Textron EZGO Owner's Manual
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Textron EZGO Owner's Manual

Textron EZGO Owner's Manual

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  • Page 2: Safety

    S A F E T Y 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. 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 The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty. Overfilling battery may void the warranty. Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty. When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SAFETY ........................ inside covers GENERAL INFORMATION ....................... ii SAFETY INFORMATION ......................v BEFORE INITIAL USE ......................1 Fig. 1 Initial Service Chart ......................1 CONTROLS AND INDICATORS ....................1 KEY/LIGHT SWITCH ............................1 Fig. 2 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge ..........2 DIRECTION SELECTOR .............................2 Fig.
  • Page 6 TABLE OF CONTENTS CHECKING THE OIL LEVEL ..........................13 Fig. 14 Clean Entire Dipstick ....................13 Fig. 15 Check Oil Level on Dipstick ..................13 CHANGING THE OIL ............................14 Fig. 16 Oil Viscosity Chart ...................... 14 Fig. 17 Clean Top of Engine ....................14 Fig.

  • Page 7: Safety Information

    S A FE T Y IN FO RMAT IO N 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.
  • Page 8 S A F ET Y IN FO RMAT IO N This vehicle conforms to the current applicable standard(s) for safety and performance requirements. These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards of the United States of America (USA) and are not equipped for operation on public streets.
  • Page 9 S A FE T Y IN FO RMAT IO N battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material. • Use specified replacement parts. Never use replacement parts of lesser quality. • Use recommended tools. •...
  • Page 10 S A F ET Y IN FO RMAT IO N Notes: Owner’s Manual and Service Guide Page viii...
  • Page 11 S A F E T Y I N F O R M AT I O N GENERAL The following text is provided as recommended by part II of ASME/ANSI B56.8-2005. E-Z-GO strongly endorses the contents of this specification. PART II FOR THE USER 4 GENERAL SAFETY PRACTICES Introduction...
  • Page 12 S A F E T Y I N F O R M AT I O N 4.5.2 The user shall periodically inspect facilities and review procedures to be certain that appropriate paragraphs of ANSI/NFPA 505, are strictly complied with, and shall familiarize carrier operators with it. Hazardous Locations 4.6.1 The user shall determine the hazard classification of the particular atmosphere or location in which the car-...
  • Page 13 S A F E T Y I N F O R M AT I O N is to be operated; (e) operational performance tests and evaluations during, and at completion of, the program. Personnel and Burden Carrier Operator Responsibility 5.3.1 Operators shall abide by the following safety rules and practices in paras.
  • Page 14 S A F E T Y I N F O R M AT I O N 5.5.12 Do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off power, and set parking brakes.
  • Page 15 S A F E T Y I N F O R M AT I O N (e) Before disconnecting any part of the engine fuel system of a gasoline or diesel powered carrier with gravity feed fuel systems, be sure shutoff valve is closed, and run engine until fuel system is depleted and engine stops running. (f) Before disconnecting any part of the engine fuel system of LP gas powered carriers, close the LP gas cylinder valve and run the engine until fuel in the system is depleted and the engine stops running.
  • Page 16 S A F E T Y I N F O R M AT I O N Notes: Page xiv Owner’s Manual and Service Guide...

  • Page 17: Before Initial Use

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Thank you for purchasing this vehicle. Before driving the Before a new vehicle is put into operation, the items vehicle, we ask you to spend some time reading this shown in the INITIAL SERVICE CHART must be per- Owner’s Manual and Service Guide.

  • Page 18: 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 ACCELERATOR PEDAL Unintentional move- ment of the acceler- a t o r p e d a l w i l l release the park brake and may cause the vehicle to move which could result in...

  • Page 19: Horn

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HORN MANUAL LIFT BED OPERATION The horn is operated by pushing the horn button located E x e r c i s e c a u t i o n on the floor to the left of the brake pedal (Ref Fig.

  • Page 20: Run-In

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings from loss of vehicle control, the following Check the area behind the vehicle before warnings must be observed: operating in reverse.

  • Page 21: Starting The Vehicle On A Hill

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 10 seconds. Allow 30 seconds between starting Place left foot on service brake and release the park attempts.

  • Page 22: Battery

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The windshield does not provide protection formance problems. If any undesirable operating symp- from tree limbs or flying objects. toms occur, use gasoline with a lower percentage of alcohol or ether.
  • Page 23 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings cause severe injury to operator or bystander, damage to seals, plastics, seat material, body finish or electrical sys- tem.

