Bad Boy HD G Owner's Manual

Gasoline powered utility vehicle
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HD & LTO GAS
OWNER'S MANUAL
617816
ISSUED JANUARY 2011
REVISED AUGUST 2012

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Summary of Contents for Bad Boy HD G

  • Page 1 HD & LTO GAS OWNER'S MANUAL 617816 ISSUED JANUARY 2011 REVISED AUGUST 2012...
  • Page 2: Safety

    SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 OWNER’S GUIDE GASOLINE POWERED UTILITY VEHICLE HD G LTO G Starting Model Year 2011 The E-Z-GO Division of Textron Inc. (e-z-go) reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously.
  • Page 4: General Information

    GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA) as a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.
  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY ........................ inside covers GENERAL INFORMATION ......................ii SAFETY INFORMATION ......................v LABELS AND PICTOGRAMS ....................ix WELCOME ..........................1 BEFORE INITIAL USE ....................... 1 Initial Service Chart ........................1 CONTROLS AND INDICATORS ....................1 KEY/LIGHT SWITCH ............................2 Key/Light Switch and Fuel Gauge .....................
  • Page 6 TABLE OF CONTENTS Clean Entire Dipstick ....................... 10 COLD STARTING .............................. 10 STARTING AND DRIVING..........................11 STARTING THE VEHICLE ON A HILL ......................11 COASTING................................. 11 FUEL .................................. 11 Fuel Tank Location ........................12 BATTERY................................12 LABELS AND PICTOGRAMS ..........................12 SUN TOP &...
  • Page 7 TABLE OF CONTENTS AIR INTAKE AND COOLING FINS ........................25 Cleaning Cooling System with Air.....................25 REAR AXLE................................25 CHECKING THE LUBRICANT LEVEL .......................25 Add, Check and Drain Rear Axle Lubricant ................26 AIR CLEANER INSPECTION AND REPLACEMENT ..................26 Air Cleaner ..........................26 SPARK PLUG..............................26 Gapping the Spark Plug......................27 PROLONGED STORAGE ..........................27 CAPACITIES AND REPLACEMENT PARTS.....................27...
  • Page 8 TABLE OF CONTENTS NOTES: Page vi...
  • Page 9: Safety Information

    SAFETY INFORMAT ION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.
  • Page 10: General Operation

    SAFETY INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. 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.
  • Page 11 SAFETY INFORMAT ION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. 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.
  • Page 12 SAFETY INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. NOTES: Page viii...
  • Page 13: Labels And Pictograms

    LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Page - ix...
  • Page 14 LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. 35962G01 35962-G01 Maximum weight in basket is 25 lbs. (11 kg). Excess weight may cause injury resulting from vehicle instability and/or frame damage. 71084G01 71084G01 71131-G01...
  • Page 15 LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD XXX lbs. AS POSSIBLE.
  • Page 16 LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. CLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE DO NOT EXPOSE UNLEADED TO FLAME GASOLINE DO NOT DO NOT DISPOSE OF SPILL FUEL BATTERIES...
  • Page 17 LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. KEEP CLEAR OPERATE HAND OR FROM FINGERS CAN DRIVERS SIDE BE TRAPPED ONLY POSITION KEEP ARMS AND LEGS POSITION WITHIN VEHICLE HEADLIGHTS TO OPERATE VEHICLE IN FORWARD:...
  • Page 18 LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. ENGINE CRANKING START REAR DIFFERENTIAL POSITION LOCK SWITCH PULL HANDLE UP TO ENGAGE PARK BRAKE FRONT DIFFERENTIAL LOCK SWITCH WARNING READ OWNER'S MANUAL BEFORE ENGAGING FRONT DIFFERENTIAL...
  • Page 19 LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. NOTES: Page - xv...
  • Page 20 LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. NOTES: Page - xvi...
  • Page 21: Welcome

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Thank you for purchasing a Gas Powered Light Duty concentration of hydrogen gas is explosive Utility Vehicle. Before driving the vehicle, we ask you to and could cause severe injury or death.
  • Page 22: Key/Light Switch

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. • fuel gauge CHOKE • low oil pressure indicator light The choke is used to aid cold starting (Ref. Fig. 4 on •...
  • Page 23: Accelerator Pedal

