to control speed when traveling
down an incline.
Slow down before and during turns. All turns
should be executed at reduced speed.
All travel should be directly up or down hills.
Use extra care when driving the vehicle across
any incline.
When driving the vehicle on unfamiliar terrain,
drive the vehicle slowly, especially when cresting
a hill.
If the vehicle is unable to climb a hill, do NOT
attempt to turn it around. Turning the vehicle
sideways on a hill could result in the vehicle rolling over. Slowly back down the hill using the service brake to control speed.
Check the area behind the vehicle before operating in reverse.
When operating the electric dump, do not back up
to a drop off, such as a loading dock or ravine.
Misjudgment or an unstable surface could cause
the vehicle to fall backward into the drop off.
Stay in designated areas
!
! and avoid steep slopes.
To reduce the possibility
of severe injury or death
resulting from improper vehicle operation, the following warnings must be observed:
The vehicle is a light duty utility vehicle. It is not
an ATV (All Terrain Vehicle).
The vehicle is not a toy and engaging in horseplay
is dangerous.
The vehicle should not be operated on public
highways. It is not designed to comply with any
DOT requirements.
The vehicle should be operated by persons with a
valid driver’s license. Children should not operate
this vehicle.
Vehicle is limited to two (2) seated occupants.
Make sure that the direction selector is in correct
position before starting the vehicle.
Always remain seated and hold on while the vehicle is in motion. Keep feet, legs, hands and arms
inside vehicle at all times.
The vehicle is not equipped with seat belts and is
not designed with roll over protection. The top
and windshield do not provide protection from
falling or flying objects.
Do not take vehicle out of ‘gear’ while in motion
(coast).
Check the area behind the vehicle before operating in reverse.
Always bring the vehicle to a complete stop
before shifting the direction selector and/or differential lock.
Use the parking brake when the vehicle is parked.
A motorcycle helmet and protective clothing are
recommended for operator and passenger at all
times.
Do not permit anyone in the load bed while vehicle is in motion.
Use caution when operating the electric dump. Do
not allow anyone behind the vehicle when operating the unit.
When operating the winch, observe all warnings
and safety decals on the vehicle. Read, understand and follow the instructions located in the
front part of this manual.
Do not winch at an angle. Do not exceed winch
capacity.
When vehicle is to be left unattended, engage
parking brake, move direction selector to ‘F’ (forward) position, turn key to ‘OFF’ position and
remove key.
Depressing the accelerator pedal energizes the starter
and ignition circuits which cause the engine to run. To
start the vehicle: Apply the service brake, place the key
Owner’s Manual and Service Guide
Page 11
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
in the key switch and turn it to the ‘ON’ position. Move the
direction selector to the direction desired. Release the
parking brake by pressing the release button in the end
of the handle while slightly raising the handle. Then lower
the parking brake handle. Slowly depress the accelerator
pedal to start the engine while releasing service brake.
The vehicle is equipped with a starter/generator. When
starting the engine, the starter/generator functions as a
starter and with the engine running, it functions as a generator. Since the engine stops when the accelerator is
released, do not attempt jump starting.
When the direction selector is in the ‘R’
(reverse) position, a warning signal will sound.
This is a device to indicate that the vehicle is
ready to run in reverse.
With the running times associated with this kind of vehicle, the generator is more than adequate to maintain the
battery charge level. The generator is not designed to
charge a discharged battery.
When the accelerator pedal is released, the ignition circuit is de-energized and the engine stops. To stop the
vehicle more quickly, depress the service brake pedal.
When leaving vehicle unattended, turn key to ‘OFF’ position and remove, engage parking brake and place direction selector in ‘FORWARD’ position.
If the vehicle is equipped with additional lights and/or a
strobe light that is used when the vehicle is not in motion,
the starter/generator may not be adequate to maintain
battery charge. If the vehicle battery has become discharged, it must be charged using a 12V charger that is
rated at 10 amps or less. Observe all instructions provided by the manufacturer of the charger.
Cold Starting
Starting a cold engine may require use of the choke.
Depress the accelerator approximately 1" (2.5 cm) or
until the starter just begins to operate.
Do not allow the starter to operate
continuously for more than 30 seconds. Allow 10 seconds before
attempting a second time. If the vehicle does not start on the
third attempt, turn the key switch off, engage the parking brake
and determine the cause of the problem.
Pull the choke knob out and hold knob in position until
engine starts and runs smoothly. Then push knob in. The
choke knob must be pushed in fully once engine has
reached operating temperature.
Starting the Vehicle on a Hill
Do not hold vehicle on hill by using
the accelerator and engine. This will
cause premature and excessive wear
to drive train components.
When starting the vehicle on a hill, it is important to follow
the procedure below to prevent excessive roll back and
possible permanent damage to the drive train system.
Place left foot on service brake and release parking
brake. Place right foot on accelerator. As accelerator is
depressed with the right foot, release the service brake.
Starting the Vehicle with a Discharged Battery
Do not attempt to ‘jump
!
! start’ a vehicle using
another vehicle.
Page 12
COASTING
On steep hills, it is possible for the vehicle to coast at
greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control, speeds should be
limited to no more than the maximum governed speed on
level ground (see GENERAL SPECIFICATIONS). Limit
speed by applying the service brake. Severe damage to
the drive train components may result due to excessive
speed. Damage caused by excessive speed may cause
a loss of control, is costly to repair, is considered abuse
and will not be covered under warranty.
FUEL
To prevent a possible
explosion, do not smoke
near the fuel tank or
refuel near open flame
or electrical items which could produce a spark.
Always wear safety glasses while refueling to prevent
possible eye injury from gasoline or gasoline vapor.
When refueling, inspect the fuel cap for leaks or
breaks that could result in fuel spillage.
Do not handle fuel in an area that is not adequately
ventilated. Do not permit anyone to smoke in an area
where vehicles are being fueled.
!
!
The fuel tank and cap is located under the passenger seat (Ref
Fig. 18 on page 13). Fill the tank with fresh, clean, automotive grade, unleaded, 87 octane (minimum) gasoline.
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Any servicing requiring adjustments to be made
to the powertrain while the motor is running must
be made with both drive wheels raised.
Wear eye protection when working on
the vehicle. In particular, use care when
working around batteries, or using solvents or compressed air.
