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EZ-GO ST 4X4 Technician's Repair And Service Manual

Gasoline powered 4 wheel drive utility vehicle
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600392
TECHNICIAN'S
REPAIR AND SERVICE MANUAL
Ref Fcv 19
ST 4X4
GASOLINE POWERED 4 WHEEL DRIVE
UTILITY VEHICLE
STARTING MODEL YEAR: 2004

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Summary of Contents for EZ-GO ST 4X4

  • Page 1 600392 TECHNICIAN’S REPAIR AND SERVICE MANUAL Ref Fcv 19 ST 4X4 GASOLINE POWERED 4 WHEEL DRIVE UTILITY VEHICLE STARTING MODEL YEAR: 2004...
  • Page 2 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.
  • Page 3 GASOLINE POWERED 4 WHEEL DRIVE UTILITY VEHICLE ST 4X4 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 informa- tion contained in this manual is subject to change without notice.
  • Page 4 NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE Safety ........................... Inside Covers Notes ..............................ii Safety Information ..........................v TITLE SECTION General Information & Routine Maintenance ...................A Safety ...............................B Body and Truckbed ..........................C Brakes ..............................D Continuously Variable Transmission (CVT)..................E Direction and Drive Selector......................F Electrical............................

  • Page 6: Notes

    TABLE OF CONTENTS Notes: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    SAFETY INFORMATION 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. To reduce the chance of personal injury or property damage, the following must be carefully observed: GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle;...
  • Page 8 SAFETY INFORMATION • Apply service brake to control speed on steep grades. • Maintain adequate distance between vehicles. • Reduce speed in wet areas. • Use extreme caution when approaching sharp or blind turns. • Use extreme caution when driving over loose terrain. •...
  • Page 9 SAFETY INFORMATION 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 water heaters and furnaces.
  • Page 10 SAFETY INFORMATION Notes: Repair and Service Manual Page viii...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. SERIAL AND MANUFACTURING NUMBER LABEL LOCATIONS..........A - 1 SERVICING THE VEHICLE ......................A - 1 TOWING............................A - 2 JUMP STARTING ..........................A - 2 ROUTINE MAINTENANCE ......................A - 3 POWERTRAIN MAINTENANCE......................A - 3 NEUTRAL POSITION ........................A - 3 BRAKES............................A - 4...
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE Notes: Repair and Service Manual Page A-ii...

  • Page 13: Serial And Manufacturing Number Label Locations

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Serial No. & Mfg No. (Stamped) Serial No. & Mfg No. (Label) Supplemental Information label Serial No.

  • Page 14: Fig. 2 Initial Service Chart

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Wear eye protection when working on the vehicle. In particular, use care ITEM SERVICE OPERATION when working around batteries, or using solvents or compressed air.

  • Page 15: Jump Starting

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings spark plug wires and disconnect battery at negative terminal before servicing. Access the powertrain by raising or removing seats. Full access to powertrain may be obtained by raising the load bed.

  • Page 16: Care And Cleaning Of The Vehicle

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BRAKES Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a To prevent severe per- sponge or soft brush and wipe with a damp cloth.

  • Page 17: Top And Windshield (If Equipped)

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings moisture, sealing against future moisture return. vehicle. The rated capacity of the trailer must exceed the (P/N 75503-G01) weight of the vehicle (see GENERAL SPECIFICATIONS •...
  • Page 18 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings • Remove spark plugs 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.

  • Page 19: Capacities

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 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.

  • Page 20: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE. BEFORE EVERY EVERY EVERY EVERY EVERY EVERY EACH ITEM WEEKLY HOURS HOURS HOURS HOURS...

  • Page 21: Fig. 7 Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BEFORE EVERY EVERY EVERY EVERY EVERY EVERY EACH ITEM WEEKLY HOURS HOURS HOURS HOURS HOURS HOURS Tie Rods/Linkages...
  • Page 22 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page A-10...

  • Page 23: Safety

    SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. LIST OF ILLUSTRATIONS GENERAL ............................B - 1 NOTES, CAUTIONS AND WARNINGS ...................B - 5 IMPORTANT SAFETY WARNING....................B - 5 MODIFICATIONS TO VEHICLE ......................B - 5 GENERAL MAINTENANCE ......................B - 5 BEFORE SERVICING THE VEHICLE .....................B - 6 BATTERY REMOVAL AND INSTALLATION ...................B - 7 Fig.
  • Page 24 SAFETY Notes: Repair and Service Manual Page B-ii...

