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. 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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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 E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852 Owner’s Manual and Service Guide...
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.
TABLE OF CONTENTS SAFETY ........................ inside covers GENERAL INFORMATION ....................... ii SAFETY INFORMATION ......................vii 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.
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TABLE OF CONTENTS Fig. 19 Tail and Brake Light Bulb Replacement ..............12 VEHICLE WITH A DISCHARGED BATTERY ....................12 TRANSPORTING VEHICLE ....................12 TOWING ................................12 NEUTRAL LOCK .............................. 12 Fig. 20 Neutral Lock ....................... 12 HAULING ................................12 SERVICE AND MAINTENANCE ....................
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TABLE OF CONTENTS DECLARATION OF CONFORMITY (EUROPE ONLY)............45 LABELS AND PICTOGRAMS .................. Appendix A Owner’s Manual and Service Guide Page v...
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TABLE OF CONTENTS Owner’s Manual and Service Guide Page vi...
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: Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-Z- GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph.
SAFETY INFORMATION 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. Some commu- nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi- nances.
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SAFETY INFORMATION 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. • 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.
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SAFETY INFORMATION Notes: Owner’s Manual and Service Guide Page x...
SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL addition which affects capacity or safe operation, or make any change not in accordance with the owner’s The following text is provided as recommended by part II manual without the manufacturer’s prior written authori- of American Society of Mechanical Engineers / American...
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SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings equip the carrier with appropriate lights in accordance 5.2.3 The user should include in the operators’ train- with the manufacturer’s recommendations. ing program the following: (a) instructional material provided by the manufac- Control of Noxious Gases and Fumes...
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SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings building structures, and equipment. 5.5.13 Avoid running over loose objects, potholes, and bumps. 5.4.8 Operators shall not add to, or modify, the car- 5.5.14 To negotiate turns, reduce speed to improve rier.
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SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 6.1.1 Carriers may become hazardous if mainte- inspected to ensure that maintenance preserves the orig- nance is neglected. Therefore, maintenance facilities, inal approved safe operating features.
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 Check for correct tire inflation. See GENERAL SPECIFI- vehicle, we ask you to spend some time reading this CATIONS.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Key/Light Switch Fuel Gauge Low Oil Pressure Indicator Light Ref Kes 2 Fig. 2 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge DIRECTION SELECTOR To reduce the possibility of component...
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Park Service Horn Brake Brake Accelerator Ref Hor 1 Ref Abc 1 Fig. 6 Horn Button Fig.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings MANUAL LIFT BED OPERATION Severe injury could result if bed is lowered and traps fingers or other body parts. Exercise caution while operating the manual lift.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ravine. A misjudgment of distance or an unstable surface could result in the vehicle falling backwards. Before operating, check to ensure no one is behind 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 OPERATING THE VEHICLE Always bring the vehicle to a complete stop before shifting the direction selector. Improper use of the vehicle or the lack Do not take vehicle out of ‘gear’...
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 required. Accelerate slowly and push the choke in com- Place left foot on service brake and release the park pletely when the engine runs smoothly.
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 vehicle, do not hold on to sun top struts and stand on body panels.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings VEHICLE CLEANING AND CARE VEHICLE CLEANING To reduce the possibility of severe injury or vehi- cle damage, read and understand all instructions supplied by manufacturer of pressure washer.
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 ................
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Use caution when inflating tires. Overinflation It is important to follow the ‘cross sequence’ pattern when installing lug nuts. This will could cause the tire to separate from the wheel or assure even seating of the wheel against the hub.
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 replace the turn signal light bulb, support turn signal If the vehicle battery has become discharged, it must be housing from backside of cowl while removing two charged using a 12 volt charger that is rated at 10 amps screws securing lens.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings off all electrical loads from the battery before removing battery wires. Hole in Direction Hole in Direction Selector Cam Wrap wrenches with vinyl Selector 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 SERIAL NUMBER LABEL LOCATION Two serial number and manufacture date code label are on the vehicle. One is placed on the body below the front, driver side of the seat.
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.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings FRONT SHOCK ABSORBERS Check for oil leakage and loose fasteners FRONT SPRINGS Check for loose hardware, cracks at attachments FRONT WHEEL ALIGNMENT Check for unusual tire wear, align if required Check for bent/binding linkage rod...