To reduce the possibility of causing an electrical
arc, which could result in a battery explosion, turn
off all electrical loads from the batteries before
removing any heavy gauge battery wires.
To prevent the possibility of powertrain failure,
never operate vehicle at full throttle for more than
4 - 5 seconds while vehicle is in a ‘no load’ condition.
High altitude or heavy use/load applications may benefit
from higher octane gasoline.
Do not use gasoline which contains Methanol.
Some fuels, called oxygenated or reformulated gasoline, are gasoline blended
with alcohols or ethers. Excessive
amounts of these blends can damage the fuel system or cause performance problems. If any undesirable operating symptoms occur, use
gasoline with a lower percentage of alcohol or ether.
Do not overfill the fuel tank. Allow adequate space for the
expansion of gasoline. Leave at least 1" (2.5 cm) space
below bottom of filler neck.
In the best interest of both vehicle owner and servicing
dealer, carefully follow the procedures recommended in
this manual. Adequate preventative maintenance,
applied at regular intervals, is the best guarantee for
keeping the vehicle both dependable and economical.
1" Min.
(2.5 cm)
Fuel
Ref Ftl 3
Fig. 18 Fuel Tank Location
TOWING
!
!
This vehicle is not
designed to be towed.
It is recommended that the vehicle be moved by placing
the entire vehicle on a trailer, flatbed truck or other suitable transport.
SERVICING THE VEHICLE
In any product, components will fail to perform properly
as the result of normal use, age, wear or abuse.
A vehicle requiring repair indicates the vehicle is no
longer functioning as designed and should be considered
potentially hazardous. Use extreme care when working
on any vehicle. When diagnosing, removing or replacing
any components that are not operating properly, consider
the safety of yourself and those around you, should the
component move unexpectedly.
Some components are heavy, spring loaded, highly corrosive, explosive, may produce amperage or reach high
temperatures. Gasoline, carbon monoxide, battery acid
and hydrogen gas could result in serious bodily injury to
the technician/mechanic and bystanders if not treated
with utmost caution. Be careful not to place hands, face,
feet or body in a location that could expose them to injury
should an unforeseen dangerous situation occur.
!
To prevent severe injury
!
! or death resulting from
improper servicing techniques, observe the following:
Do not attempt any type of servicing operations
before reading and understanding all notes, cautions and warnings in this manual.
To prevent personal
injury or death, observe
the following:
Before working on the vehicle, remove all jewelry
(rings, watches, necklaces, etc.)
Be sure that no loose clothing or hair can contact
moving parts.
Use care not to touch hot objects.
Owner’s Manual and Service Guide
!
Page 13
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Raise entire vehicle and support on jack stands
before attempting to run or adjust powertrain.
Hydrogen gas is formed when charging batteries.
Do not charge batteries without adequate ventilation.
Do not permit open flame or anyone to smoke in
an area that is being used for charging batteries.
A concentration of 4% hydrogen gas or more is
explosive.
Engine exhaust gas (carbon monoxide) is deadly.
Carbon monoxide is an odorless, colorless gas
that is formed as a natural part of incomplete
combustion of hydrocarbon fuels. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.
The following are symptoms of carbon monoxide
inhalation:
• Dizziness
• Vomiting
• Intense headache
• Muscular twitching
• Weakness and sleepiness
• Throbbing in temples
If any of these symptoms are experienced, get
fresh air immediately. Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area.
Neutral Lock
To prevent the driven clutch from turning the rear wheels
during service operations, a neutral lock is located under
the passenger side of the console panel (Ref Fig. 19 on
page 14). To operate, turn the key switch to ‘OFF’ and
raise the passenger seat. Place the direction selector in
the ‘F’ position. Reach under the passengers side of console panel and rotate the neutral lock lever clockwise
until it snaps into the slot in the direction selector bracket
as shown. Next, pull the direction selector handle to the
rear until it locks in place in the neutral position. When in
this position, the direction selector remains locked in the
neutral position. To activate the direction selector, pull the
neutral lock lever out of the slot and rotate counter-clockwise until it snaps into the detent position in the direction
selector bracket.
Page 14
Direction
Selector
Console
Front of
Vehicle
Ref Nlk 2
Unlocked Locked
Position Position
Direction
Selector
Bracket
Slot
2
Detent
Neutral
Lock
ut and
rotate 90 o
to lock
out and
rotate 90 o
to unlock
Fig. 19 Neutral Lock
Lifting the Vehicle
Tool List
Qty. Required
Floor jack .....................................................................1
Jack stands..................................................................4
Wheel chocks ..............................................................4
To prevent possible inju!
! ry or death resulting
from a vehicle falling
from a jack, be sure the
vehicle is on a firm and level surface. Never get under
a vehicle while it is supported by a jack. Use jack
stands and test the stability of the vehicle on the
stands. Always place chocks in front and behind the
wheels not being raised. Use extreme care since the
vehicle is extremely unstable during the lifting process.
Some servicing operations may require the rear wheels
or the entire vehicle be raised.
Install chocks in front and behind each front wheel (Ref
Fig. 20 on page 15). Center the jack under the rear
bumper. Raise the vehicle and locate a jack stand under
the outer end of each rear axle. Lower the jack and test
the stability of the vehicle on the two jack stands.
Place the jack at the center of the front axle. Raise the
vehicle and position jack stands under the frame cross-
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
member as indicated. Lower the jack and test the stability
of the vehicle on the four jack stands.
If only the front or rear of the vehicle is to be raised, place
the chocks in front and behind each wheel not being
raised in order to stabilize the vehicle.
Lower the vehicle by reversing the lifting sequence.
POWERTRAIN MAINTENANCE
Access powertrain by raising or removing the seats and/
or load bed.
!
!
To prevent severe personal injury or death,
observe the following:
Always install a positive stop to prevent load bed
from unexpectedly falling.
Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench ‘shorting out’ a battery, which could result in an explosion.
Prevent accidental starting by removing and
grounding spark plug wires and disconnecting
battery at negative terminal before servicing.
Some service procedures may require the vehicle be
lifted. Refer to “Lifting the Vehicle” for proper lifting procedure and safety information.
