Ezgo ST SPORT 2+2 Service Manual
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Ezgo ST SPORT 2+2 Service Manual

Ezgo ST SPORT 2+2 Service Manual

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OWNER'S MANUAL
&
SERVICE GUIDE
ST SPORT 2+2

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Summary of Contents for Ezgo ST SPORT 2+2

  • Page 1 OWNER'S MANUAL & SERVICE GUIDE ST SPORT 2+2...

  • Page 2: Safety

    SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact a represen- tative 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 pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground (See GENERAL SPECIFICATIONS).
  • Page 3 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 E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852 Owner’s Manual and Service Guide...

  • 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 ......................vii WELCOME ..........................1 BEFORE INITIAL USE ......................1 Fig. 1 Initial Service Chart ......................1 PORTABLE CHARGER INSTALLATION ................. 2 Fig. 2 Proper Charger Installation .....................2 Fig.
  • Page 6 TABLE OF CONTENTS ENVIRONMENTAL CONCERNS ........................10 REPAIR ............................ 11 LIFTING THE VEHICLE ............................ 11 Fig. 13 Lifting the Vehicle ....................... 11 WHEELS AND TIRES ......................11 TIRE INSPECTION ............................11 TIRE REPAIR ..............................11 WHEEL INSTALLATION ........................... 12 Fig. 14 Wheel Installation ....................... 12 UNIDIRECTIONAL TIRES ..........................
  • Page 7 TABLE OF CONTENTS USING A HYDROMETER ..........................24 Fig. 31 Hydrometer Temperature Correction ................25 BATTERY CHARGER MAINTENANCE ......................25 PROLONGED STORAGE ....................... 25 Fig. 32 Freezing Point of Electrolyte ..................25 GENERAL SPECIFICATIONS....................27 Fig. 33 Vehicle Dimensions andVehicle Incline Specifications..........29 Fig. 34 Turning Clearance Diameter..................30 VEHICLE WARRANTIES ......................
  • Page 8 TABLE OF CONTENTS Notes: Owner’s Manual and Service Guide Page vi...

  • Page 9: Safety Information

    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-Z- GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph.

  • Page 10: General Operation

    SAFETY INFORMATION 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.
  • Page 11 SAFETY INFORMATION 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.
  • Page 12 SAFETY INFORMATION Notes: Owner’s Manual and Service Guide Page x...

  • Page 13: General Safety Practices

    SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL manual without the manufacturer’s prior written authori- zation. Where authorized modifications have been made, The following text is provided as recommended by part II the user shall ensure that capacity, operation, warning, of ASME/ANSI B56.8-1988.
  • Page 14 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Control of Noxious Gases and Fumes turer; 4.8.1 When equipment powered by internal com- (b) emphasis on safety of passengers, material loads, bustion engines is used in enclosed areas, the atmo- carrier operator, and other employees;...
  • Page 15 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 5.4.9 Carriers shall not be parked or left unattended smooth, sweeping motion. such that they block or obstruct fire aisles, access to Loading stairways, or fire equipment.
  • Page 16 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Maintenance Procedures prevent the use of the carrier until the leak has been eliminated. 6.2.1 Maintenance and inspection of all carriers The carrier manufacturer’s capacity, operation, shall be performed in conformance with the manufac- and maintenance instruction plates, tags, or decals shall...

  • Page 17: Welcome

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Thank you for purchasing this vehicle. Before driving the Hydrogen gas is generated as a natural part of the vehicle, we ask you to spend some time reading this lead acid battery charging process.

  • Page 18: Portable Charger Installation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PORTABLE CHARGER batteries are fully charged and the DC plug can be removed to permit use of the vehicle. INSTALLATION Looping the DC cord through the steering To prevent overheating...

  • Page 19: State Of Charge Meter

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings is ‘ON’ and park brake is set, depressing the accelerator inadvertently will release the park brake and will cause Key/Light Switch the vehicle to move which could cause severe injury or State of Charge Meter...

  • Page 20: Load Bed

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LOAD BED To reduce the possibility of severe injury or death, read, understand and fol- low the Danger label affixed to the front of the load bed.

  • Page 21: Seating

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings SEATING VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER To prevent severe injury or death, rear seat pas- sengers should hold on to both the hip restraints and the rear hand hold when the vehicle is in motion.

  • Page 22: Operating The Vehicle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings OPERATING THE VEHICLE Make sure that the direction selector is in correct position before attempting to start the vehicle. Improper use of the vehicle or the lack Always bring the vehicle to a complete stop of proper maintenance may result in...