  • Page 25: General

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL B.1.1.1.4 The controlling party shall train vehicle operators to adhere strictly to the operating instructions The following text is provided as recommended by part II stated in vehicle operator's manual and those additional of SAE J2258 DEC 2003.
  • Page 26 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings B.1.1.4.2 The controlling party shall supervise the B.2 Operating Safety Rules and handling of liquefied petroleum gas fuels (when used) to Practices be certain it is in accordance with appropriate sections of ANSI/NFPA 505 and ANSI/NFPA 58 or as required by...
  • Page 27 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings B.2.3.4 Riding on the vehicle by persons other than B.2.4.4 Avoid material loads exceeding the physical the operator is authorized only on seat(s) provided by the dimensions of the vehicle or as specified by the vehicle vehicle manufacturer.
  • Page 28 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings equipped, is closed, following vehicle manufacturer's rec- Hydraulic systems, if so equipped, shall be ommended practice. checked for leaks and condition of parts. Keep body and hands away from pin hole leaks or nozzles that eject (e) Before disconnecting any part of the fuel system of hydraulic fluid under high pressure.

  • Page 29: Notes, Cautions And Warnings

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings NOTES, CAUTIONS AND WARNINGS battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders if Throughout this manual, the following NOTES, CAU- not treated with utmost caution.

  • Page 30: Before Servicing The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BEFORE SERVICING THE VEHICLE grounded spark plug. If the spark function is to be observed at the spark Before attempting to inspect or service a vehicle, be sure plug, be sure to install a spare spark plug into the to read and understand the following warnings:...

  • Page 31: Battery Removal And Installation

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BATTERY REMOVAL AND INSTALLATION To prevent severe per- sonal injury or death, resulting from a battery explosion: Aerosol containers of battery protectant must be used with extreme care.

  • Page 32: Lifting The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings LIFTING THE VEHICLE To prevent possible inju- Center of ry or death resulting Front Axle from a vehicle falling from a jack, be sure the vehicle is on a firm and level surface.

  • Page 33: Body And Truckbed

    BODY AND TRUCKBED TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. COMPONENT REPLACEMENT ..................... C - 1 Seat Bottom Replacement....................C - 1 Seat Back Replacement ....................... C - 1 Gas Spring Replacement ..................... C - 1 Light Guard Side Replacement .................... C - 2 Front Brush Guard Replacement..................
  • Page 34 BODY AND TRUCKBED Notes: Repair and Service Manual Page C-ii...

  • Page 35: Seat Bottom Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U %1/210'06 4'2.#%'/'06 Seat Bottom Replacement Tool List...

  • Page 36: Light Guard Side Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Fig.

  • Page 37: Front Brush Guard Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Fig.

  • Page 38: Rear Hitch Receiver Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Tighten the hardware per torque specification table given below.

  • Page 39: Cowl Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Fig.

  • Page 40: Instrument Panel Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Fig.
  • Page 41 BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Fig.

  • Page 42: Rocker Panel Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Torx bit screwdriver T- 45..........

  • Page 43: Seat Panel (Passenger Side) Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Installation of seat panel (passenger side) is reverse of disassembly.

  • Page 44: Seat Support Panel Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Installation of seat panel (driver side) is reverse of disas- sembly.

  • Page 45: Rear Fender Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U To Carburetor Fig.

  • Page 46: Lower Side Panel Replacement

    BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Lower Side Panel Replacement Front Fender Well Replacement 6JG HTQPV HGPFGT YGNN...
  • Page 47 BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U the cowl assembly (Ref Cowl Replacement Section on Tighten the hardware per torque specification table given page C-5).
  • Page 48 BODY AND TRUCKBED G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Fig.

  • Page 49: Brakes

    BRAKES TABLE OF CONTENTS FOR SECTION ‘D’ SECTION TITLE PAGE NO. GENERAL ............................D - 2 How The Hydraulic System Works ..................D - 2 Rear Wheel Brake ........................ D - 2 Front Disc Brake........................D - 2 MAINTENANCE ..........................D - 2 Daily Brake Performance Test....................
  • Page 50 BRAKES Notes: Repair and Service Manual Page D-ii...
  • Page 51 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Master Cylinder Clevis Yoke Extension Spring Brake Pedal Mounts To Frame To Passenger Side Caliper Rotor Mounts To Frame Rear Brake Line Front Brake...

  • Page 52: General

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL Brake adjustment is automatic (Ref Fig. 2 on page D-3). Adjustment takes place, if needed, whenever the brakes How The Hydraulic System Works are applied (forward or reverse stop or when the vehicle is stationary).