King Pin
Ref Liv 4
King Pin
View from Underside of Vehicle
Fig. 20 Lifting the Vehicle
Routine Maintenance
Ball Joint
on Rack
and Rod
Steering
Unit
This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic
Service Schedule for appropriate service intervals (Ref
Fig. 38 on page 25). Refer to Lubrication Points (Ref Fig.
21 on page 15) for lubrication locations.
Do not use more than three (3) pumps
of grease in grease fitting at any one
time. Excess grease may cause
grease seals to fail or grease migration into areas that could
damage components.
Some items must be serviced more frequently
on vehicles used under severe driving conditions.
Ref Lub 2
Fig. 21 Lubrication Points
Owner’s Manual and Service Guide
Page 15
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Removing Debris
Oil Capacity
To prevent possible
!
! burns, engine parts
should be kept clean to
reduce risk of overheating and ignition of accumulated debris.
Engine oil capacity is approximately 1 1/2 quarts (1.4
liters) when changing oil and filter.
After every off road use, allow to cool and then check for
a build up of dirt and debris in the air intake and cooling
fins. Dirt and debris may clog the engine’s air cooling
system. Clean areas shown to prevent engine damage
(Ref Fig. 22 on page 16). Keep linkages, springs and
controls clean. Keep area around muffler free of any
combustible material.
The oil must be high quality detergent oil classified ‘For
Service SF, SG, SH, SJ’ or higher. Do not use special
additives and do not mix oil with gasoline. The selection
of oil viscosity is dependent upon the climate in which the
vehicle will be used. Most vehicles require SAE 30 oil;
however, vehicles used in cold climates will require a
multi-viscosity oil (Ref Fig. 23 on page 16).
Synthetic oil meeting ILSAC GF-2, API certification mark
and API service symbol with ‘SJ/CF ENERGY CONSERVING’ or higher, is an acceptable oil at all temperatures. Use of synthetic oil does not alter required oil
change intervals.
Cooling
Fins
Air
Intake
Ref Cai 2
Fig. 22 Cleaning Cooling Fins and Air Intake
Replacing the Fuel Filter
To prevent a possible
!
! explosion, do not smoke
near the fuel tank or in
an area where gasoline
is being handled. Do not perform procedures involving fuel system near open fire or electrical items
which could produce a spark.
Do not handle gasoline in an area that is not adequately ventilated.
Always wear safety glasses to prevent possible eye
injury from gasoline or gasoline vapor.
To replace fuel filter, use a pair of pliers to move clamps
off ends of filter and pull filter up higher than the fuel
pump to reduce the amount of gas that will spill (Ref Fig.
24 on page 17). Remove hose coming from fuel tank first
and plug. Remove filter from hose going to fuel pump
and discard.
Orient direction of new fuel filter according to
the FLOW arrow on the side of filter.
Install new fuel filter and reposition the clamps over the
inlet and outlet.
Page 16
Oil Recommendations
Do not use special additives in recommended
oil.
Do not mix oil with gasoline.
Air cooled engines run hotter than
automotive engines. The use of nonsynthetic multi-viscosity oils (5W-30,
10W-30, etc.) in temperatures above 40° F (4° C) will result in
higher than normal oil consumption. When using a multi-viscosity
oil, check oil level more frequently.
SAE 30 oil, if used below 40° F (4° C) will result in hard starting
and possible engine bore damage due to inadequate lubrication.
SAE 30
5W-30, 10W-30
Synthetic 5W-20, 5W-30
F0
-20
0
C -30
0
-20
Ref Ovc 2
20
40
60
-10
0
20
10
(Air Temperature)
80
100
30
40
Fig. 23 Oil Viscosity Chart
Checking the Oil Level
Tool List
Qty. Required
Clean cloth...................................................................2
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Check oil level daily before starting the engine. The vehicle must be on a level surface with the parking brake
engaged. Use a cloth to wipe clean the oil dipstick handle
and oil fill cap (Ref Fig. 24 on page 17). This is necessary
to prevent debris from falling into the engine.
Both the oil dipstick and fill cap must be in place before operating the engine. Failure to install the dipstick and fill cap will
result in oil becoming contaminated and/or oil being discharged
into the engine compartment.
Maximum oil level
DO NOT OVERFILL
ADD
Oil Fill
Cap
FULL
Ref Dsk 3
Fig. 26 Check Oil Level on Dipstick
Oil
Dipstick
Changing the Oil
Tool List
Fuel
Pump
Qty. Required
Pliers ........................................................................... 1
Oil drain pan ................................................................ 1
Clean cloth .................................................................. 2
Fuel
Filter
Ref Ofc 2
Fuel Line
From Tank
Fig. 24 Oil Fill Cap, Dipstick and Fuel Filter
Remove the dipstick and wipe off the entire area indicated with a clean cloth (Ref Fig. 25 on page 17).
ADD
For maximum performance and longevity, the engine oil
should be replaced after the first five (5) to eight (8) hours
of operation. After the initial oil change, it should be
changed per the Periodic Service Schedule (Ref Fig. 38
on page 25).
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 the engine warm. Park the vehicle on a level surface, engage the parking brake and remove the
key. Place a drain pan under the engine. Wipe the oil fill cap
clean with a cloth and remove the cap (Ref Fig. 24 on page
17).
FULL
Ref Ced 2
Fig. 25 Clean Entire Dipstick
Insert the dipstick fully into the dipstick tube and remove.
Examine the level of oil on the dipstick. Oil should be at
the FULL mark (Ref Fig. 26 on page 17).
If oil is required, remove oil fill cap and add oil slowly to
bring level to the FULL mark. Do not overfill.
Replace dipstick fully into the dipstick tube and firmly
replace the oil fill cap.
Clean the area around the oil drain valve (Ref Fig. 27 on
page 18). Open the valve and allow the oil to drain
through the hole in the engine mounting plate. Close
valve once oil has drained.
Add 1 quart (1 liter) of oil. Start and drive vehicle at a
slow speed for 30 seconds. Stop and turn off vehicle on a
level surface and wait 30 seconds for the oil to settle to
the bottom of the engine. Check for leaks. Slowly add
more oil to bring level to the FULL mark on dipstick. Do
not overfill.
Replace dipstick fully into the dipstick tube and firmly
replace the oil fill cap.
When adding oil between oil changes, do not
mix brands and viscosity grades of oil.
Owner’s Manual and Service Guide
Page 17
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
(Ref Fig. 28 on page 18). If necessary, vacuum or wipe
out any loose dirt or trash from the air cleaner base.
