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E-Z-GO ST 480 Owner's And Service Manual
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E-Z-GO ST 480 Owner's And Service Manual

E-z-go all terrain vehicle owner's & service guide
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Summary of Contents for E-Z-GO ST 480

  • Page 1 A Textron Company...

  • Page 2: Manual Information

    MANUAL INFORMATION For any questions on material contained in this manual, contact a representative Please observe these notes, cautions, and warnings; be aware that servicing a for clarification. vehicle requires mechanical skill and a regard for conditions that could be haz- ardous.
  • Page 3 E-Z-GO Division of Textron Inc. is not liable for errors in this manual or for incidental or consequential damage that result from the use of material in this manual. CUSTOMER SERVICE DEPARTMENT 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.

  • Page 4: Notes

    NOTES 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 manufacture date code. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty. Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty.

  • Page 5: Table Of Contents

    TITLE PAGE TITLE MANUAL INFORMATION... Inside Front Cover SERVICE BRAKE PEDAL ...3-10 PARK BRAKE ... 3-10 NOTES ... i HORN ...3-10 DIFFERENTIAL LOCK ... 3-10 SAFETY INFORMATION ...2-1 LOAD BED ... 3-11 ELECTRIC LIFT BED OPERATION ... 3-11 OPERATION AND SERVICE INFORMATION ...3-1 BEFORE INITIAL USE ...3-1 OPERATING THE VEHICLE ...
  • Page 6 PERIODIC SERVICE SCHEDULE ... 3-26 Fig. 22 Periodic Service Schedule ... 3-26 GENERAL SPECIFICATIONS... 4-1 TIRE INSPECTION ... 3-28 ST 480 ... 4-1 SEAT PROP ... 3-28 Fig. 23 Seat Prop ... 3-29 REPLACING THE FUEL FILTER ... 3-29 CHECKING THE OIL LEVEL ... 3-29 Fig.

  • Page 7: Safety Information

    • Follow all safety rules established in the area where the vehicle is being • E-Z-GO Division of Textron Inc. is not liable for errors in this manual or for operated. incidental or consequential damages that result from the use of the mate- rial in this manual.
  • Page 8 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE • Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated until inspected and repaired. The following information is very important in the maintenance of the vehicle.

  • Page 9: Operation And Service Information

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Service Parts Manuals, Technician’s Repair and Service Manuals and engine Repair Manuals are available from a local Distributor, an autho- rized Branch or the Service Parts Department.

  • Page 10: Fig. 1 Initial Service Chart

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Record and keep key number. lated (minimum of 5 air exchanges per hour). To reduce the chance of battery explosion that could result in Remove the protective clear plastic, that protect the seat bottom and severe injury or death, never smoke around or charge batter- back rest during shipping, before placing the vehicle in service.

  • Page 11: 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 MODIFICATIONS TO VEHICLE Slow down when in unfamiliar terrain. Slow down when cresting a hill in an area that you are unfamiliar with.

  • Page 12: Environmental Concerns

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings injury or death. Charging must take place in an area that is adequately ventilated (minimum of 5 air exchanges per hour). This vehicle may be equipped with an optional winch.

  • Page 13: Fig. 3 Winch Remote Control

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Before moving the winch, unplug the winch connector from the wire operate winch while sitting in passenger seat. Read the following sec- harness.

  • Page 14: Five Turns Around Drum

    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 object the winch is attached to could fall on the vehicle Replace frayed wire cable with a direct factory replace- and it’s occupants.

  • Page 15: Fig. 6 Do Not Hook Cable To Itself

    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 damage to the wire cable, never hook the cable to itself. Always use a nylon sling (Ref Fig. 6 on page 3-7) (Ref Fig.

  • Page 16: Controls And Indicators

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CONTROLS AND INDICATORS Vehicle controls and indicators consist of: Correct • key/light switch • direction selector •...

  • Page 17: Fig. 9 Key/Light Switch, Low Oil Pressure Light And Fuel Gauge

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Fuel Key/Light Switch Gauge Low Oil Pressure Indicator Light Fig. 9 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge component damage, the vehicle must be completely stopped before moving the direction selector.

  • Page 18: Accelerator Pedal

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings If oil level is below ADD mark on dipstick, add oil to bring level to FULL SERVICE BRAKE PEDAL mark (Refer to page 3-29).

  • Page 19: Load Bed

    To engage the differential lock, stop vehicle and push the lock lever for- When using the electric lift on the ST 480, be sure to avoid backing up ward towards the red ‘locked’ symbol (Ref Fig. 10 on page 3-9).

  • Page 20: Fig. 12 Electric Lift Switch

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings or holes and avoid steep slopes. Maintain a safe speed when driving down hill. Use service brake to control speed when traveling down an incline.

  • Page 21: 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 is not designed to comply with any DOT requirements. ty decals on the vehicle. Read, understand and follow the instructions located in the front part of this manual.

  • Page 22: Cold Starting

    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 oil should be changed in accordance with the Periodic Service parking brake handle. Schedule while the engine is warm. See SERVICE AND MAINTE- •...