  • Page 53: Brake System Inspection

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Wheel Cylinder New Brake Shoes Installed: Adjusters Set to Neutral Position. Backing Plate Torx Bolt Brake Shoe Tube Frame Brake Springs Washer...

  • Page 54: Master Cylinder

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings The hydraulic system may be checked for leaks by Hydraulic brake systems must be totally flushed if the fluid becomes contaminated with applying pressure to the pedal gradually and steadily.

  • Page 55: Brake Drum Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Teflon tape............... A/R (item 7) is not fastened to master cylinder (item 1). Remove the master cylinder (item 1) from the vehicle. Installation of a new master cylinder is the reverse of dis- assembly using new lock nuts.

  • Page 56: Brakes

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Do not apply the brake when removing the WHEEL BRAKE SERVICE AND wheel lug nuts; the shoes may not fully retract REPLACEMENT preventing removal of the brake drum.
  • Page 57 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Grease ..............A/R 1/2" socket and extension. Pull the brake assembly (item 8) and rear axle shaft (item 9) out from the axle tube High temperature lubricant........
  • Page 58 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings A backing plate assembly that shows any indication (item 18), and to anchor. Position the adjusters (item 17) of galling or gouging is not repairable and must be so that the pins (item 18) are at the 12 o'clock position.

  • Page 59: Front Disc Brake Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Tighten the hardware and brake lines per torque specifi- Adjustment cation table given below. After the brake system has been bled, make 3 to 10 for- ward and reverse stops by applying firm pressure to the ITEM NO TORQUE SPECIFICATION...

  • Page 60: Disc Brake Pad Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Torque wrench, 1/2" drive, 165 ft. lbs capacity ....1 Impact socket, 3/4", 1/2" drive ........1 Allen wrench, 9 mm, 3/8" drive ........1 Needle nose pliers ............1 Park the vehicle on a level surface, engage park brake.

  • Page 61: Disc Brake Rotor Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Tighten the hardware per torque specification table Park the vehicle on a level surface, engage park brake. below. Loosen the four nuts on the front wheels half turn.

  • Page 62: Bleeding Sequence

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings insure that air cannot enter the system. It is also important that the brake pedal be returned to full ‘up’ position. Bleeder Valve Bleed at each wheel cylinder in succession, beginning...

  • Page 63: Brake Pedal Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BRAKE PEDAL REPLACEMENT To prevent severe injury or death resulting from a battery explosion: The battery negative (-) cable must be removed using insulated wrench before removing brake pedal from vehicle.

  • Page 64: Cable Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 13 Parking Brake With the parking brake fully released, the clevis pins Tighten spherical nut (item 7) and nut (item 6) firmly (item 2) at the parking brake lever should either be loose against equalizer bracket to secure or only under light spring pressure.
  • Page 65 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings The parking brake to equalizer cable may require replacement if it shows signs of wear. Cable replacement consists of first removing the wire tie securing the rubber boot to the parking brake (item 1).
  • Page 66 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page D-16...

  • Page 67: Continuously Variable Transmission (Cvt)

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. GENERAL ............................E - 1 CLUTCHES ............................E - 1 Drive Clutch ...........................E - 1 Driven Clutch .........................E - 1 Increased Load........................E - 2 Equilibrium..........................E - 2 Drive Clutch Replacement.....................E - 2 Driven Clutch Replacement....................E - 3 DRIVE BELT ............................E - 4 Removing the Drive Belt......................E - 4...
  • Page 68 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Notes: Repair and Service Manual Page E-ii...

  • Page 69: General

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Drive Belt Driven Clutch Drive Clutch CVT Cover Fig. 1 Continuously Variable Transmission System (CVT) GENERAL sheaves close, the driven clutch sheaves are forced open by the belt as it rises in the drive clutch.

  • Page 70: Increased Load

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings As the drive belt starts to rotate, the driven clutch starts to To prevent serious personal injury or death, use only sockets designed for use with an impact rotate.
  • Page 71 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 2 CVT Components Driven Clutch Replacement Installation of the driven clutch is the reverse of disas- sembly.

  • Page 72: Driven Clutch Replacement

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings DRIVE BELT Drive Belt Service The drive belt will require no service unless the vehicle Removing the Drive Belt has been operated in an extremely dusty or muddy loca- With the vehicle on level ground, remove the drive belt by...