Oil Filter
Oil Drain
Valve
Air Cleaner
Cover
Knob
Plate
Cartridge
Ref Odf 2
Fig. 27 Oil Drain and Filter
Pre-cleaner
Changing the Oil Filter
Tool List
Air Cleaner
Base
Qty. Required
Oil filter wrench, to fit 3" (76 mm) oil filter.................... 1
Oil drain pan ................................................................ 1
Clean cloth .................................................................. 2
Clean the area around the oil filter and oil drain. Drain
engine oil per ‘Changing the Oil’ and remove oil filter (Ref
Fig. 27 on page 18). Make sure the seal came off with filter and is not stuck to the engine.
Wipe around the sealing surface of filter mount with a
clean, lint free cloth. Lightly oil the seal on the new filter
with fresh, clean oil. Screw filter on by hand until the seal
contacts the filter mount. Tighten 1/2 to 3/4 turn more.
Refill engine with new oil per ‘Changing the Oil’.
AIR CLEANER MAINTENANCE
The air cleaner is a dual filter cleaner, equipped with a
foam pre-cleaner over a conventional paper cartridge.
The filters must be serviced per the Periodic Service
Schedule (Ref Fig. 38 on page 25) for optimum engine
life and performance.
Ref Air 3
Fig. 28 Air Cleaner
Pre-Cleaner Service
To prevent damage to air filter cartridge and reduced engine performance, do not apply oil to the pre-cleaner.
Carefully remove pre-cleaner from cartridge and wash it
in liquid detergent and water. Rinse. Dry by squeezing
pre-cleaner in a clean cloth. Replace pre-cleaner and air
cleaner cover making sure the entire flange around bottom of cover fits over the top edge of the air cleaner
base. Secure with the spring clips.
Cartridge Service
To prevent engine damage, be careful
not to let debris fall into the carburetor when servicing the air cleaner.
Unscrew the knob securing the cartridge to the air
cleaner base and remove plate. Remove cartridge and
inspect. Replace if too dirty to clean or at the first sign of filter
paper deterioration. Clean cartridge by gently tapping on a
flat surface.
To prevent water entering air cleaner and causing starting or
engine problems, replace air cleaner cover making sure the
entire flange around the bottom of the cover fits over the top
edge of the air cleaner base. Secure with the spring clips.
Do not use petroleum solvents, pressurized water, or compressed air to
clean cartridge. Doing so will damage
the cartridge and will damage the engine.
Access the filters by unsnapping the spring clip on each
side of the air cleaner and removing the air cleaner cover
The paper cartridge is a dry unit. Do not use oil
on the cartridge.
Page 18
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Install cartridge, plate, knob, and pre-cleaner.
Replace air cleaner cover making sure that the entire
flange around the bottom of the cover fits over the top
edge of the air cleaner base. Secure with the spring clips.
REAR AXLE
The rear axle is provided with a lubricant level check plug
located on the driver side at the rear of the housing (Ref
Fig. 29 on page 19). Unless leakage is evident, an
annual lubricant check is sufficient.
Socket, 1/4" hex bit, 3/8" drive .................................... 1
Ratchet, 3/8" drive ....................................................... 1
Socket, 3/4", 3/8" drive ................................................ 1
Socket, 1/2", 3/8" drive ................................................ 1
Pry bar......................................................................... 1
Torque wrench, 3/8" drive, ft. lbs. ................................ 1
The starter/generator belt tension should be checked
after the first 15-20 hours of operation and set to 75 - 80
lbs. (34 - 36 kg).
A loose belt can cause audible vibration and
squeal.
Checking the Lubricant Level
Tool List
Qty. Required
Wrench, 13 mm........................................................... 1
Funnel ......................................................................... 1
Clean area around 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 (SAE 30 oil) 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. Capacity of axle is 48 oz. (1.4 liters).
Tighten a new starter/generator belt to 90 - 110 lbs. (41 50 kg) tension when a gauge is applied half way between
the two pulleys (Ref Fig. 30 on page 19).
Ref Cbg 1
Fig. 30 Check Belt Tension with Gauge
Although not as accurate, the belt may be depressed
with a finger. A maximum deflection of 3/8" (1 cm) is
acceptable for a new belt (Ref Fig. 31 on page 19).
Check Plug
Ref Raf 2
3/8" (1 cm) Max. Deflection
for New Belt
1/2" (1.3 cm) Max. Deflection
for Existing Belt
Drain Plug
Ref Cbf 1
Fig. 29 Add, Check and Drain Rear Axle Lubricant
STARTER/GENERATOR BELT TENSION
Tool List
Qty. Required
Belt tension gauge ...................................................... 1
Wrench, 3/4" ............................................................... 1
Wrench, 1/2" ............................................................... 2
Fig. 31 Check Belt Tension with Finger
Tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the same technique. A maximum deflection of
1/2" (1.3 cm) is acceptable.
Adjusting the Belt
Loosen front and back pivot bolts of starter/generator
(Ref Fig. 32 on page 20).
Owner’s Manual and Service Guide
Page 19
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Use care not to overtighten the plug.
Overtightening can damage the aluminum cylinder head threads.
Loosen adjusting bolt. Use pry bar to force starter/generator towards front of vehicle until proper belt tension is
achieved. Hold starter/generator in place and tighten
adjusting bolt.
Tighten pivot bolts to 25 ft. lbs. (35 Nm) torque.
Spark Plug
Adjusting Bolt
.030"
(.76 mm)
Gap
Ref Spg 1
Fig. 33 Gap Spark Plugs
Pivot Bolt
Ref Abt 2
Fig. 32 Adjust Belt Tension
BRAKES
The master cylinder is located under the driver side seat.
SPARK PLUGS
Tool List
Qty. Required
Spark plug socket, 5/8", 1/2" drive............................... 1
Ratchet, 1/2" drive ....................................................... 1
Plug gauge, wire type.................................................. 1
Anti-seize compound................................................ AR
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
Remove and inspect the spark plugs per the Periodic
Service Schedule (Ref Fig. 38 on page 25). Fouled spark
plugs are indicated by a wet, black appearance. This
could be caused by a dirty air filter element or other
restrictions in the air intake system. Incorrectly adjusted
valves, spark plug wires which are in poor condition or
poor quality fuel could also contribute to the problem.
