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Summary of Contents for EZ-GO ST 4X4
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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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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.
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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.
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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.
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............................
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;...
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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. •...
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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.
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SAFETY INFORMATION Notes: Repair and Service Manual Page viii...
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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...
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GENERAL INFORMATION & ROUTINE MAINTENANCE Notes: Repair and Service Manual Page A-ii...
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.
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.
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.
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.
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 •...
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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.
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.
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...
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...
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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...
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.
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SAFETY Notes: Repair and Service Manual Page B-ii...
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.
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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...
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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.
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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.
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.
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:...
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.
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.
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..................
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BODY AND TRUCKBED Notes: Repair and Service Manual Page C-ii...
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...
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.
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.
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.
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.
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.
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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.
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..........
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.
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.
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.
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...
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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).
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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.
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....................
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BRAKES Notes: Repair and Service Manual Page D-ii...
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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...
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).
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...
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.
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.
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.
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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........
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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.
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...
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.
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.
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...
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.
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.
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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).
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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...
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.
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.
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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.
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...
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...
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DIRECTION AND DRIVE SELECTOR Notes: Repair and Service Manual Page F-ii...
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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...
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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:...
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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...
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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.
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 ......................
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ELECTRICAL Notes: Repair and Service Manual Page G-ii...
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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...
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...
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.
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.
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.
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:...
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.
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)
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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.
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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"...
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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...
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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...
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........................
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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.
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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...
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.
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-...
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.
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...
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.
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.
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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.
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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...
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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"...
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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.
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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.
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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 ................
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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.
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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 &...
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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).
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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).
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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...
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 .......................
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FRONT SUSPENSION AND STEERING Notes: Repair and Service Manual Page J-ii...
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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...
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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).
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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.
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...
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.
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.
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............
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.
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.
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.
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"...
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"...
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...
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FUEL SYSTEM Notes: Repair and Service Manual Page K-ii...
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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...
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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...
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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 ..............
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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.
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.
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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...
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 ..........................
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PAINT Notes: Repair and Service Manual Page L-ii...
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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.
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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.
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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...
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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...
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 ..................
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REAR AXLE AND SUSPENSION Notes: Repair and Service Manual Page M-ii...
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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...
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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.
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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.
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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.
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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...
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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.
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.
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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...
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................
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SPEED CONTROL Notes: Repair and Service Manual Page N-ii...
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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...
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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...
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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.
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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’...
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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.
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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...
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...
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TROUBLESHOOTING Notes: Repair and Service Manual Page P-ii...
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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...
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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...
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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...
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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...
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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...
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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&...
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...
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WHEELS AND TIRES Notes: Repair and Service Manual Page R-ii...
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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.
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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’...
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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.
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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...
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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...
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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...
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...
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LIMITED WARRANTY Notes: Repair and Service Manual Page T-ii...
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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 &...
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LIMITED WARRANTY Notes: Repair and Service Manual Page T-2...
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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:...
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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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