  • Page 73: Direction And Drive Selector

    DIRECTION AND DRIVE SELECTOR TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. GENERAL ............................F- 2 Direction And Drive Selector Cables Adjustment ..............F- 2 DIRECTION SELECTOR .........................F - 3 Direction Selector Replacement ....................F - 3 DRIVE SELECTOR ..........................F - 3 Drive Selector Replacement....................F - 3 Proximity Sensor Switch Replacement..................F - 4 LIST OF ILLUSTRATIONS...
  • Page 74 DIRECTION AND DRIVE SELECTOR Notes: Repair and Service Manual Page F-ii...
  • Page 75 DIRECTION AND DRIVE SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Direction Selector Handle Knob Drive Selector Handle Drive Selector Cable Rivet Direction Selector Cable Proximity Sensor Switch Label Hand Control Cover Plate...
  • Page 76 DIRECTION AND DRIVE SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL The cable length can be adjusted (increased/decreased) at it’s mounting bracket. This is accomplished by moving Always observe the following warnings when the cable housing forward or backward at the bracket working on or near batteries:...
  • Page 77 DIRECTION AND DRIVE SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Pull Fig. 3 Removal Of Cable From Ball Joint DIRECTION SELECTOR Direction Selector Replacement Fig. 4 Direction Selector Replacement To prevent serious per- Tighten the hardware per torque specification table sonal injury or death...
  • Page 78 DIRECTION AND DRIVE SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Raise the cowl and latch the support. Unscrew and indicate 00.0 and the audible device will sound, indicat- remove the knob (item 1) from the direction selector han- ing continuity.

  • Page 79: Electrical

    ELECTRICAL TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. CIRCUITS AND CONTROLS......................G - 2 STARTING ............................G - 2 CHARGE COIL/ALTERNATOR ...................... G - 2 DIGITAL VOLT OHM METER (DVOM)................... G - 2 TESTING IGNITION CIRCUIT ......................G - 3 TESTING THE IGNITION COIL ......................
  • Page 80 ELECTRICAL Notes: Repair and Service Manual Page G-ii...
  • Page 81 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 1 Electrical System Circuit Repair and Service Manual Page G-1...

  • Page 82: Circuits And Controls

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings CIRCUITS AND CONTROLS 2) The fuel shut off solenoid opens and permits fuel to flow to the carburetor main jet. To prevent severe per- 3) The magneto ground is opened, allowing the sonal injury or death...

  • Page 83: Testing Ignition Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings This section assumes the fuel system is func- tioning and that the engine is receiving fuel. Tool List Qty.

  • Page 84: Testing Starting Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings meter should be “0” Ω with the switch key in the ‘ON’ TESTING STARTING CIRCUIT position and OL with the switch in the ‘OFF’ position. To prevent the possibili- If the meter does not register, replace the switch.

  • Page 85: Testing Charging Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Battery voltage can be checked using a voltmeter (Ref connected, the accessory alternator is checked in the Fig. 3 on page G-5). Attach the negative (-) lead of the same way as the charge coil.

  • Page 86: Storage Of Battery

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings STORAGE OF BATTERY ing out to the device that is not working. Be sure to check both sides of all switches and fuses. A battery that is removed from service for storage must When no battery voltage is found, the problem lies be cared for as follows:...

  • Page 87: Accessory Wiring

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Check power wire The Fuel Gauge Sending unit test is described in the ‘FUEL SYSTEM’. If the sending unit and the wiring from The white power wire supplies power to the the unit to the instrument cluster connector is satisfac- entire fuse block.

  • Page 88: Fuel Cut Solenoid

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings FUEL CUT SOLENOID page G-10). If the switch is good, check that the wire har- ness does not have an internal break. The fuel cut solenoid is located in the carburetor and shuts off the flow of fuel to the carburetor main jet when TAILLIGHT (ACCESSORY)
  • Page 89 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Packard Connector From Harness o Head light RED/YEL 25Amp Fuse INSTRUMENT CLUSTER RED/WHT #10 GA. WHT FUSE BLOCK Fig.
  • Page 90 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings KEY SWITCH YEL To "I" 12V OUTLET On Key Switch BLK To "M1" On Key Switch RED/WHT To "M2"...
  • Page 91 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 2-Pin Connector From Harness To Neutral Switch Fig. 6 Neutral Switch And Fuel Sending Unit Repair and Service Manual Page G-11...
  • Page 92 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 3 Pin Connector To Rear Differential DRIVER SIDE FRONT OF VEHICLE 3 Pin Connector To Front Differential Fig. 7 Differential Lock Solenoids DRIVER SIDE DRIVER SIDE BEHIND SIDE...