  • Page 23: Fuel

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings above recommended speeds, limit speed with service brake. On steep hills, it is possible for the vehicle to coast at greater than nor- blended with alcohols or ethers.

  • Page 24: Labels And Pictograms

    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 vehicle uses a combination starter/generator to both start the downpour. This vehicle is not equipped with seat belts and the sun top engine and charge the battery.

  • Page 25: Vehicle Cleaning And Care

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings kg) and no more than 50 lbs (23 kg) tongue weight may be attached to Clean windshield with lots of water and a clean cloth. Minor scratches the hitch.

  • Page 26: Vehicle Care Products

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings aerosol cans of Battery Protector, Penetrant/Lubricant, White Lith- VEHICLE CARE PRODUCTS ium Grease, and Carburetor and Choke Cleaner. (P/N 75508- To help maintain the vehicle there are several products available G01) through local Distributors, authorized Branches, or the Service Parts...

  • Page 27: Fig. 16 Lifting The 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 Place the jack at the center of the front axle. Raise the vehicle and posi- tion jack stands under the frame crossmember as indicated. Lower jack and test the stability of vehicle on the four jack stands.

  • Page 28: Wheel Installation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings only impact sockets. Regular sockets are not designed for A tire explosion can cause severe injury or death. Never exceed infla- impact pressures exerted by power tools.

  • Page 29: Fig. 17 Wheel Installation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings With the valve stem to the outside, mount the wheel onto the hub with lug nuts. Be sure to position the wheel on hub correctly with arrow indi- cating direction of rotation when moving forward.

  • Page 30: Transporting 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 Roll Rubber TOWING Bezel Away Tail/Brake From Body Light It is recommended that the vehicle be moved by placing the entire vehi- Rear cle on a trailer, flatbed truck or other suitable transport.

  • Page 31: 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 for tightness of hardware and cracks in sun top at mounting points. Always remove windshield when transporting. Always check that the Direction vehicle and contents are adequately secured before transporting.
  • Page 32 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings In any product, components will fail to perform properly as the result of Wrap wrenches with vinyl tape to reduce the possibility of a dropped normal use, age, wear or abuse.

  • Page 33: Serial Number Plate Location

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings of 4% hydrogen gas or more is explosive. Engine exhaust gas (carbon monoxide) is deadly. Carbon monoxide is an odorless, colorless gas that is formed as a natural part of incomplete combustion of hydrocarbon fuels.

  • Page 34: 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 ✓ ♦ ▲ Replace Check Clean, Adjust, etc. To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for this vehicle.
  • Page 35 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ✓ STEERING ASSEMBLY Check for abnormal play, tightness of all hardware ✓ TIE RODS/LINKAGES Check for excessive play, bent components or loose connections ✓...

  • Page 36: 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 ♦ RACK END BALL JOINT Lubricate, use wheel bearing grease ✓ REAR AXLE Check for unusual noise and loose or missing mounting hardware ✓...

  • Page 37: Fig. 23 Seat Prop

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings fuel tank first and plug. Remove filter from hose going to fuel pump and discard. Install new fuel filter and reposition the clamps over the inlet and outlet. CHECKING THE OIL LEVEL Tool List Clean cloth ...

  • Page 38: Fig. 24 Oil Fill Cap, Dipstick And Fuel Filter

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings If oil is required, remove oil fill cap and add oil slowly to bring level to the FULL mark.

  • Page 39: Fig. 27 Oil Viscosity Chart

    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 oil must be high quality detergent oil classified ‘For Service SF, SG, SH, SJ’ or higher. Do not use special additives and do not mix oil with gasoline.

  • Page 40: Changing The Oil Filter

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LUBRICATION Oil Filter fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that Oil Drain could damage components.

  • Page 41: 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 AIR CLEANER INSPECTION AND REPLACEMENT The air cleaner is a dual filter cleaner, equipped with a foam pre-cleaner over a conventional paper cartridge.

  • Page 42: Rear Axle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Unscrew the knob securing the cartridge to the air cleaner base and from the check plug hole. Install the check plug and the fill plug. In the remove plate.

  • Page 43: Fig. 32 Check Belt Tension With Gauge

    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 starter/generator belt tension should be checked after the first 15- 20 hours of operation and set to 75 - 80 lbs. (34 - 36 kg). A loose belt can cause audible vibration and squeal.

  • Page 44: 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 components adjacent to the battery which should also be sprayed with BATTERY CLEANING the sodium bicarbonate (baking soda) solution. To reduce the possibility of damage to vehicle or floor, neutralize acid before rinsing battery.

  • Page 45: Fig. 36 Cleaning 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 After every off road use, allow to cool and then check for a build up of Remove and inspect the spark plugs at intervals per the Periodic Ser- dirt and debris in the air intake and cooling fins.

  • Page 46: 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 After the vehicle has been put into service, it is recommended that the Preparing the engine for a prolonged storage period (30 days or more) brakes be checked daily by performing the following test: calls for a few simple steps to prevent a build up of varnish and gum in the carburetor and corrosion in the engine.

