Textron Ezgo 628442-G Owner's Manual
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Textron Ezgo 628442-G Owner's Manual

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Owner's Guide
GASOLINE POWERED VEHICLE
628442-G
ISSUED MAY 2012
REVISED JULY 2018

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  • Page 1 Owner’s Guide GASOLINE POWERED VEHICLE 628442-G ISSUED MAY 2012 REVISED JULY 2018...
  • Page 2 WELCOME Thank you for purchasing this vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Guide. This guide contains the information that will assist you in maintaining this highly reliable vehicle. Some illustrations may show items that are optional for your vehicle. This guide covers the operation of several vehicles; therefore, some illus- trations may not represent your vehicle.
  • Page 3 E-Z-GO Division of Textron Inc. reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold or leased previously.
  • Page 4 FOREWORD Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. This vehicle has been designed and manufactured in the United States of America (USA). The Standards and Specifications listed in the following text originate in the USA unless oth- erwise indicated.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SECTION PAGE NO. SAFETY....................................1-1 GENERAL SPECIFICATIONS............................. 2-1 INTRODUCTION.................................. 3-1 OPERATING PROCEDURES.............................. 4-1 MAINTENANCE................................... 5-1 Page iii...
  • Page 6 TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : Page iv...

  • Page 7: Safety

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. GENERAL ................................... 1-2 NOTICES, CAUTIONS, WARNINGS, AND DANGERS....................... 1-2 GENERAL OPERATION ..............................1-3 MAINTENANCE .................................. 1-4 VENTILATION ..................................

  • Page 8: General

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. GENERAL For any questions on material contained in this manual, contact an authorized representative for clarification. Read 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.

  • Page 9: General Operation

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Engine exhaust from this product contains chemicals known, in certain quantities, to cause can- cer, birth defects, or other reproductive harm. The exhaust emissions of this vehicles’...

  • Page 10: Maintenance

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. If you have any questions regarding this vehicle, contact your E-Z-GO dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.

  • Page 11: Ventilation

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. • Use recommended tools • Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle •...

  • Page 12: Labels And Pictograms

    SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LABELS AND PICTOGRAMS 608465 608465 608529 608529 OPERATING INSTRUCTIONS BEFORE OPERATING READ all warning labels and the owner’s manual. Contact an authorized E-Z-GO dealer or visit www.ezgo.com for a replacement manual.
  • Page 13 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 1 - 7...
  • Page 14 SAFETY Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 1 - 8...

  • Page 15: General Specifications

    GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. Vehicle Specifications ..............................2 - 2 Vehicle Dimensions .................................2 - 3 Turning Diameter and Incline Information ........................2 - 3 2 - 1...
  • Page 16 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. MODEL: TXT LIFTED VALOR GAS TYPE: GAS PERSONAL USE LIFTED GOLF CAR MODEL YEAR: 2012 Part No.: 628444 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Engine: 13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki...
  • Page 17 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 46.5 in. (118 cm) Front 4.25 in. 34.0 in. (86 cm) (11.0 cm) Ground Rear Clearance 38.5 in.
  • Page 18 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. RECOMMENDED MAX SIDE TILT RECOMMENDED MAX RAMP 25% GRADE or 14 o MAX 25% GRADE or 14 o MAX TURNING CLEARANCE DIAMETER VALOR...
  • Page 19 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 2 - 5...
  • Page 20 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 2 - 6...

  • Page 21: Introduction

    INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. FEATURES..................................3-2 General Information ....................................3-2 Key Switch / Headlight Switch..................................3-3 Direction Selector......................................3-3 Choke..........................................
  • Page 22 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. FEATURES General Information If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’...
  • Page 23 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 1. Key Switch / Headlight Switch Located on the dash panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key.
  • Page 24 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 3 - 4...

  • Page 25: Operating Procedures

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. SERIAL NUMBER LOCATION ............................4-2 BEFORE INITIAL USE ................................ 4-3 OPERATING THE VEHICLE ............................... 4-3 Run-in..........................................

  • Page 26: Serial Number Location

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SERIAL NUMBER LOCATION Two serial number and manufacture date code plates are on the vehicle. One is placed on the body below the front, driver side seat.

  • Page 27: Before Initial Use

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. BEFORE INITIAL USE Read, understand and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle and its equipment as well as how to use it safely.
  • Page 28 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. down an incline. A sudden stop or change of direction may result in loss of control. Slow down before and during turns.

  • Page 29: Run-In

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Run-in Check for oil or fuel leaks that could have developed in Maximum Oil Level Fill Cold Engine shipment from the factory.