Clean and gap to .030" (.76 mm). If a plug has been
burned beyond .035" (.89 mm) or the porcelain is
cracked, it should be replaced (Ref Fig. 33 on page 20).
Do not sand blast spark plugs. They should be
cleaned by scraping or wire brushing by hand
and washing in a commercial solvent.
All new spark plugs should be properly gapped to .030"
(.76 mm) (CHAMPION RC12YC), given a light coat of
anti-seize compound and tightened to 15 ft. lbs. (20 Nm)
torque.
Page 20
It is important to maintain proper fluid levels in the brake
master cylinder. The fill cap for the cylinder is located
under the seat. When checking the fluid, wipe off any dirt
from the fill cap before removing it to prevent contamination. Fluid level should be maintained at 1/4" (6 mm)
below the top of the housing. Use DOT 3 automotive
brake fluid.
DAILY BRAKE TEST
After the vehicle has been put into service, it is recommended that the brakes be checked daily by performing
the following test:
To prevent severe injury
or death resulting from
operating a vehicle with
improperly operating
brake system, the braking system must be properly
maintained. All driving brake tests must be done in a
safe location with regard for the safety of all personnel.
!
!
Depress the brake pedal. The pedal should have some
free travel and then become hard. A brake pedal that has
no free travel, excessive free travel or a spongy feel is
indicating that a brake inspection is required. A brake
pedal that falls after it is applied indicates a leak in the
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
master or wheel cylinders. Check for adequate brake
fluid level. Adjust brakes if required and inspect system
for fluid leaks.
TIRES
Standard tires for this vehicle are uni-directional
and should never be moved from one side of
vehicle to the other.
This vehicle comes standard with uni-directional tires.
Left side tires should always remain on the left side of the
vehicle. Right side tires should always remain on the
right side of the vehicle. Uni-directional tires have an
arrow on the sidewall indicating direction of rotation when
moving forward. Tire condition should be inspected and
inflation pressures checked per the Periodic Service
Schedule when the tires are cool. Be sure to install valve
dust cap after checking or inflating.
!
!
A tire explosion can
cause severe injury or
death. Never exceed
inflation pressure rating
on tire sidewall.
To prevent tire explosion, pressurize tire with
small amount of air applied intermittently to seat
beads. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face
and eyes from escaping air when removing valve
core.
Use caution when inflating tires. Due to the low
volume of these small tires, overinflation can
occur in a matter of seconds. Overinflation could
cause the tire to separate from the wheel or cause
the tire to explode, either of which could cause
personal injury.
Tire inflation will depend on the type of tires fitted but
under no condition should inflation pressure be higher
than recommended on the tire sidewall. Standard and
optional tires should be inflated to pressure designated in
GENERAL SPECIFICATIONS on page 4-1. If pressure is
not designated in GENERAL SPECIFICATIONS, inflate
to pressure designated on tire sidewall. All four tires
should have the same pressure for optimum handling
characteristics. Do not overinflate. Due to the low volume of these small tires, overinflation can occur in a matter of seconds. Be sure to install valve dust cap after
checking or inflating.
Wheel and Tire Service
Tool List
Qty. Required
Lug wrench, 3/4" ......................................................... 1
Impact socket, 3/4", 1/2" drive..................................... 1
Impact wrench, 1/2" drive ............................................ 1
Torque wrench, 1/2" drive, ft. lbs. ................................ 1
!
!
To prevent injury caused
by a broken socket, use
only sockets designed
for impact wrench use.
The vehicle is fitted with low pressure tubeless tires
mounted on one piece rims. When removing wheels with
an impact wrench, use only impact sockets. Regular
sockets are not designed for impact pressures exerted
by power tools.
Generally, the most cost effective way to repair a flat tire
resulting from a puncture in the tread portion of the tire is
to use a commercial tire plug.
Tire plug tools and plugs are available at most
automotive parts outlets and have the advantage of not requiring the tire be removed from
the wheel.
If the tire is flat, raise vehicle and remove wheel. Refer to
‘Lifting the Vehicle’ for proper lifting procedure and safety
information. Inflate tire to maximum recommended pressure. Immerse the tire in water to locate the leak and
mark with chalk. Insert tire plug in accordance with manufacturer’s specifications.
If the tire is to be removed or mounted, the tire changing
machine manufacturer’s recommendations must be followed in order to minimize the possibility of personal
injury. Be sure to position tire on wheel correctly. Arrow
on tire indicates rotation when moving forward.
To prevent injury, be
sure mounting/demounting machine is anchored
to floor. Wear OSHA
approved safety equipment when mounting/demounting tires.
!
!
Follow all instructions and safety warnings provided by
the mounting/demounting machine manufacturer.
Do not tighten lug nuts to more than
85 ft. lbs. (115 Nm) torque.
It is important to follow the ‘cross sequence’
pattern when installing lug nuts. This will assure
even seating of the wheel against the hub.
Owner’s Manual and Service Guide
Page 21
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
With the valve stem to the outside, mount the wheel onto
the hub with lug nuts. Be sure to position the wheel on
hub correctly with arrow indicating direction of rotation
when moving forward. Finger tighten lug nuts in a ‘cross
sequence’ pattern (Ref Fig. 38 on page 25). Then,
tighten lug nuts to 50 - 85 ft. lbs. (70 - 115 Nm) torque in
20 ft. lbs. (30 Nm) increments following the same ‘cross
sequence’ pattern.
Rot
a
'Cross Sequence'
1
3
n
tio
Front of
Vehicle
Ref Whi 4
To replace fuses, locate the fuse block under the driver
side seat. Pull out old fuse and replace with a new automotive type fuse of the same amperage.
Headlight and taillight bulbs and fuses are available from
a local distributor, an authorized Branch or the Service
Parts Department.
PROLONGED STORAGE
!
!
To prevent serious injury or death resulting
from a possible explosion:
2
4
Tire style may vary
Fig. 34 Wheel Installation
LIGHT BULB AND FUSE REPLACEMENT
To replace the headlight bulb, locate the two screws on
backside of cowl that secure headlight (Ref Fig. 35 on
page 22). Remove screws, pull headlight out and disconnect wires. Connect wires to new headlight, install in cowl
and secure with screws previously removed.
