Table Of Contents - Ezgo WorkHorse ST 480 Technician's Repair And Service Manual

Table of Contents

Safety2
Notes, Cautions And Warnings2
Notes4
Table Of Contents5
Safety Information7
General7
General Operation7
Maintenance8
Ventilation9
General Information & Routine Maintenance11
Serial Number Plate Location13
Servicing The Vehicle13
Starting The Vehicle With A Discahrged Battery13
Towing14
Neutral Lock14
Routine Maintenance14
Powertrain Maintenance14
Brakes15
Tires15
Care And Cleaning Of The Vehicle15
Vehicle Care Products15
Top And Windshield16
Trailering16
Prolonged Storage16
Hardware17
Torque Specifications17
Bolt Grades17
Periodic Service Schedule18
8 Hours Or Daily18
25 Hours18
50 Hours18
100 Hours19
250-300 Hours Or Yearly19
500 Hours20
General Safety Practices23
Stability23
Fuel Handling And Storage23
Lighting For Operating Areas23
Operating Safety Rules And Practices24
Control Of Noxious Gases And Fumes24
Warning Device24
Personnel And Burden Carrier Operator Responsibility24
Maintenance Practices25
Traveling25
Loading25
Operator Care Of Personnel And Burden Carriers25
Maintenance Procedures26
Important Safety Warning27
Modifications To Vehicle27
General Maintenance27
Before Servicing The Vehicle28
Battery Removal And Installation29
Lifting The Vehicle29
Body And Truckbed31
Component Replacement33
Drill Out Metal Rivet33
Drive Rivet Removal33
Instrument Panel Replacement34
Tool List34
Cowl Replacement35
Front Bumper Replacement35
Rocker Panel Replacement36
Seat Bottom Replacement36
Seat Back Replacement36
Seat Components36
Body Components (Rear)37
Seat Support Panel Replacement38
Seat Filler Panel Replacement38
Side Panel Replacement38
Electric Lift Toggle Switch And Winch Receptacle38
Rear Fender Replacement39
Rear Panel Replacement39
Truck Bed Replacement39
Electric Lift Actuator39
Truckbed Components40
Hitches41
Hydraulic Brake System Components45
Part Of Frame45
How The Hydraulic System Works46
Daily Brake Performance Test46
Wheel Brake46
Brake System Inspection46
Master Cylinder47
Brake Fluid47
Master Cylinder Replacement47
Replacing Master Cylinder47
Brake Linkage48
Brake Pedal Bumper Adjustment48
Tool List Qty. Required48
Wrench, 9/1648
Teflon Tape48
Crowfoot Wrench, 1", 3/8" Drive48
Torque Wrench, In. Lbs., 3/8" Drive48
Lock Nut48
Brake Drum Removal And Installation49
Linkage Adjustment49
Factory Settings Before Adjustment49
Wheel Brake Components50
Wheel Brake Service51
Cleaning And Inspection51
Socket, 7/16", 3/8" Drive51
Socket, 9/16", 3/8" Drive51
Replacing An Adjuster52
Belleville Washer Installation52
Wheel Brake Assembly Replacement53
Bleeding And Flushing53
Bleeding Sequence53
Brake Pedal Removal And Installation54
Bleeder Valve54
Flushing54
Parking Brake55
Cable Replacement55
Parking Brake System Components56
Continuously Variable Transmission57
Clutches59
Drive Clutch59
Driven Clutch59
Increased Load60
Equilibrium60
Drive Clutch Removal60
Cvt Components60
Drive Clutch Installation61
Driven Clutch Removal61
Driven Clutch Repair61
Torque Ramp Buttons61
Storage62
Driven Clutch Installation62
Drive Belt Service62
Removing The Drive Belt62
Direction Selector63
Removing Direction Selector65
Direction Selector Components65
Replacing The Reverse Warning Buzzer66
Shift Cable Adjustment66
Replacing A Micro Switch66
Electrical67
Electrical System Components69
Circuits And Controls70
Electrical Plate Assembly70
Starter/Generator71
Digital Volt Ohm Meter71
Starter Mode71
Generator Mode71
Testing Charging Circuit72
Starting And Charging System Wiring Diagram73
Starter/Generator Disassembly74
Starter/Generator Inspection75
Starter/Generator Brush Removal75
Bearing Removal75
Battery Voltage Test75
Storage Of Battery76