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. ACCELERATOR PEDAL HORN The horn is operated by pushing the horn button located on the floor to the left of the brake pedal. 12 VOLT POWER OUTLET Unintentional movement of the accelerator pedal will release the park brake and may...
  • Page 24: Winch Mounted To Vehicle

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. ENGAGED LOCKED OUT If mounting winch at rear of vehicle, the winch must be mounted upside down. Pull out Winch shown mounted at front of vehicle Clutch Knob Front Axle...
  • Page 25: Never Operate Winch With Less Than Five Turns Around Drum

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. If attaching the winch to a dead tree, a sec- tion could fall. When pulling vehicle with winch, pull straight only. Do not permit the cable to contact the side of the drum.
  • Page 26: Do Not Hook Cable To Itself

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. If the vehicle is being used as an anchor to winch a load, it should have the park brake set and chocks installed on all wheels.
  • Page 27: Environmental Concerns

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Slow down when in unfamiliar terrain. Slow down when MODIFICATIONS TO VEHICLE cresting a hill in an area that you are unfamiliar with. Some hills are too steep to climb.
  • Page 28: Load Bed Configurations And Capacities

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Always place a gas can on the ground before filling. ELECTRIC LIFT BED OPERATION Never fill a gas can in the bed of the vehicle. Static elec- tricity is built up during the fueling process and could discharge causing the gasoline vapor to ignite.
  • Page 29: Storage

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. STORAGE center of gravity must not be higher than 4" (10 cm) above the platform, and securely fastened down. Fail- ure to follow these instructions could cause personal VEHICLES EQUIPPED WITH CONVERTIBLE injury, damage to the vehicle and/or cause the vehicle...
  • Page 30: Run-In

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Never drive vehicle up, down, or across an Maximum Oil Level For Hot Fill Cold Engine incline that exceeds 14° (25% grade). Engine Do Not Overfill To This Point To reduce the possibility of severe injury or...
  • Page 31: Starting And Driving

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. STARTING AND DRIVING death from coasting at above recommended speeds, limit speed with service brake. On steep hills, it is possible for the vehicle to coast at greater than normal speeds encountered on a flat sur- To reduce the possibility of roll-back which face.
  • Page 32: Fuel Tank Location

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. 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;...
  • Page 33: Repair

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. with lukewarm or cold water and mild detergent is To raise the entire vehicle, install chocks in front and required to preserve the painted surfaces.
  • Page 34: Wheel Installation

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Immerse the tire in water to locate the leak and mark with chalk. Insert tire plug in accordance with manufac- turer’s instructions.
  • Page 35: Headlight Replacement

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. erator functions as a starter and with the engine run- Turn Signal Lens Inside ning, it functions as a generator. of Cowl With the short running times associated with this kind of vehicle, the generator is more than adequate to main-...
  • Page 36: Neutral Lock

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. NEUTRAL LOCK tions before reading and understanding all notes, cautions and warnings in this manu- To prevent the driven clutch from turning the rear wheels during service operations and to prevent wear to Any servicing requiring adjustments to be the belt while being towed, a neutral lock is located on...
  • Page 37: Serial Number Label Location

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. tee for keeping the vehicle both dependable and eco- Design changes take place on an ongoing basis. In nomical.
  • Page 38: Periodic Service Schedule

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. PERIODIC SERVICE SCHEDULE    Check Clean, Adjust, etc. Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representa- tive or see the Repair and Service Manual for this vehicle.
  • Page 39 OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.  Check for bent/binding linkage rod  Check for damage or wear to latch arm or catch bracket PARK BRAKE ...
  • Page 40: Tire Inspection

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. TIRE INSPECTION Tire condition should be inspected per the Periodic Ser- vice Schedule (Ref. Fig. 27 on page 18). Inflation pres- sures should be checked when the tires are cool.
  • Page 41: Changing The Oil

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Changing the Oil Oil Fill Cap Tool List Qty. Socket, ................ 1 Ratchet ................ 1 Extension, 8" ............... 1 Oil Drain Pan ...............
  • Page 42: Oil Drain Plug