Turn Signal Lens
Inside
of Cowl
Headlight
Bulb
Turn Signal
Housing
Ref Hdr 4
Fig. 35 Headlight Replacement
To replace the turn signal light bulb, support turn signal
housing from backside of cowl while removing two
screws securing lens. Install new bulb and replace lens.
Page 22
To replace the tail and brake light bulb, roll the rubber
bezel from around the edge of the taillight and remove
lens. Install replacement bulb and replace lens
Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or
refuel near open flame or electrical items which
could produce a spark.
Store vehicle in a clean, dry area. Do not store in
same area as a stove, furnace, water heater, or
other appliance that uses a pilot light or has a
device that can create a spark.
When refueling, inspect the fuel cap for leaks or
breaks that could result in fuel spillage.
Always wear safety glasses while refueling to prevent possible eye injury from gasoline or gasoline
vapor.
Keep hands, clothing and jewelry away from moving parts. Use care not to contact hot objects.
Raise the rear of the vehicle and support on jack
stands before attempting to run the engine.
Preparing the engine for a prolonged storage period (30
days or more) calls for a few simple steps to prevent a
build up of varnish and gum in the carburetor and corrosion in the engine.
• Raise the rear of the vehicle and support on jack stands.
Refer to ‘Lifting the Vehicle’ for proper lifting procedure and
safety information.
• If fuel tank contains oxygenated or reformulated gasoline
(gasoline blended with an alcohol or ether), remove the
passenger side seat bottom and disconnect the fuel hose
at the fuel tank. Keep end of hose up near the top of the
tank to prevent spilling fuel. With proper ventilation,
depress the accelerator pedal and allow engine to run until
it stops due to lack of fuel. Reattach fuel line to tank and
Owner’s Manual and Service Guide
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Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
replace seat bottom.
-orIf fuel tank contains non-oxygenated or non-reformulated
gasoline, add a gasoline additive to the tank in accordance with the manufacturer’s recommendations. Drive
the vehicle for several minutes to circulate the additive
through the carburetor.
• While engine is still warm, change oil (Refer to page 17).
• Remove spark plugs (Refer to page 20) and pour about 1
oz. (30 ml) of engine oil into each cylinder. Replace spark
plugs, ground spark plug wires and use starter to turn
engine over a few seconds to distribute oil.
• Clean body, chassis and engine of debris, mud, chaff or
grass (Refer to page 16).
CARE AND CLEANING OF THE VEHICLE
When pressure washing vehicle, do
not use pressure in excess of 700 psi.
To prevent cosmetic damage, do not
use any abrasive or reactive solvents to clean plastic parts.
It is important that proper techniques and cleaning materials be used.
TRANSPORTING VEHICLE
To reduce the possibility
of severe injury or death
while transporting vehicle:
Secure the vehicle and contents.
Never ride on vehicle being transported.
Always remove windshield before transporting.
Maximum speed with sun top installed is 50 mph (80
kph).
!
!
If the vehicle is to be transported at highway speeds, the
sun top must be removed and the seat bottoms secured.
When transporting vehicle below highway speeds, check
for tightness of hardware and cracks in sun top at mounting points. Always remove windshield when transporting.
Always check that the vehicle and contents are adequately secured before transporting. The rated capacity
of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle
weight) and load. Lock the park brake and secure the
vehicle using ratchet tie downs.
Normal cleaning of vinyl seats and plastic or rubber trim
requires the use of a mild soap solution applied with a
sponge or soft brush and wipe with a damp cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require
the use of a commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive
appearance and durable protection. Frequent washing
with lukewarm or cold water is the best method of preserving the painted surfaces.
Do not use hot water, strong soap or harsh chemical
detergents.
Rubber parts should be cleaned with non-abrasive
household cleaner.
Occasional cleaning and waxing with non-abrasive products designed for ‘clear coat’ automotive finishes will
enhance the appearance and durability of the painted
surfaces.
Corrosive materials can collect on the underbody of the
vehicle. These materials will accelerate corrosion of
underbody parts. It is recommended that the underbody
be flushed occasionally with plain water. Thoroughly
clean any areas where mud or other debris can collect.
Sediment packed in closed areas should be loosened to
ease it’s removal, taking care not to chip or otherwise
damage paint.
Owner’s Manual and Service Guide
Page 23
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
HARDWARE
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref Fig. 37 on page
24). Use care when tightening fasteners and refer to the
Technician’s Repair and Service Manual for specific
torque values.
Generally, two grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three
marks on the hexagonal head. Unmarked hardware is
Ref Bgr 1
Grade 5
Grade 2
Fig. 36 Bolt Grades
TORQUE SPECIFICATIONS
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)
Fig. 37 Torque Specifications
Page 24
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
PERIODIC SERVICE SCHEDULE
✓ Check
♦ Clean, Adjust, etc.
