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E-Z-GO 602080 Owner's Manual And Service Manual

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602080
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REVISED DATE: JAN. 2007

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Summary of Contents for E-Z-GO 602080

  • Page 1 602080 REVISED DATE: JAN. 2007...

  • Page 2: Safety

    For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. See APPENDIX 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 E-Z-GO Division of TEXTRON, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.

  • Page 4: General Information

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

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY ... inside covers GENERAL INFORMATION ... ii SAFETY INFORMATION ... vii WELCOME ... 1 BEFORE INITIAL USE ... 1 Fig.1 Initial Service Chart ...1 CAPABILITIES ... 1 TERRAIN ...1 VEHICLE CAPACITY ...1 MODIFICATIONS TO VEHICLE ...2 COMMON SENSE OPERATION ...
  • Page 6 TOP AND WINDSHIELD ... 12 TRANSPORTING VEHICLE ... 12 TOWING ... 12 HAULING ... 12 TOWING A TRAILER ... 12 OPENING THE COWL (HOOD) ... 13 DATA LABEL LOCATION ... 13 MAINTENANCE ... 14 PERIODIC SERVICE SCHEDULE ... 15 BASIC SERVICE PARTS ... 16 LIFTING THE VEHICLE ...
  • Page 7 TABLE OF CONTENTS LIGHT BULB REPLACEMENT ... 25 Fig. 35 Headlight Replacement ...25 FUSE REPLACEMENT ... 25 SPARK ARRESTER ... 25 Fig. 36 Cleaning Spark Arrester ...25 PROLONGED STORAGE ... 25 FRONT AND REAR AXLES ... 26 CHECKING LUBRICANT LEVEL ...26 Fig.
  • Page 8 TABLE OF CONTENTS Notes: Owner’s Manual and Service Guide Page vi...

  • Page 9: Safety Information

    SAFETY INFORMATION This manual has been designed to assist 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 10 • 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 11 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 12 SAFETY INFORMATION Notes: Owner’s Manual and Service Guide Page x...
  • Page 13 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL The following text is provided as recommended by part II of SAE J2258 DEC 2003. E-Z-GO strongly endorses the contents of this specification. B.1 PART II FOR THE CONTROLLING PARTY B.1.1 Maintenance and Operations...
  • Page 14 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings B.1.1.4.2 The controlling party shall supervise the handling of liquefied petroleum gas fuels (when used) to be certain it is in accordance with appropriate sections of ANSI/NFPA 505 and ANSI/NFPA 58 or as required by local ordinance.
  • Page 15 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings B.2.3.4 Riding on the vehicle by persons other than the operator is authorized only on seat(s) provided by the vehicle manufacturer. All parts of each person's body shall remain within the plan view outline of the vehicle while the vehicle is in motion.
  • Page 16 Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings equipped, is closed, following vehicle manufacturer's rec- ommended practice. (e) Before disconnecting any part of the fuel system of LP/CNG powered vehicles, close the fuel cylinder valve and run the engine until fuel in the system is depleted, the engine stops running, and is allowed to cool (f) Disconnect battery(s).

  • Page 17: Welcome

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings WELCOME Thank you for purchasing this utility vehicle. Before driv- ing vehicle, we ask you to spend some time reading this Owner’s Manual and Service Guide and the Owner’s Manual provided by Honda Motor Co., Ltd.

  • Page 18: Modifications To Vehicle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ways the vehicle may be used, it is important the operator consider any potential hazards before use to prevent serious injury or death.

  • Page 19: Controls & Indicators

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CONTROLS & INDICATORS SERVICE BRAKE PEDAL Ref Sbp 1 Fig. 2 Service Brake Pedal The service brake is a hydraulic front disc/rear drum brake system.

  • Page 20: Direction Selector

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Choke Pull Ref Chk 4 Fig. 4 Choke If vehicle is equipped with factory installed cus- tom accessories, some accessories remain operational with key switch in ‘OFF’...

  • Page 21: 2Wd/4Wd Selector

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Place direction selector in forward and set park brake when leaving vehicle unattended. 2WD/4WD SELECTOR To reduce possibility of drivetrain dam- age, vehicle must completely stop before switching between two wheel and four wheel drive.

  • Page 22: Accelerator

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To prevent draining the battery, always place differential lock switches in the ‘unlocked’ position, turn the key switch to ‘off’ and remove the key.

  • Page 23: Low Oil Pressure Indicator Light

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HOURS Ref Ftl 4 Fig. 10 Fuel Tank and Gauge LOW OIL PRESSURE INDICATOR LIGHT Low oil pressure indicator light is located in gauge cluster at left of dash panel.