  • Page 24: Repair

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings REPAIR Center of LIFTING THE VEHICLE Front Axle Tool List Qty. Required Floor jack..............1 Jack stands ..............4 Chocks ................

  • Page 25: 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 caused by a broken socket when remov- Wheel Installation ing wheels, use only sockets designed To reduce the possibility of com- for impact wrench use.

  • Page 26: Vehicle With A Discharged Battery

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings from a local Distributor, an authorized Branch or the Ser- the pin will snap into the hole in the direction selector vice Parts Department.

  • Page 27: Service And Maintenance

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings physician immediately. cle (see GENERAL SPECIFICATIONS for vehicle weight) and load. Lock the park brake and secure the Any electrolyte spills should be neutral- vehicle using ratchet tie downs.

  • Page 28: Periodic Service Schedule

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE ✓ Check ♦ Clean, Adjust, etc. ▲ Replace To perform service that is listed in this schedule but not described in this manual, contact a local Service Representa- tive or see the Repair and Service Manual for this vehicle.

  • Page 29: Tire Inspection

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ✓ Check for leaks at tank, cap, system lines, filters, pump, carburetor FUEL SYSTEM ✓ Check system lines for cracks/deterioration ✓...

  • Page 30: Changing The Oil

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HEAVY DUTY WORK 10W-30 10W-30 10W-40 10W-40 LIGHT DUTY WORK 10W-30 10W-30 Ref Ced 1 Fig. 14 Clean Entire Dipstick (AIR TEMPERATURE) The engine can be operated safely as long as oil is within Ref Ovc 1...

  • Page 31: Starter/Generator Belt Tension

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings filter engages over a short nipple in the engine. The filter should slide easily onto the nipple and seat against the Large engine using light hand pressure only.

  • Page 32: 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 Ratchet, 3/8" drive ............1 Socket, 3/4", 3/8" drive ..........1 The starter/generator belt tension should be checked after the first 15 - 20 hours and set to 75 - 80 lbs.

  • Page 33: Brakes

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings spray wand or a plastic spray bottle. The solution should consist of the amounts of sodium bicarbonate (baking soda) and clear water shown below (Ref Fig.

  • Page 34: Air Intake And Cooling Fins

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Periodic Brake Test for Mechanical Brakes The purpose of this test is to compare the braking perfor- mance of the vehicle to the braking performance of new or ‘known to be good’...

  • Page 35: Air Cleaner Inspection And Replacement

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Cleaning the Air Filter Element Do not use compressed air to clean the air filter; doing so will Fill Plug damage the filter which may result in damage to the engine.

  • Page 36: Prolonged Storage

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • coat of anti-seize compound and tighten to 18 ft. lbs. (24 Remove spark plugs (Refer to SPARK PLUGS on Nm) torque.

  • Page 37: Capacities And Replacement Parts

    OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings O QU Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
  • Page 38 OPERATION AND SERVICE INFORMATION Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Notes: Page 22 Owner’s Manual and Service Guide...

  • Page 39: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 23...

  • Page 40: St Sport Ii

    GENERAL SPECIFICATIONS ™ ST SPORT II STANDARD EQUIPMENT: WEIGHT (dry fuel tank) 850 lbs (386kg) fuel capacity 36 lbs (16 kg) TIRES (4 ply rated) 20 x 11 x 10 (4 ply rated) TIRE PRESSURE 18 - 22 psi (124 - 152 kPa) LOAD CAPACITY 800 lbs (408 kg) (including operator, passenger, cargo and accessories) GROUND CLEARANCE...
  • Page 41 GENERAL SPECIFICATIONS 15 in (38 cm) 49.5 in (125.7 cm) 9.5 in (24 cm) 66.2 in (168.1 cm) (Front) 37.4 in (95.25 cm) 103 in (261.6 cm) (Rear) 36 in (91.5 cm) 38.7 in (98.3 cm) 47 in ST SPORT II ™ (119 cm) RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT...
  • Page 42 GENERAL SPECIFICATIONS TURNING CLEARANCE DIA. Approx. 24 ft (7.3 m) Ref Tur 24 Fig. 35 VehicleTurning Clearance Diameter Page 26 Owner’s Manual and Service Guide...

  • Page 43: Vehicle Warranties

    VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 27...