▲ Replace
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions
8 HOURS or DAILY
ENGINE
✓ Check oil level (See Note 1)
SERVICE BRAKE
✓ Check brake performance, smooth operation and adjust if required
PARKING BRAKE
✓ Check brake performance and adjust if required
REVERSE WARNING DEVICE
✓ Check operation when direction selector is in reverse
TIRES
✓ Examine for cuts, excessive wear and pressure. See GENERAL
SPECIFICATIONS section
WHEELS
✓ Check for bent rims, missing or loose lug nuts
FUEL GAUGE
✓ Check for proper operation (at fueling), and fuel cap vent is free of dirt
BODY
♦ Clean body components as required
COOLING SYSTEM
♦ Clean fins and inside blower housing (See Note 3)
25 HOURS (includes items listed in previous tables & the following)
♦ Clean foam pre-cleaner (See Note 3)
ENGINE
✓ Check for unusual noise, vibration, acceleration, oil leaks
♦ Clean battery & terminals with 1/4 cup (60 ml) baking soda to 1 1/2 gallons (6 liters)
water solution, rinse with clear water
BATTERY
✓ Check charge condition and all connections
WIRING
✓ Check all wiring for loose connections and broken/missing insulation
ACCELERATOR CABLE
✓ Check for smooth movement - DO NOT LUBRICATE CABLE
CHOKE CABLE
✓ Check for smooth movement and adjustment - DO NOT LUBRICATE CABLE
CARBURETOR LINKAGE
✓ Check attachment, adjust as required
DIRECTION SELECTOR
✓ Check for smooth movement and attachment, adjust as required
STARTER/GENERATOR BELT
✓ Check for tension, wear and cracks
STEERING ASSEMBLY
✓ Check for abnormal play, tightness of all hardware
TIE RODS/LINKAGES
✓ Check for excessive play, bent components or loose connections
REAR AXLE
✓ Check for leakage, add SAE 30 oil as required
50 HOURS (includes items listed in previous tables & the following)
ENGINE
EXHAUST
▲ Change oil, DO NOT OVERFILL (See Notes 1 and 2)
✓ Check spark plug wires for cracks/loose connections
✓ Inspect/clean spark arrestor
Fig. 38 Periodic Service Schedule
Owner’s Manual and Service Guide
Page 25
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
FRONT AXLE
✓ Check for damage to axle and loose or missing hardware
FRONT SHOCK ABSORBERS
✓ Check for oil leakage and loose fasteners
FRONT SPRINGS
✓ Check for loose hardware, cracks at attachments
FRONT WHEEL ALIGNMENT
✓ Check for unusual tire wear, align as required. See FRONT SUSPENSION AND
STEERING section
✓ Check for binding cables
PARKING BRAKE
✓ Check for damage or wear
♦ Lubricate, use light oil. DO NOT LUBRICATE CABLES
HYDRAULIC BRAKE FLUID
✓ Check level, add if required (DOT 3) and check for leakage
REAR SHOCK ABSORBERS
✓ Check for oil leakage, loose mounting hardware
✓ Check for leaks at tank, cap, lines, filter, pump and carburetor
FUEL SYSTEM
✓ Check fuel lines for cracks/deterioration
THROTTLE/GOVERNOR LINKAGE
✓ Check operation and governed speed
100 HOURS (includes items listed in previous tables & the following)
▲ Change oil filter (See Note 1)
ENGINE
▲ Change air cleaner cartridge if damaged or dirty (See Note 3)
DIRECTION SELECTOR
✓ Check for wear and smooth movement (lubricate shaft with light oil if required)
✓ Check shift cable spring length
✓ Check for excessive play and tightness of retaining nuts
KING PINS
♦ Lubricate, use wheel bearing grease
STEERING ASSEMBLY
♦ Lubricate linkage, use wheel bearing grease
TIE RODS/LINKAGES
♦ Lubricate, use wheel bearing grease
REAR AXLE
✓ Check for unusual noise and loose missing mounting hardware
250-300 HOURS or YEARLY (includes items listed in previous tables & the following)
▲ Replace or clean spark plugs
ENGINE
FRONT WHEEL BEARINGS
REAR AXLE
SERVICE BRAKES
MUFFLER/EXHAUST
▲ Replace in-line fuel filter
✓ Check valve clearance, refer to Briggs & Stratton® Repair Manual (P/N 272144) for
VANGUARD™ V-Twin Overhead Valve Engines
♦ Adjust. See FRONT SUSPENSION AND STEERING section
♦ Pack with wheel bearing grease
✓ Check lubricant, if oil seepage is evident, add lubricant (SAE 30) as required
♦ Clean. See HYDRAULIC BRAKES section
✓ Check brake shoe linings, wear limit .06" (1.5 mm)
✓ Check mounting hardware; check for leaks at head and muffler gaskets
Fig. 38 Periodic Service Schedule
Page 26
Owner’s Manual and Service Guide
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
500 HOURS
REAR AXLE
▲ Replace lubricant
ENGINE
♦ Clean combustion chamber deposits, refer to Briggs & Stratton® Repair Manual
(P/N 272144) for VANGUARD™ V-Twin Overhead Valve Engines
Fig. 38 Periodic Service Schedule
Note 1 - Change oil after first 8 hours, then after every 50
hours.
Note 2 - Change oil every 25 hours when operating
under heavy load or in high temperatures.
Note 3 - Clean more often under dusty conditions or
when airborne debris is present. Clean foam pre-cleaner
first and replace paper cartridge if dirty. Replace either if
showing signs of damage.
Owner’s Manual and Service Guide
Page 27
GASOLINE UTILITY VEHICLES
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Page 28
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Owner’s Manual and Service Guide
Page 29
GENERAL SPECIFICATIONS
Jacobsen 4800
STANDARD EQUIPMENT:
BATTERY
ENGINE
TRANSAXLE
TRANSMISSION
FUEL TANK
BRAKES
PARKING BRAKE
FRONT SUSPENSION
REAR SUSPENSION
STEERING
STEERING WHEEL
SEATING
SEATING CAPACITY
TOTAL LOAD CAPACITY
SPEED
CHASSIS
VEHICLE PROTECTION
BODY
STANDARD COLOR(S)
DASH PANEL
LOAD BED
LOAD BED FEATURES
LIGHTING/HORN (Standard)
TIRES (Standard)
TIRE PRESSURE
WEIGHT (Without Fuel)
OPERATING CONTROLS
& INSTRUMENTATION
One 12 Volt Maintenance Free (515 CCA, 82 Minute Reserve)
16 H.P. (11.9 kW) 29.2 ci (480 cc) Twin Cylinder, Overhead Valve
Pressurized Lubrication with Spin Off Filter
Magnetron™ Ignition with Transistor Module
Replaceable Dry Cartridge Air Filter with Pre-Filter & Remote Intake
Fixed Jet Bowl Carburetor, Pulse Fuel Pump
13.32:1 Helical geared with Differential Lock and Ground Speed Governor
Automatic Continuously Variable Transmission (CVT)
6 Gallon (23 Liters) Tank. 36 lbs. (16 kg) Fuel Weight
Dual Rear Wheel, Self-Adjusting Hydraulic Drum Brakes
Hand Operated Mechanical Parking Brake
Leaf Springs with Hydraulic Shock Absorbers
Leaf Springs with Hydraulic Shock Absorbers
Single Reduction Rack & Pinion
Dual Handgrips
Cushion Foam/Vinyl Cover Bucket Seats, Hip Restraint/Hand Hold
Operator & 1 Passenger
800 lbs. (365 kg) Including Operator, Passenger, Accessories & Cargo
500 lbs. (230 kg) Maximum Bed Load
16.5 mph (26.5 kph) Max
Powder Coated (DuraShield™), Welded Tubular Steel
Tubular Steel Front Bumper with Brush Guards
Flexible Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer) with Base
Coat/Clear Coat Front Cowl. DuraShield™ Powder Coated Steel Rear Body
Jacobsen Orange
Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) with 4 Drink Holders
Rotomolded Cross Link Polyethelene & Electric Dump
Hinged Removable Tailgate
Dual Halogen Headlights, Horn
22 x 9 - 10 Stryker 1 ® (Uni-directional)
12 - 16 psi (85 - 110 kPa)
1100 lbs (480 kg)
Removable Key, ‘Deadman’ Accelerator Control, Direction Selector, Audible Reverse Warning,
Analog Fuel Gauge, Low Oil Pressure Indicator and 12 Volt Power Outlet
Specifications subject to change without notice
Page 30
Owner’s Manual and Service Guide
GENERAL SPECIFICATIONS
110.5 in (281 cm)
18 in
(46 cm)
49 in
(125 cm)
78 in
(198 cm)
or
75 in
(191 cm)
with Brush
Guard
Cage
11.5 in
(29 cm)
34 in
(86 cm)
15 in
(38 cm)
77 in (196 cm)
6 in
(15 cm)
Ground Clearance
Rear
38 in (96 cm)
Front
38.5 in (97 cm)
50 in
(127 cc)
42.5 in (108 cm)
Maximum Recommended Ramp Grade
25% or 14˚ Max.