  • Page 23: Starting The Vehicle On A Hill

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • Slowly depress the accelerator pedal to start the VEHICLE CAPACITY motor. Release service brake when motor starts. Due to the variety of •...

  • Page 24: Fig. 10 Load Bed Configurations And Capacities

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CONVERTIBLE CARRIER (Rear Facing Seat/Cargo Deck) 2 Persons. or Cargo not to exceed 200 Lbs (90 kg) Maximum Vehicle Capacity 800 lbs.
  • Page 25 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Clean windshield with lots of water and a clean cloth. Occasional cleaning and waxing with non-abrasive prod- ucts designed for ‘clear coat’...

  • Page 26: Common Sense Operation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings COMMON SENSE OPERATION Slow down when in unfamiliar terrain. Slow down when cresting a hill in an area that you are unfamiliar with. To prevent severe injury Some hills are too steep to climb.

  • Page 27: Repair

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings REPAIR Use extreme care since the vehicle is extremely unstable during the lifting process. LIFTING THE VEHICLE When lifting vehicle, position jacks and Tool List Qty.

  • Page 28: Wheel Installation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To reduce the possibility of severe injury caused by a WHEEL INSTALLATION broken socket when removing wheels, use only sock- To reduce the possibility of component ets designed for impact wrench use.

  • Page 29: Light Bulb Replacement

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LIGHT BULB REPLACEMENT Roll Rubber To reduce the possibility of premature Bezel Away From Body bulb failure, do not touch new bulbs with bare fingers.

  • Page 30: Service And Maintenance

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Always remove windshield before transporting. which can cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and Maximum speed with sun top installed is 50 eyes with extended flushing with clear water.

  • Page 31: Periodic Service Schedule

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE Lift Flap on Access Panel To prolong vehicle life, some mainte- nance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures, Serial Number extreme dust/debris conditions, frequent use with maximum...

  • Page 32: Tire Inspection

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PARK BRAKE Check brake performance and adjust if required DIRECTION SELECTOR Check attachment, tighten if required STEERING ASSEMBLY Check for abnormal play, tightness of all hardware TIE ROD/LINKAGES...

  • Page 33: Periodic Brake Test For Mechanical Brakes

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Establish the acceptable stopping distance by testing a new or ‘known to be good’ vehicle and recording the Dry, Level, Clean, Paved Surface stopping location or stopping distance.

  • Page 34: Capacities And Replacement Parts

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CAPACITIES AND REPLACEMENT PARTS Rear Axle Oil 40 oz (1.2 liters) 15 amp (P/N 18392-G1) Fuse P/N 20209-G2 Headlight Sealed Beam P/N 19180-G2...

  • Page 35: Hardware

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HARDWARE torque values. Generally, three grades of hardware are used in the vehi- Periodically, the vehicle should be inspected for loose cle.

  • Page 36: Batteries And Charging

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings BATTERIES AND CHARGING Wrap wrenches with vinyl tape to prevent the possibility of a SAFETY Ref Isl 1S dropped wrench from ‘shorting out’...

  • Page 37: Monthly

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings MONTHLY loss will weaken the concentration of acid within the elec- trolyte and reduce the life of the battery. •...

  • Page 38: Battery Cleaning

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Even if the water is colorless, odorless, tasteless and fit for drinking, the water should be analyzed to see that it 1 1/2 gallons 1 quart does not exceed the impurity levels specified in the table.

  • Page 39: Volt System Battery Connections

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • To prevent battery explo- The charger connector is fully inserted into the sion that could result in vehicle receptacle.

  • Page 40: Hydrometer

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HYDROMETER Do not perform a hydrometer test on a battery that has just been watered. The battery must A hydrometer (P/N 50900-G1) is used to test the state of go through at least one charge and discharge cycle in order to charge of a battery cell (Ref.

  • Page 41: Battery Charger Maintenance

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings and replaced with a good battery of the same brand, type When it reaches 1.240, which it will do in less than and approximate age.
  • Page 42 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Owner’s Manual and Service Guide Page 26...