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Be careful of hot oil when drained. It may be hot enough to burn you severely Drain the oil by removing the drain plug found at the rear of the engine base.
  • Page 43: Check Belt Tension Manually

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. BATTERY CLEANING A loose belt can cause audible vibration and squeal. Tighten a new starter/generator belt to 90 - 110 lbs. (41-50 kg) tension when a gauge is applied half way between the two pulleys. 3/8"...
  • Page 44: Brakes

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. The correct cleaning technique is to spray the top and Establish the acceptable stopping distance by testing a sides of the battery with a solution of sodium bicarbon- new or ‘known to be good’...
  • Page 45: Lubrication

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. the line or marker in the test area and remove foot from AIR INTAKE AND COOLING FINS pedal. The vehicle should stop aggressively. The wheel brakes may or may not lock.
  • Page 46: Add, Check And Drain Rear Axle Lubricant

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Cleaning the Air Filter Element For vehicles with LSD axle, add 2 ounces of friction modifier during refill. Do not use compressed air to clean the air filter;...
  • Page 47: Gapping The Spark Plug

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. Preparing the engine for a prolonged storage period (30 Plug days or more) calls for a few simple steps to prevent a build up of varnish and gum in the carburetor and corro- sion in the engine.
  • Page 48: Hardware

    OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. HARDWARE Use care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific Periodically, the vehicle should be inspected for loose torque values.
  • Page 49 OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. NOTES: Page 29...
  • Page 50 OPERATION AND SERVICE INFORMATION Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. NOTES: Page 30...
  • Page 51: General Specifications

    GENERAL SPECIFICATIONS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. GENERAL SPECIFICATIONS Page 27...
  • Page 52 GENERAL SPECIFICATIONS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. MODEL: HD G TYPE: GASOLINE POWERED TRUCK MODEL YEAR: 2011 Part No:. 617791 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki...
  • Page 53 GENERAL SPECIFICATIONS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. MODEL: LTO TYPE: GAS POWERED PERSONNEL CARRIER MODEL YEAR: 2011 Part No: 617795 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki Valve Train: Fuel System: Overhead valve...
  • Page 54 GENERAL SPECIFICATIONS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. 10 in 47 in (25 cm) (119 cm) (Front) 38 in (97 cm) 66 in (168 cm) (Rear) 103 in (262 cm) 38 in (97 cm) 35 in (89 cm) HD VEHICLE...
  • Page 55: General Specifications

    GENERAL SPECIFICATIONS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 o MAX 25% or 14 o MAX TURNING CLEARANCE DIAMETER 20.5 ft (6.3 m) 23.5 ft (7.2 m) Page 31...
  • Page 56 GENERAL SPECIFICATIONS Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. NOTES: Page 32...
  • Page 57: Vehicle Warranties

    VEHICLE WARRANTIES Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. VEHICLE WARRANTIES Page 33...
  • Page 58: Domestic Warranty

    VEHICLE WARRANTIES Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. 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.
  • Page 59: California Emission Control Warranty Statement

    VEHICLE WARRANTIES - CALIFORNIA CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and E-Z-GO are pleased to explain the evaporative emission control system warranty on your 2010 vehicle. In California, new vehicles must be designed, built and equipped to meet the State’s stringent anti-smog standards.
  • Page 60: Vehicle Dimensions

    VEHICLE WARRANTIES - CALIFORNIA (3) Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part. If the part fails before the first scheduled replacement, the part will be repaired or replaced by ABC, Inc.
  • Page 61: Vehicle Dimensions (Continued)

    VEHICLE WARRANTIES - FEDERAL FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Kawasaki Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
  • Page 62: Vehicle Incline Specifications And Turning Clearance Diameter

    VEHICLE WARRANTIES Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 63 Be sure that no loose clothing or hair can contact moving parts. Use care not to touch hot objects. Check area behind the vehicle before Raise entire vehicle and support on jack stands operating in reverse. before attempting to run or adjust power train. Make sure the direction selector is in correct Wear eye protection when working on or position before attempting to start the vehicle.
  • Page 64 E-Z-GO Division Of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 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: 001-706-798-4311, FAX: 001-706-771-4609  2011 E-Z-GO Division of Textron Inc. This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc.

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