  • Page 93: Engine And Transmission

    ENGINE AND TRANSMISSION TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. POWERTRAIN MAINTENANCE..................... H - 2 Removing Debris ........................H - 2 Oil Capacity .......................... H - 2 Oil Recommendations ......................H - 2 Checking the Oil Level......................H - 2 Changing the Oil........................
  • Page 94 ENGINE AND TRANSMISSION TABLE OF CONTENTS FOR SECTION ‘H’ (CONT.) SECTION TITLE PAGE NO. Fig. 20 Transmission Replacement ....................H - 14 Fig. 21 Transmission Lubricant Level................... H - 14 Fig. 22 Spark Arrester Removal ....................H - 15 Fig. 23 Spark Arrester Cleaning ....................H - 15 Fig.
  • Page 95 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Oil Fill Cap Air Plenum Air Hose Exhaust Manifold Air Cleaner Starter Dip Stick Fig. 1 Engine Repair and Service Manual Page H-1...

  • Page 96: Powertrain Maintenance

    ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings This section describes procedures for performing regular tion. When using a multi-viscosity oil, check oil level more fre- quently.

  • Page 97: Changing The Oil

    ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Oil Fill Cap Maximum oil level DO NOT OVERFILL FULL Fig. 6 Check Oil Level on Dipstick Changing the Oil Be aware that engine flu- ids may be hot and con-...

  • Page 98: Changing The Oil Filter

    ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Replace dipstick fully into the dipstick tube and firmly install the oil fill cap. Front of Vehicle Oil Filter Oil Drain Plug Fig.

  • Page 99: Alternator Belt Tension

    ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Air Cleaner Cover 3/8" (1 cm) Max. Deflection for New Belt 1/2" (1.3 cm) Max. Deflection for Existing Paper Filter Clip Element...

  • Page 100: Spark Plugs

    ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Spark Plugs ENGINE DESCRIPTION Use care not to overtighten the plug. The engine is a four cycle air cooled, V block, twin cylin- Overtightening can damage the alumi- der, overhead valve unit.

  • Page 101: Vehicle Preparation To Evaluate Engine Condition

    ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Vehicle Preparation To Evaluate Engine Condition To prevent severe per- sonal injury or death resulting from inadvert- ent movement of vehicle raise entire vehicle and place in neutral per Section B.
  • Page 102 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings In the following text, there are references to Drain oil from engine. removing/installing bolts, etc. Additional hard- ware (nuts, washers, etc.) that is removed must always be CVT Back Cover Removal installed in its original position unless otherwise specified.
  • Page 103 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Front of Vehicle Fig. 15 Air Intake System Removal Fig. 16 Accelerator and Governor Cable Removal Repair and Service Manual Page H-9...
  • Page 104 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings • Engine Removal Remove choke/governor cable bracket from old engine. Detach governor cable and choke link Remove the bolts (item 1) using 5/8"...
  • Page 105 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Engine Installation Connect exhaust pipe to the engine and tighten clamp till no loose play is present. T h e f o l l o w i n g s t e p Check oil level in engine and adjust as needed.
  • Page 106 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 18 Muffler Replacement Tighten the hardware per torque specification table given tion in CVT). Remove springs (item 1) using needle nose below.
  • Page 107 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 19 Exhaust Manifold Replacement TRANSMISSION REPLACEMENT Wrench, 9/16".............. 2 Needle nose pliers............1 To prevent the possibili- Pliers ................
  • Page 108 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings on page H-7). Remove the front drive shaft (Ref Front Apply anti seize compound on all splines and appropriate commercially available thread lock for bolts before instal- Drive Shaft Replacement section in FRONT SUSPEN- lation.
  • Page 109 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings If lubricant is to be added, use a funnel and add correct type lubricant (Ref Transfer Case in Capacities table in GENERAL INFORMATION &...
  • Page 110 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 24 Engine Sub frame Replacement Remove the seat bottom (Ref Seat Bottom Replacement ISOLATION MOUNT REPLACEMENT section in BODY AND TRUCK BED).
  • Page 111 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 25 Isolation Mount Replacement Remove the seat bottom (Ref Seat Bottom Replacement section in BODY AND TRUCK BED). Remove seat back assembly and seat crossmember (Ref Seat Back Replacement section in BODY AND TRUCK BED).
  • Page 112 ENGINE AND TRANSMISSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page H-18...