  • Page 44: Domestic Warranty

    VEHICLE WARRANTIES DOMESTIC WARRANTY (U.S. AND CANADA) To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer date code. Page 28 Owner’s Manual and Service Guide...

  • Page 45: International Warranty (2004)

    BY E-Z-GO, OR WERE NOT INSTALLED PER E-Z-GO’S INSTRUCTIONS, OR, FOR GASOLINE VEHICLES, THE USE OF NON- RECOMMENDED FUELS AND LUBRICANTS. FOR FURTHER INFORMATION, CALL 1-706-798-4311 OR WRITE TO E-Z-GO DIVISON OF TEXTRON, INC., ATTENTION: WARRANTY DEPARTMENT, 1451 MARVIN GRIFFIN ROAD, AUGUSTA , GEORGIA 30906.
  • Page 46 VEHICLE WARRANTIES BATTERY MAINTENANCE INSTRUCTIONS WARNING! - ALWAYS WEAR A FACE SHIELD, RUBBER GLOVES AND PROTECTIVE CLOTHING WHEN WORKING ON BATTERIES. WATERING – PERIODICALLY CHECK THE LEVEL IN EVERY CELL AND FILL THE BATTERIES TO THE CORRECT LEVEL AS REQUIRED (see picture below). As batteries age the frequency will increase. The use of a battery-watering gun will assist in accurately completing this task.

  • Page 47: Federal Emission Component Defect Warranty

    EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Fuji Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
  • Page 48 VEHICLE WARRANTIES - FEDERAL (2006) deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte- nance. As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 49: California Emission Control Warranty Statement

    CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board and E-Z-GO Division of Textron Inc. (E-Z-GO) are pleased to explain the evaporative emission control system (EECS) on your 2006 gasoline powered vehicle. In California, new equipment that use small off-engines must be designed, built, and equipped to meet the State’s stringent anti-smog standards.
  • Page 50 VEHICLE WARRANTIES - CALIFORNIA (2006) Page 34 Owner’s Manual and Service Guide...

  • Page 51: Declaration Of Conformity (Europe Only)

    DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Page 35...
  • Page 52 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION Page 36 Owner’s Manual and Service Guide...

  • Page 53: Labels And Pictograms

    LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
  • Page 54 LABELS AND PICTOGRAMS See Following Pages For Explanation Of These Pictograms: (2,3,4,6,9,36,37, 35962-G01 38,39,40,29) 35962G01 35964G01 See Following Pages For Explanation Of These Pictograms: 71131-G01 (19,43,44,45) 71131G01 74443G01 74443G01 See Following Pages For See Following Pages Explanation For Explanation Of Of These These Pictograms: Pictograms:...
  • Page 55 LABELS AND PICTOGRAMS WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD AS POSSIBLE. xxx lbs. xxx kg MAXIMUM LOAD BED WARNING CAPACITY USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE...
  • Page 56 LABELS AND PICTOGRAMS CLEAN UP GASOLINE DO NOT SPILLS WITH WATER EXPOSE TO FLAME BEFORE STARTING ENGINE UNLEADED DO NOT GASOLINE DISPOSE OF BATTERIES DO NOT IN LANDFILL SPILL FUEL ON A HOT ENGINE DO NOT DRIVE ON GROUND HIGHWAY FUEL PUMP WINDSHIELDS LOW OIL PRESSURE...
  • Page 57 LABELS AND PICTOGRAMS KEEP CLEAR OPERATE HAND OR FROM FINGERS CAN DRIVERS SIDE BE TRAPPED ONLY POSITION KEEP ARMS AND LEGS POSITION WITHIN VEHICLE HEADLIGHTS TO OPERATE VEHICLE IN FORWARD: ✱ TURN KEY TO ON UNLOCKED ✱ MOVE DIRECTION SELECTOR TO FORWARD ✱...
  • Page 58 LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD Ref Pic 1-4 Appendix A - 6 Owner’s Manual and Service Guide...
  • Page 59 S A F E T Y Read and understand the following warnings move unexpectedly. before attempting to operate the vehicle: Some components are heavy, spring loaded, highly cor- rosive, explosive or may produce high amperage or prevent personal reach high temperatures. Gasoline, carbon monoxide, injury or death, observe battery acid and hydrogen gas could result in serious the following:...
  • Page 60 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 TO CONTACT US North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc.

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