Troubleshooting76
Power Supply76
Check For Loose Or Bare Wires76
Accessory Wiring Diagram77
Accessory Wiring78
Light Bulb Replacement78
Check Power Wire78
Check Fuse78
Horn And Fuse Block79
Headlight, Turn Signal And Taillight81
Hour Meter82
Engine83
Power Train Maintenance86
Removing Debris86
Oil Capacity86
Oil Recommendations86
Changing The Oil87
Cleaning The Top Of The Engine87
Clean Entire Dipstick87
Check Oil Level On Dipstick87
Air Cleaner Maintenance88
Starter/Generator Belt Tension88
Pre-Cleaner Service88
Cartridge Service88
Spark Plugs89
Adjusting Belt Tension89
Checking Belt Tension With Finger89
Gapping The Spark Plug89
Engine Description90
Vehicle Preparation To Test Engine Condition90
Engine Specifications90
Engine Operation90
Engine Removal91
Disconnect Accelerator, Governor, And Choke Cables91
Disconnect Differential Lock Cable92
Engine Installation93
Disconnect White Engine Stop Wire93
Ignition Control Module And Fuel Line93
Disconnect Starter And Ground Cables93
Starter/Generator Removal94
Starter/Generator Installation94
Starter/Generator Mounting95
Starter/Generator Wiring95
Front Suspension And Steering97
Front Suspension99
Front Shock Absorber Replacement99
Shock Boot Removal And Replacement99
Front Axle Replacement99
Front Spring Replacement100
Suspension Components100
Front Axle Alignment100
Tie Rod, Wheel Bearing And King Pin Inspection101
Tie Rod Replacement101
Steering102
Steering Wheel Replacement102
Steering Shaft Replacement102
Hub Cover Removal102
Steering Housing Assembly Replacement103
Steering Components103
Idler Arm Replacement104
Rack Tensioner Replacement104
Rack Replacement104
Rack Ball Joint Removal104
Rack Ball Joint Installation105
Lubrication105
Steering Pinion And Bearing Replacement105
Wheel Bearing Inspection/Packing105
Seal Installation106
Bearing Adjustment106
Lubrication Points106
Wheel Bearing Replacement106
King Pin Bushing Replacement107
Wheel Alignment107
Front Spindle And Bearing107
Front End Alignment108
Fuel System109
Fuel System Components111
Fuel112
Fuel System Component Service And Replacement112
Fuel Tank Location112
Fuel Lines And Filters113
Fuel Pump113
Fuel Tank113
Choke System113
Choke Cable Installation And Adjustment114
Carburetor114
Paint115
Painting117
Minot Scratches117
Complete Panel Repair117
Larger Scratches117
Rear Axle And Suspension119
Rear Axle Maintenance121
Checking The Lubricant Level121
Rear Axle And Suspension Components121
Differential Lock Cable Adjustment122
Rear Axle Removal122
Check, Add Or Drain Rear Axle Lubricant122
Disconnect Parking Brake Cables123
Disconnect Brake Lines123
Rear Axle Installation124
Disconnect Accelerator Cable And Governor124
Disconnect Direction Selector Cables124
Detach Differential Link124
Rear Suspension125
Shock Absorber Removal125
Shock Absorber Installation125
Rear Spring Removal125
Speed Control127
Accelerator, Governor And Carburetor Linkage129
Governor Operation129
General Cable Adjustment Procedure130
Accelerator/Governor Cable Adjustment130
Cable Adjustment130
Pedal Box Adjustments131
Accelerator Pedal Arm Adjustment131
Micro Switch Adjustment131
Access To Pedal Box131
Control Arm Link132
Accelerator Linkage132
Governor Compression Spring Adjustment133
Road Test133
Gasoline Vehicle Performance137
Weather Protection143
Sun Top145
Rear Strut Installation145
Front Strut Installation145
Sun Top Installation145
Fold Down Windshield147
One-Piece Windshield148
Wheels And Tires149
Wheel And Tire Service151
Tire Repair151
Wheel Installation151
Standard Equipment155
Options/Accessories155
Vehicle Dimensions156
Vehicle Incline Specifications And Turning Clearance Diameter157
Intersecting Aisle Clearance158