  • Page 113: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. FRONT SUSPENSION ........................J - 2 Front Suspension Disassembly ..................... J - 2 Control Arm Replacement ..................... J - 3 Front Steering Knuckle Replacement..................J - 4 Front Strut Replacement .......................
  • Page 114 FRONT SUSPENSION AND STEERING Notes: Repair and Service Manual Page J-ii...
  • Page 115 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Frame Steering Assembly Front Brake Line Strut Tie Rod End Knuckle Ball Joint Bearing Rotor Half Shaft Front Differential Spindle Cap...
  • Page 116 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings FRONT SUSPENSION The installation of the wheels and brake is the reverse of disassembly (Refer WHEELS AND TIRES section for In the following text, there are references to wheel lug nuts torque specification).
  • Page 117 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings The installation of the tie rod end is the reverse of disas- Plastic faced hammer..........1 sembly using new cotter pin.

  • Page 118: Front Steering Knuckle Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Tighten the hardware per torque specification table below. ITEM NO TORQUE SPECIFICATION 36 - 44 ft.lbs (49 - 60 Nm) 20 - 25 ft.lbs (27 - 34 Nm) Front Steering Knuckle Replacement Tool List...

  • Page 119: Torque Specifications

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Jack stands ..............2 The installation of the front strut is the reverse of disas- sembly using new cotter pins and new lock nuts.

  • Page 120: Fig. 5 Torque Specifications

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Brake line Rotor Fig. 7 Bearing Replacement The installation of the bearing is the reverse of disassem- Plastic faced hammer ..........1 bly.

  • Page 121: Half Shaft Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Wrench, 3/4"..............1 Wrench, 9/16".............. 1 Plastic faced hammer..........1 Straight blade screwdriver ........... 1 Needle nose pliers............

  • Page 122: Front Drive Shaft Removal

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Frame Strut To Steering Tie Rod End Fig. 9 Half Shaft Replacement Front Drive Shaft Removal Use a commercially available Anti-Seize com- pound on Shaft and Bearing splines.

  • Page 123: Front Differential Guard Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Tighten the hardware per torque specification table Fig. 11 on page J-9). Remove the front differential guard below.

  • Page 124: Steering Wheel Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 12 Steering Assembly Replacement Replace the front wheels per WHEELS AND TIRES sec- Steering Wheel Replacement tion and lower vehicle.

  • Page 125: Steering Column Replacement

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Remove the steering wheel cover (item 1) using screw Wrench, 13mm ............1 driver (Ref Fig. 13 on page J-11). Remove lock nut (item Remove the steering wheel (item 1) (Ref Steering Wheel 2) using 3/4"...

  • Page 126: Maintenance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE To adjust the wheel alignment, cut-off wire tie on boot at steering unit using diagonal cutters. Pull boot away from Wheel Alignment housing and hold tie rod on flat groove using 9/16"...

  • Page 127: Fuel System

    FUEL SYSTEM TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. GENERAL ............................K - 2 FUEL ..............................K - 2 FUEL SYSTEM COMPONENT SERVICE AND REPLACEMENT...........K - 2 Fuel Lines and Filter ......................K - 2 Fuel Pump ..........................K - 3 Fuel Tank..........................K - 3 Choke System ........................K - 4 Choke Operation ........................K - 4...
  • Page 128 FUEL SYSTEM Notes: Repair and Service Manual Page K-ii...
  • Page 129 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings (APPROVED Fuel Line From Tank Fuel Filter Fuel Level Gauge Fuel Pump Fuel Hose Pulse Line To Carburetor From Engine Fuel Line To Fuel Filter...
  • Page 130 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL FUEL SYSTEM COMPONENT SERVICE AND REPLACEMENT In the following text, there are references to removing/installing bolts, etc. Additional hard- To prevent serious per- ware (nuts, washers, etc.) that is removed must always be sonal injury or death...
  • Page 131 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Remove the hose (item 3) coming from fuel tank first and Pliers ................1 plug. Remove filter (item 2) from hose (item 4) going to Duct tape ..............
  • Page 132 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Tighten the hardware per torque specification table given entire operating range. If there is any binding or sharp below.

  • Page 133: Prolonged Storage

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Carburetor Cleaning To prevent serious injury or death resulting from explosion or fire, discon- nect the battery negative (-) cable. Tool List Qty.
  • Page 134 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page K-6...