  • Page 24: Starting And Driving

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Overuse of accessories may drain bat- tery and leave insufficient reserve to start vehicle. A 12 volt power outlet, rated at 15 amps, is located left of ignition switch (Ref.

  • Page 25: Tailgate

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Before operating, verify no one is behind vehicle. Always place a gas can on ground for filling. Never fill a gas can in load bed of vehicle.

  • Page 26: Winch Mounting

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Do not pull at an angle (Ref. Fig. 16 on page 10). This will cause cable to pile up on one end, jam- ming and damaging winch.

  • Page 27: Fig. 18 Use Nylon Sling And Install A Damper When Winching

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Winch shown mounted at front of vehicle Spring Clevis Ref Wmt 2 Fig. 17 Mounting Winch Pull out desired amount of cable and secure. Engage drum by rotating knob until it snaps in place.

  • Page 28: Fig. 19 Winch Operation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings as possible from side of vehicle. Do not operate winch while sitting in passenger seat. Read ‘Winch Applica- tions’...

  • Page 29: Opening The Cowl (Hood)

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Vehicle may be equipped with a receiver that accepts a standard 2" ball hitch. Trailer range of motion is limited by the ball and hitch and should not be used on rough trails or over objects such as logs, large rocks, holes, etc.

  • Page 30: Maintenance

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE To reduce possibility of severe injury or death from improper servicing techniques: Do not attempt any type of servicing operations before reading and understanding all notes, cau- tions and warnings in this manual.

  • Page 31: Periodic Service Schedule

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE ITEM Service Brake Check (Pedal Pressure) (Fluid Level) Check (Pads & Shoes) Inspect (Rotors & Drums) Clean Park Brake Clean Tires...

  • Page 32: Basic Service Parts

    To order parts, SERVICE PARTS Department contact information is as follows: In 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 E-Z-GO Division of TEXTRON, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 Page 16 BEFORE EVERY...

  • Page 33: Lifting The Vehicle

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LIFTING THE VEHICLE Tool List Floor jack ... 1 Jack stands ... 4 Chocks ... 4 To prevent possible inju- ry or death resulting from vehicle falling off jack, be sure vehicle is on a firm and level surface.

  • Page 34: Oil Level Check

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings OIL LEVEL CHECK To reduce possibility of engine damage, do not run engine with oil level too low. Park vehicle on level surface, shut off engine and wait a minute for oil to settle.

  • Page 35: Spark Plugs

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Ref Ofi 1 Fig. 27 Oil Filter Change Fill engine to upper hole on dipstick with appropriate oil (Ref. OIL CHANGE on page 18). Return oil fill cap and dipstick and lower seat.

  • Page 36: Air Cleaner

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 3/8" (1 cm) 1/2" (1.3 cm) Max. Deflection for Existing Ref Abt 3 Fig. 28 Adjusting Alternator Belt AIR CLEANER CANISTER TYPE AIR CLEANER Air cleaner element is accessible by unsnapping two...

  • Page 37: Lubrication Points

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Ref Ffi 1 Fig. 30 Fuel Filter LUBRICATION POINTS Do not use more than three (3) pumps of grease in any grease fitting at any one time.

  • Page 38: Battery Cleaning

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings BATTERY CLEANING To reduce possibility of damage to vehicle or floor, neutralize acid before rinsing battery. To reduce possibility of damage to electrical components while cleaning, do not use a pressure washer.

  • Page 39: Care Products

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Weak Battery Strong Battery Ref Jmp 1 Fig. 33 Jump Starting tem. Do not use pressure in excess of 700 psi (4800 kPa) to wash exterior of vehicle.

  • Page 40: Wheels And Tires

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings WHEELS AND TIRES Tires are uni-directional and should never be moved from one side of vehicle to the other. This vehicle comes standard with low pressure, tubeless, uni-directional tires mounted on one piece wheels (Ref.

  • Page 41: Light Bulb Replacement

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LIGHT BULB REPLACEMENT Headlight Bulb Ref Hdr 4 Fig. 35 Headlight Replacement Replacement bulbs are available from a local Distributor, an authorized Branch or the Service Parts Department (Ref.

  • Page 42: Front And Rear Axles

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • Add fuel stabilizer to fuel tank following instruc- tions on stabilizer container. • Attach fuel line to tank and drive vehicle for sev- eral minutes to circulate fuel stabilizer through car- buretor.

  • Page 43: Fig. 39 Cleaning Air Intake And Cooling Fins

    Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Cooling Fins Ref Cai 2 Fig. 39 Cleaning Air Intake and Cooling Fins After every off road use, allow to cool and then check for build up of dirt and debris in air intake and cooling fins (Ref.

  • Page 44: Hardware

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HARDWARE Periodically, vehicle should be inspected for loose fasten- ers. Fasteners should be tightened in accordance with the Torque Specifications table (Ref.