  • Page 47: Fig. 37 Torque Specifications And Bolt Grades

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Generally, three grades of hardware are used in the vehicle. Grade 5 and grade 8 hardware is identified by 6 marks on the head. Unmarked hardware can be identified by the three marks on the hexagonal head hardware is Grade 2 (Ref Fig.

  • Page 48: 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 CAPACITIES AND REPLACEMENT PARTS Fuel Tank / Fuel 6.0 gal (22.5 liters) 87 Octane 1 1/2 qt (1.4 liters) Engine Oil P/N 492932 Oil Filter...

  • Page 49: General Specifications

    ST 480 STANDARD EQUIPMENT: DASH PANEL ...Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) BATTERY...One 12 Volt Maintenance Free (515 CCA, 82 Minute Reserve) ENGINE...16 H.P. (11.9 kW) 29.2 ci (480 cc) Twin Cylinder, Overhead Valve LOAD BED...Rotomolded cross link polyethelene & Electric Dump Pressurized Lubrication with Spin Off Filter LOAD BED FEATURES...Hinged Removable Tailgate, Removable Bed Sides...

  • Page 50: Fig. 1 Vehicle Dimensions

    GENERAL SPECIFICATIONS 110.5 in (281 cm) 49 in (125 cm) 78 in (198 cm) 15 in (38 cm) 75 in (191 cm) 77 in (196 cm) with Brush Guard Cage Rear 38 in (96 cm) Front 38.5 in (97 cm) Fig.

  • Page 51: Fig. 2 Vehicle Incline Specifications

    GENERAL SPECIFICATIONS Maximum Recommended Ramp Grade Maximum Recommended Side Tilt 25% or 14˚ Max. 25% or 14˚ Max. Fig. 2 Vehicle Incline Specifications...

  • Page 52: Fig. 3 Vehicle Turning Clearance Diameter

    GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER Approx. 23.5 ft (7.2 m) Fig. 3 Vehicle Turning Clearance Diameter...

  • Page 53: Limited Warranty

    EMISSION CONTROL SYSTEM WARRANTY ENGINE OWNER WARRANTY POLICY STATEMENT Refer to the Briggs & Stratton (Owner’s Defect Warranty Rights and Obligations) with vehicle, for Engine Warranty information. ® Refer to the Briggs & Stratton Operating & Maintenance Instructions, provided with vehicle, for Emission Control System Warranty information. LIMITED WARRANTY ®...
  • Page 54 LIMITED WARRANTY Notes:...

  • Page 55: Declaration Of Conformity

    DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION...
  • Page 56 DECLARATION OF CONFORMITY Notes:...
  • Page 57 See Following Pages For Explanation Of These Pictograms: (2,3,4,6,9,36,37, 38,39,40,29) See Following Pages For Explanation Of These Pictograms: (19,43,44,45) 75808-G01 75808G01 74093-G01 See Following Pages 74093G01 For Explanation Of These Pictograms: (1,23,27,18,20, 22,17,15) See Following Pages For Explanation Of These Pictograms: (1,35) 75696G01 75696G01...

  • Page 58: Labels And Pictograms

    LABELS AND PICTOGRAMS WARNING See Following Pages For Windshields do not provide protection Explanation Of Pictogram: (30) from golf balls or other flying objects. EGWHL14 See Following Pages For Explanation Of Pictogram: (49) WARNING Keep entire body inside car. 27653G01 See Following Pages For Explanation Of These Pictograms:...
  • Page 59 WARNING READ MANUAL WARNING USE CAUTION IN INCLEMENT WEATHER WARNING DO NOT OPERATE IF USING ALCOHOL OR DRUGS Fig. 3 Pictogram Definitions LABELS AND PICTOGRAMS MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED 14˚ / 25% WARNING MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED LOAD WITH HIGH CENTER...
  • Page 60 LABELS AND PICTOGRAMS WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL SECURE LOAD AS FAR FORWARD AS POSSIBLE. xxx lbs . MAXIMUM LOAD MAX LOAD MAX LOAD xxx kg BED CAPACITY XXX LBS XXX LBS XXX KG XXX KG DO NOT RIDE IN LOAD BED Fig.
  • Page 61 CLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE UNLEADED 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 Fig. 5 Pictogram Definitions (Continued) LABELS AND PICTOGRAMS SHORTING BATTERY TERMINALS MAY...
  • Page 62 LABELS AND PICTOGRAMS DO NOT DISPOSE OF BATTERIES IN LANDFILL DO NOT DRIVE ON HIGHWAY WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS BATTERIES ARE HEAVY. USE CARE LIFTING USE INSULATED TOOLS Fig. 6 Pictogram Definitions (Continued) Appendix A-6 WEAR EYE PROTECTION NO SMOKING HOT SURFACE...
  • Page 63 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 REVERSE ✱...
  • Page 64 LABELS AND PICTOGRAMS POSITION POSITION HEADLIGHTS UNLOCKED LOCKED Fig. 8 Pictogram Definitions (Continued) Appendix A-8 DIFFERENTIAL LOCKED WARNING KEEP ENTIRE BODY INSIDE CAR...
  • Page 66 A Textron Company E-Z-GO Division of Textron Inc. P.O. Box 388 Augusta, Georgia 30903-0388 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.