  • Page 135: Paint

    PAINT TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. PAINTING (EXCEPT FRONT COWL) ..................... L - 1 Minor Scratches........................L - 1 Larger Scratches ........................L - 1 Complete Panel Repair ......................L - 1 PAINTING (FRONT COWL ONLY) ....................L - 2 Procedure ..........................
  • Page 136 PAINT Notes: Repair and Service Manual Page L-ii...
  • Page 137 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PAINTING (EXCEPT FRONT COWL) touch-up paint. Follow the paint manufacturer’s recommendations for III. Apply spray touch up paint in light even overlapping specific painting procedures and information.
  • Page 138 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings • Blow off the area to be filled with clean dry com- e) Allow parts to air-dry for approximately 30 pressed air.
  • Page 139 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings • In the spray booth a) Apply two to four wet mils of Valspar brand product #KPGOO64 repaired area. b) Remove all tape around the repaired area immediately after third coat of Val- spar...
  • Page 140 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page L-4...

  • Page 141: Rear Axle And Suspension

    REAR AXLE AND SUSPENSION TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR AXLE ............................ M - 2 Maintenance ......................... M - 2 Checking Lubrication Level ....................M - 2 Solenoid Replacement ......................M - 2 Rear Drive Shaft Removal....................M - 3 Rear Differential Guard Replacement ..................
  • Page 142 REAR AXLE AND SUSPENSION Notes: Repair and Service Manual Page M-ii...
  • Page 143 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Leaf Shock Absorber Spring Plate Rear Shackle Rear Leaf Spring Solenoid Shock Mounting Rear Drive Shaft Rear Parking Brake...
  • Page 144 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REAR AXLE Solenoid Replacement Maintenance Check solenoid for free actuation after assem- bly. The rear axle is provided with a lubricant level fill plug located on the passenger side at rear of housing.
  • Page 145 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Front of the Vehicle Front of the Vehicle Fig. 4 Rear Drive Shaft Removal Tighten the hardware per torque specification table below.
  • Page 146 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Hold the nut (item 1) using open end wrench and remove Ball peen hammer ............1 the screw (item 2) using torx bit screwdriver (Ref Fig.
  • Page 147 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Park Brakes Hydraulic Brakes Fig. 6 Rear Axle Components Repair and Service Manual Page M-5...
  • Page 148 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Tighten the hardware per torque specification table below. ITEM NO TORQUE SPECIFICATIONS 11 - 14 ft. lbs (15 - 19 Nm) 16 - 20 ft.

  • Page 149: Tires

    REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings If both springs are to be replaced and the rear ITEM NO TORQUE SPECIFICATIONS axle is not to be removed, it is important to remove and replace one spring at a time.
  • Page 150 REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page M-8...

  • Page 151: Speed Control

    SPEED CONTROL TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. ACCELERATOR, GOVERNOR AND CARBURETOR LINKAGE ........... N - 2 System Operation......................... N - 2 Governor Operation......................N - 2 General Cable Adjustment Procedure.................. N - 2 Governor Compression Spring Adjustment ................N - 3 Accelerator/governor Cable Adjustment................
  • Page 152 SPEED CONTROL Notes: Repair and Service Manual Page N-ii...
  • Page 153 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Accelerator Pedal Return Spring Accelerator Pedal Accelerator Cable Accelerator Cable/ Governor Spring Governor Extension Spring Governor Cable Governor Bellcrank Carburetor Throttle...
  • Page 154 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ACCELERATOR, GOVERNOR AND nor lever position which controls the position of the carburetor throttle plate. The compression spring pro- CARBURETOR LINKAGE vides cushioning of sudden changes in throttle linkage System Operation...
  • Page 155 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings To permit proper cable adjustment, the cable length may Pre-adjust governor compression spring (item 4) by hold- be increased/decreased at its mounting bracket.
  • Page 156 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Never confuse the positive and negative cables. Wrap wrenches with vinyl tape to prevent the possibil- ity of a dropped wrench from ‘shorting out’...
  • Page 157 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Refer to SAFETY section before you start. test and adjustment procedure until the factory recom- mended governed speed is achieved. Park the vehicle on a level surface, engage park brake.
  • Page 158 SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page N-6...