Maximum Recommended Side Tilt
25% or 14˚ Max.
Fig. 39 Vehicle Dimensions and Incline Specifications
Owner’s Manual and Service Guide
Page 31
GENERAL SPECIFICATIONS
TURNING CLEARANCE DIAMETER
Approx. 23.5 ft (7.2 m)
Fig. 40 Vehicle Turning Clearance Diameter
Page 32
Owner’s Manual and Service Guide
VEHICLE WARRANTIES
VEHICLE WARRANTIES
Owner’s Manual and Service Guide
Page 33
VEHICLE WARRANTIES
DOMESTIC WARRANTY
(U.S. AND CANADA)
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch
or the Warranty Department with vehicle serial number and manufacturer date code.
EMISSION CONTROL SYSTEM WARRANTY STATEMENT
(Owner’s Defect Warranty Rights and Obligations)
Refer to the Briggs & Stratton® Operating & Maintenance Instructions, provided with vehicle, for Emission Control
System Warranty information.
ENGINE OWNER WARRANTY POLICY
Refer to the Briggs &
information.
Page 34
Stratton® Operating
& Maintenance Instructions, provided with vehicle, for Engine Warranty
Owner’s Manual and Service Guide
Read and understand the following warnings
before attempting to operate the vehicle:
!
!
To prevent personal
injury or death, observe
the following:
When vehicle is to be left unattended, engage parking
brake, move direction selector to ‘F’ (forward)
position, turn key to ‘OFF’ position and remove key.
Drive vehicle only as fast as terrain and safety
considerations allow. Consider the terrain and traffic
conditions. Consider environmental factors which
effect the terrain and the ability to control the vehicle.
Some components are heavy, spring loaded, highly corrosive, explosive or may produce high amperage or
reach high temperatures. Gasoline, carbon monoxide,
battery acid and hydrogen gas could result in serious
bodily injury to the technician/mechanic and bystanders if
not treated with the utmost caution. Be careful not to
place hands, face, feet or body in a location that could
expose them to injury should an unforeseen situation
occur.
Always use the appropriate tools listed in the tool list and
wear approved safety equipment.
!
!
Before working on the
vehicle,
remove
all
jewelry (rings, watches,
Avoid driving fast down hill. Sudden stops or change
of direction may result in a loss of control. Use service
brake to control speed when traveling down an incline.
necklaces, etc.)
Use extra care and reduced speed when driving on
poor surfaces, such as loose dirt, wet grass, gravel,
etc.
Use care not to touch hot objects.
All travel should be directly up or down hills.
Be sure that no loose clothing or hair can contact
moving parts.
Raise rear of vehicle and support on jack stands
before attempting to run or adjust powertrain.
Use extra care when driving the vehicle across an
incline.
Wear eye protection when working on or around
vehicle. In particular, use care when working around
batteries, using solvents or compressed air.
Stay in designated areas and avoid steep slopes. Use
the parking brake whenever the vehicle is parked.
Hydrogen gas is formed when charging batteries. Do
not charge batteries without adequate ventilation.
Keep feet, legs, hands and arms inside vehicle at all
times.
Do not permit open flame or anyone to smoke in an
area that is being used for charging batteries. A
concentration of 4% hydrogen gas or more is
explosive.
Avoid extremely rough terrain.
Check area behind the vehicle before operating in
reverse.
Make sure the direction selector is in correct position
before attempting to start the vehicle.
Slow down before and during turns. All turns should
be executed at reduced speed.
Always bring vehicle to a complete stop before
shifting the direction selector.
See GENERAL SPECIFICATIONS for vehicle load and
seating capacity.
Read and understand the following text and
warnings before attempting to service vehicle:
In any product, components will eventually fail to perform
properly as the result of normal use, age, wear or abuse.
It is virtually impossible to anticipate all possible component failures or the manner in which each component
may fail.
Be aware that a vehicle requiring repair indicates that the
vehicle is no longer functioning as designed and therefore should be considered potentially hazardous. Use
extreme care when working on any vehicle. When diagnosing, removing or replacing any components that are
not operating correctly, take time to consider the safety of
yourself and others around you should the component
move unexpectedly.
Engine exhaust gas (carbon monoxide) is deadly.
Carbon monoxide is an odorless, colorless gas that is
formed as a natural part of incomplete combustion of
hydrocarbon fuels. Carbon monoxide is a dangerous
gas that can cause unconsciousness and is
potentially lethal.
The following are symptoms of carbon monoxide
inhalation:
• Dizziness
• Vomiting
• Intense Headache
• Muscular Twitching
• Weakness and Sleepiness
• Throbbing in Temples
If any of these symptoms are experienced, get fresh air
immediately. Never work around or operate a vehicle
in an environment that does not ventilate exhaust
gases from the area.
E-Z-GO Division of Textron Inc.
P.O. Box 388 Augusta, Georgia 30903-0388 USA
Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124
Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609
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