  • Page 45: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 29...
  • Page 46 GENERAL SPECIFICATIONS 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 BATTERY One 12 Volt Maintenance Free (340 CCA, 38 Minute Reserve) ENGINE Honda 18 H.P.

  • Page 47: Fig. 42 Vehicle Dimensions

    50" (127 cm) Front 43 3/8" (110 cm) 9 1/2" (24 cm) Clearance At Lowest Rear 43 3/4" (111 cm) Point On Frame Ref Dim 3-1 Ref Dim 3-2 Maximum Recommended Ramp Grade 25% or 14˚ Max. GENERAL SPECIFICATIONS 112" (285 cm) 16"...

  • Page 48: Fig. 44 Vehicle Turning Clearance Diameter And Intersecting Aisle Clearance

    GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER Approx. 25'-6" (7.8 m) Ref Dim 3-3 Fig. 44 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance Owner’s Manual and Service Guide Page 32...

  • Page 49: Vehicle Warranties

    VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 33...
  • Page 50 VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 34...

  • Page 51: Emission Control System Warranty Statement

    VEHICLE WARRANTIES EMISSION CONTROL SYSTEM WARRANTY STATEMENT (Owner’s Defect Warranty Rights and Obligations) Refer to the HONDA Emission Control System Warranty sheet, provided with vehicle, for information. ENGINE OWNER WARRANTY POLICY Refer to the Warranty sheet, provided with vehicle, for Engine Warranty information. INTERNATIONAL WARRANTY STATEMENT Refer to the International Warranty sheet, provided with vehicle, for information.
  • Page 52 VEHICLE WARRANTIES Notes: Owner’s Manual and Service Guide Page 36...

  • Page 53: Declaration Of Conformity (Europe Only)

    DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Declaration of Conformity is packaged with vehicle. For additional information, contact: Ransomes Jacobsen Limited West Road, Ransomes Europark, Ipswich, England, IP3 9TT Owner’s Manual and Service Guide Page 37...

  • Page 54: Declaration Of Conformity

    DECLARATION OF CONFORMITY Notes: Owner’s Manual and Service Guide Page 38...

  • Page 55: Labels And Pictograms

    LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
  • Page 56 LABELS AND PICTOGRAMS Notes: Owner’s Manual and Service Guide Appendix A - 2...
  • Page 57 See Following Pages For Explanation Of These Pictograms: START (43,44,51) 73767G01 See Following Pages For Explanation Of This Pictogram: (28) 35493-G01 35493G01 See Following Pages For Explanation Of These Pictograms: (1,2) 71489G01 See Following Pages For Explanation Of These Pictograms: (1,2,3,4,6,9,29, 36,37,54,55) 73771G01...
  • Page 58 LABELS AND PICTOGRAMS M AX 14 ° / 25 % 14 ° / 25 % Appendix A - 4 WARNING READ MANUAL WARNING USE CAUTION IN INCLEMENT WEATHER WARNING DO NOT OPERATE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED WARNING...
  • Page 59 CLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE UNLEAD GASOLINE DO NOT SPILL FUEL ON A HOT ENGINE GROUND FUEL PUMP LOW OIL PRESSURE NEGATIVE GROUND BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION TAMPERING.
  • Page 60 LABELS AND PICTOGRAMS Appendix A - 6 OPERATE FROM DRIVER’S SIDE ONLY KEEP ARMS AND LEGS WITHIN VEHICLE TO OPERATE VEHICLE IN FORWARD: * TURN KEY TO ON * MOVE DIRECTION SELECTOR TO FORWARD * DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO OPERATE VEHICLE IN REVERSE: * TURN KEY TO ON * MOVE DIRECTION SELECTOR TO...
  • Page 61 WARNING READ OWNER’S MANUL BEFORE OPERATING VEHICLE IN FORWARD OR REVERSE WARNING READ OWNER’S MANUAL BEFORE PARKING VEHICLE AND LEAVING IT UNATTENDED FORWARD NEUTRAL REVERSE WARNING READ OWNER’S MANUAL BEFORE ENGAGING TWO OR FOUR WHEEL DRIVE PUSH TOP OF SWITCH TO LOCK DIFFERENTIAL PUSH BOTTOM OF SWITCH TO UNLOCK...
  • Page 62 LABELS AND PICTOGRAMS Notes: Owner’s Manual and Service Guide Appendix A - 8...
  • Page 63 Check area behind the vehicle before operating in reverse. Make sure the direction selector is in correct position before attempting to start the vehicle. Slow down before and during turns. All turns should be executed at reduced speed. Always bring vehicle to a complete stop before shifting the direction selector.
  • Page 64 E-Z-GO Division Of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 TO CONTACT US North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material...

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