  • Page 159: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. ENGINE............................P - 1 GASOLINE VEHICLE PERFORMANCE..................P - 1 STARTER / GENERATOR.......................P - 5 SUSPENSION AND STEERING......................P - 6 Repair and Service Manual Page P-i...
  • Page 160 TROUBLESHOOTING Notes: Repair and Service Manual Page P-ii...
  • Page 161 G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U '0)+0' For engine troubleshooting, diagnostic and repair procedures, refer to Honda Engines Owner’s Manual 6 X...
  • Page 162 G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Condition Possible Cause Correction...
  • Page 163 G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Condition Possible Cause Correction...
  • Page 164 G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U Condition Possible Cause Correction...
  • Page 165 G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U 56#46'4  )'0'4#614 Condition Possible Cause...
  • Page 166 G C F C N N Q H 5 G E V K Q P $ C P F V J K U U G E V K Q P D G H Q T G C V V G O R V K P I C P [ R T Q E G F W T G  2 C [ R C T V K E W N C T C V V G P V K Q P V Q C N N 0 Q V G U  % C W V K Q P U C P F 9 C T P K P I U 5752'05+10 #0&...

  • Page 167: Wheels And Tires

    WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION ‘R’ SECTION TITLE PAGE NO. WHEEL AND TIRE SERVICE ......................R - 1 Tire Replacement / Repair....................R - 1 Wheel Installation ......................... R - 2 LIST OF ILLUSTRATIONS Fig. 1 Wheels and Tires ......................... R - 3 Repair and Service Manual Page R-i...
  • Page 168 WHEELS AND TIRES Notes: Repair and Service Manual Page R-ii...
  • Page 169 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings WHEEL AND TIRE SERVICE Tire inflation will depend on the type of tires fitted but under no condition should inflation pressure be higher To prevent serious per- than recommended on the tire sidewall.
  • Page 170 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Wheel Installation Do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque. It is important to follow the ‘cross sequence’...
  • Page 171 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Tire style may vary Front of Vehicle Valve stem is always to outside of wheel Always replace dust cap 'CROSS SEQUENCE' Fig.
  • Page 172 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: Repair and Service Manual Page R-4...

  • Page 173: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘S’ SECTION TITLE PAGE NO. Gasoline Powered ST 4X4 Utility Vehicle ..................S - 1 LIST OF ILLUSTRATIONS Fig. 1 Vehicle Dimensions.......................S - 2 Fig. 2 Vehicle Incline Specifications ....................S - 3 Fig. 3 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance........S - 4...
  • Page 174 GENERAL SPECIFICATIONS Notes: Repair and Service Manual Page S-ii...
  • Page 175 GENERAL SPECIFICATIONS Gasoline Powered ST 4X4 Utility Vehicle STANDARD EQUIPMENT: CHASSIS Welded steel, hot-dip galvanized, front hitch receiver BODY (Front) Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer) with Base Coat/Clear Coat BODY (Rear) Lightweight, replaceable steel panels, plastic rear fenders...
  • Page 176 GENERAL SPECIFICATIONS 40" (102 cm) 50" (127 cm) 107" (272 cm) 18 in. 11.5 in. (46 cm) (29 cm) 50" (127 cm) 31.5" (80 cm) 16" (40.6 cm) Front 76" (193 cm) 43 3/8" (110 cm) 9 1/2" (24 cm) 8 3/8"...
  • Page 177 GENERAL SPECIFICATIONS Maximum Recommended Ramp Grade Maximum Recommended Side Tilt 25% or 14° Max. 25% or 14° Max. Fig. 2 Vehicle Incline Specifications Repair and Service Manual Page S-3...
  • Page 178 GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER Approx. 25 ft (7.6 m) Fig. 3 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance Repair and Service Manual Page S-4...

  • Page 179: Limited Warranty

    LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION ‘T’ SECTION TITLE PAGE NO. EMISSION CONTROL SYSTEM WARRANTY STATEMENT ............T - 1 ENGINE OWNER WARRANTY POLICY ..................T - 1 Repair and Service Manual Page T-i...
  • Page 180 LIMITED WARRANTY Notes: Repair and Service Manual Page T-ii...
  • Page 181 LIMITED WARRANTY EMISSION CONTROL SYSTEM WARRANTY STATEMENT (Owner’s Defect Warranty Rights and Oblications) ® Refer to the HONDA Operating & Maintenance Instructions, provided with vehicle, for Emission Control System War- ranty information. ENGINE OWNER WARRANTY POLICY ® Refer to the HONDA Operating &...
  • Page 182 LIMITED WARRANTY Notes: Repair and Service Manual Page T-2...
  • Page 183 Read and understand the following warnings not operating correctly, take time to consider the safety of before attempting to operate the vehicle: yourself and others around you should the component move unexpectedly. prevent personal Some components are heavy, spring loaded, highly cor- injury or death, observe rosive, explosive or may produce high amperage or the following:...
  • Page 184 E-Z-GO Division of Textron, Inc. 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 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.

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