  • Page 30: Starting And Driving

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. STARTING AND DRIVING To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release service brake until engine has started.

  • Page 31: Fuel

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. FUEL To decrease the risk of severe injury or death from improper fuel handling: Do not smoke near the fuel tank. Do not add fuel near open flame or electrical items that can cause a spark.

  • Page 32: Late Production Fuel Tank

    OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Late Production Fuel Tank Late production fuel tanks can be identified by the location of the fuel cap which is located in the rear of the top of the tank as shown.

  • Page 33: Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. TITLE PAGE NO. VEHICLE CLEANING AND CARE ............................5-3 Vehicle Cleaning ......................................5-3 COMMON SENSE OPERATION ............................5-3 ENVIRONMENTAL CONCERNS............................
  • Page 34 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LUBRICATION ..................................5-16 BATTERY CLEANING...............................5-16 BRAKES ....................................5-17 Periodic Brake Test For Mechanical Brakes ............................. 5-17 PROLONGED STORAGE..............................5-18 HARDWARE ..................................5-19 CAPACITIES AND REPLACEMENT PARTS ........................5-19 PERIODIC SERVICE SCHEDULE .............................5-20 5 - 2...

  • Page 35: Vehicle Cleaning And Care

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. VEHICLE CLEANING AND CARE Vehicle Cleaning To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.

  • Page 36: Environmental Concerns

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when oper- ating vehicle in rough or densely wooded terrain. When driving at full speed on a dirt road, loose surfaces or wet grass, vehicle stopping distance will increase.

  • Page 37: Wheels And Tires

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. To raise the entire vehicle, install chocks in front and behind each front wheel. Center the jack under the rear frame crossmember.

  • Page 38: Wheel Installation

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section for rec- ommended tire inflation pressure.

  • Page 39: Light Bulb Replacement

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. LIGHT BULB REPLACEMENT To reduce the possibility of premature bulb failure, do not touch new bulbs with bare fingers. Use clean, dry tissue or paper towel to handle the glass portion of the bulb.

  • Page 40: Vehicle With A Discharged Battery

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. VEHICLE WITH A DISCHARGED BATTERY To reduce the possibility of severe injury or death from inadvertent motion, do not attempt to ‘jump start’...

  • Page 41: Hauling

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Hauling To reduce the possibility of severe injury or death while transporting the vehicle: Secure the vehicle and contents. Never ride on the vehicle being transported.

  • Page 42: Routine Maintenance

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual.

  • Page 43: Changing The Oil

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Remove the dipstick and wipe off the entire area with a lint free cloth. Insert the dipstick fully into the dipstick hole and remove. Exam- Maximum Oil Level Fill Cold Engine ine the level of the oil on the dipstick.
  • Page 44 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Place the oil drain pan under the oil drain plug (1) found at the rear of the engine base. Remove the drain plug (1), allow the oil to drain into the pan.

  • Page 45: Air Intake And Cooling Fins

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Both the oil dipstick and fill cap must be in place before operating the engine. Failure to install the dipstick and fill cap will result in oil being discharged into the engine compartment As a final check, check the oil level again with the vehicle on level ground.

  • Page 46: Starter/Generator Belt Tension

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. STARTER/GENERATOR BELT TENSION Tool List Qty. Tool List Qty. Belt Tension Gauge .............1 Ratchet ..............1 Wrench, 13 mm ............1 Socket, 13 mm............

  • Page 47: Spark Plugs

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. SPARK PLUGS Tool List Qty. Tool List Qty. Spark Plug Socket, 13/16” .......... 1 Ratchet..............1 Plug Gauge, Wire Type ..........1 Anti-seize Compound...........

  • Page 48: Lubrication

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

  • Page 49: Brakes

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. BRAKES To reduce the possibility of severe injury or death, always evaluate pedal travel before oper- ating a vehicle to verify some braking function is Dry, Level, Clean, Paved Surface present.

  • Page 50: Prolonged Storage

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PROLONGED STORAGE To reduce the possibility of severe injury or death resulting from a possible explosion: Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark.

  • Page 51: Hardware

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. HARDWARE Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table unless otherwise specified.

  • Page 52: Periodic Service Schedule

    MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE REMARKS Tires - pressure, condition of tires &...
  • Page 53 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. REMARKS Rear Axle - drain & replace fluid Rear Suspension - shock oil leakage, worn bushings, loose or missing hardware Front Suspension - strut oil leakage, excessive play in hubs or kingpins, worn bushings, loose or missing hardware...
  • Page 54 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. N o t e s : 5 - 22...
  • Page 56 The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. E-Z-GO Division of Textron Inc., 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts &...

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