  • Page 43: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 27...
  • Page 44 GENERAL SPECIFICATIONS ST MODEL SPORT 2+2 STANDARD EQUIPMENT: CHASSIS Welded Tubular Steel; Powder Coated (DuraShield™) BODY Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer) with Base Coat/Clear Coat BATTERIES 36 VDC, six 6 volt deep cycle (105 Minute Minimum, 220 Amp-Hour @ 20 Hour Discharge Rate) SPEED CONTROLLER Solid State, 300 Amp Capacity with Non-Contact Inductive Throttle Sensor MOTOR...
  • Page 45 Rear 38 in (96 cm) 46.5 in Front (118 cm) 38.5" (97 cm) ST SPORT 2+2 RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 Fig. 33 Vehicle Dimensions and Incline Specifications Owner’s Manual and Service Guide...

  • Page 46: Fig. 34 Turning Clearance Diameter

    GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER ST SPORT 2+2 20.5 ft (6.3 m) Fig. 34 Turning Clearance Diameter Owner’s Manual and Service Guide Page 30...

  • Page 47: Vehicle Warranties

    VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 31...

  • Page 48: Domestic Warranty

    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. Owner’s Manual and Service Guide Page 32...

  • Page 49: International Warranty (2005)

    VEHICLE WARRANTIES 2005 INTERNATIONAL WARRANTY (ALL COUNTRIES OUTSIDE THE U.S. AND CANADA) The E-Z-GO DIVISION OF TEXTRON, INC. (“E-Z-GO”) warrants to the Original Retail Purchaser or the Origi- nal Retail Lessee that any 2005 E-Z-GO vehicle and/or Battery Charger shall be free from any defects in material or workmanship for one year from the date of installation at the customer’s location with respect to parts and labor.
  • Page 50 VEHICLE WARRANTIES Notes: Owner’s Manual and Service Guide Page 34...

  • Page 51: Declaration Of Conformity (Europe Only)

    DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Declaration of Conformity is packaged with vehicle. For additional information, contact: Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, England, IP3 9TT Owner’s Manual and Service Guide Page 35...
  • Page 52 DECLARATION OF CONFORMITY Notes: Owner’s Manual and Service Guide Page 36...

  • Page 53: Labels And Pictograms

    LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
  • Page 54 LABELS AND PICTOGRAMS Notes: Owner’s Manual and Service Guide Appendix A - 2...
  • Page 55 LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
  • Page 56 LABELS AND PICTOGRAMS Notes: Owner’s Manual and Service Guide Appendix A - 2...
  • Page 57 LABELS AND PICTOGRAMS 35962G01 Gas 35964G01 Electric 35962-G01 71129-G02 71129G02 Electric 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 71131G01 Gas FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY WARNING...
  • Page 58 LABELS AND PICTOGRAMS WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD xxx lbs . AS POSSIBLE. MAXIMUM LOAD xxx kg BED CAPACITY WARNING USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE...
  • Page 59 LABELS AND PICTOGRAMS WARNING LETHAL VOLTAGE CLEAN UP GASOLINE SPILLS WITHWATER BEFORE STARTING ENGINE DO NOT EXPOSE UNLEAD TO FLAME GASOLINE DO NOT DO NOT DISPOSE OF SPILL FUEL BATTERIES ON A HOT IN LANDFILL ENGINE GROUND DO NOT FUEL PUMP DRIVE ON HIGHWAY LOW OIL PRESSURE...
  • Page 60 LABELS AND PICTOGRAMS KEEP CLEAR OPERATE HAND OR FROM FINGERS CAN DRIVERS SIDE BE TRAPPED ONLY POSITION KEEP ARMS AND LEGS WITHIN VEHICLE POSITION HEADLIGHTS TO OPERATE VEHICLE IN FORWARD: ✱ TURN KEY TO ON UNLOCKED ✱ MOVE DIRECTION SELECTOR TO FORWARD ✱...
  • Page 61 LABELS AND PICTOGRAMS WARNING READ OWNER'S MANUAL AUXILIARY LIGHTS BEFORE OPERATING VEHICLE IN FORWARD OR REVERSE WARNING HORN BUTTON READ OWNER'S MANUAL BEFORE PARKING VEHICLE AND LEAVING IT UNATTENDED FORWARD NEUTRAL REVERSE WARNING READ OWNER'S MANUAL BEFORE ENGAGING TWO OR FOUR WHEEL DRIVE PUSH TOP OF SWITCH TO LOCK DIFFERENTIAL PUSH BOTTOM OF...
  • Page 62 LABELS AND PICTOGRAMS Notes: Owner’s Manual and Service Guide Appendix A - 8...
  • Page 63 Read and understand the following warnings Read and understand the following text and before attempting to operate the vehicle: 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. prevent personal It is virtually impossible to anticipate all possible compo-...
  • Page 64 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: 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.

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