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 500 HOURS (includes items listed in previous tables & the following) TIMING BELT Check tension and for signs of wear/damage, replace if worn or damaged CARBURETOR Clean Remove carbon from cylinder head and pistons...
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Large HEAVY DUTY WORK 'O' Ring 10W-40 10W-40 10W-30 10W-30 Filter LIGHT DUTY WORK Small 'O' Ring Inside End Of Oil Filter Ref Rof 1 10W-30...
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 filter mounting plate with the holes in the engine. Wrench, 3/4"..............1 Install and hand tighten the bolts before tightening them Wrench, 9/16"..............
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Adjusting the Belt clean battery and keep all smoking materials, open flame or sparks away from the battery. Loosen the starter/generator pivot bolt.
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’...
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 1/4" below top of reservoir. Add DOT 3 or 4 fluid as required. AIR INTAKE AND COOLING FINS Fill Plug T o p r e v e n t p o s s i b l e b u r n s , e n g i n e p a r t s...
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings correctly installed. Insert cover into the lower portion of the enclosure and swing it up into place. Squeeze hous- Air Filter ing together and secure with top clips.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • Remove and inspect the spark plugs at intervals indi- Remove spark plugs (Refer to SPARK PLUGS on cated in the Periodic Service Schedule (Ref.
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OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 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.
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 L) / 87 Octane Engine Oil 1 1/2 qt (1.4 L) Oil Filter P/N 26591-G01...
GENERAL SPECIFICATIONS 10 in (25 cm) 47 in (119 cm) 66 in (168 cm) (Front) 37.5 in (95 cm) 103 in (262 cm) (Rear) 35 in (89 cm) 38 in (97 cm) 47 in MPT ™ 800 (119 cm) INDUSTRIAL ™ 800 18 in (46 cm) 47 in...
GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP GRADE RECOMMENDED MAX SIDE TILT 25% or 14 25% or 14 TURNING CLEARANCE DIAMETER MPT ™ 800 19 ft (5.8 m) MPT ™ 1200 22 ft (6.7 m) INDUSTRIAL ™ 800 19 ft (5.8 m) INDUSTRIAL ™...
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GENERAL SPECIFICATIONS Notes: Owner’s Manual and Service Guide Page 34...
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. Owner’s Manual and Service Guide Page 36...
VEHICLE WARRANTIES 2004 INTERNATIONAL WARRANTY (ALL COUNTRIES OUTSIDE THE U.S. AND CANADA) E-Z-GO Division of Textron, Inc. ("E-Z-GO") warrants to the Original Retail Purchaser or the Original Retail Lessee that any 2004 E-Z-GO vehicle and/or Battery Charger shall be free from any defects in material or workmanship for one year from the date of installation at the customer's location with respect to parts and labor.
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VEHICLE WARRANTIES Notes: Owner’s Manual and Service Guide Page 38...
VEHICLE WARRANTIES - FEDERAL (2004) FEDERAL EMISSIONS 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.
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VEHICLE WARRANTIES - FEDERAL (2004) 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.
VEHICLE WARRANTIES - CALIFORNIA (2004) CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Fuji Heavy Industries Ltd. (herein "FUJI") are pleased to explain the emis- sion control system warranty on your 2004 and later small off-road engine (herein "engine"). In California, new en- gine must be designed, built and equipped to meet the State's stringent anti-smog standards.
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VEHICLE WARRANTIES - CALIFORNIA (2004) part which is scheduled for replacement as required maintenance shall be warranted for the pe- riod of time up to the first scheduled replacement point for that part. 3. DIAGNOSIS You shall not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized dealer, distributor or service provider.
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VEHICLE WARRANTIES - CALIFORNIA (2004) (iii) Spark advance/retard system, if applicable (4) Exhaust manifold, if applicable (5) Miscellaneous Items Used in Above Systems (i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies (iii) Filter lock assy (gaseous fuel, if applicable) I.
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VEHICLE WARRANTIES - CALIFORNIA (2004) Owner’s Manual and Service Guide Page 44...
DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Owner’s Manual and Service Guide Page 45...
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DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION Owner’s Manual and Service Guide Page 46...
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LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1...
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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 See Following 74443G01 Pages For See Following Pages Explanation For Explanation Of Of These These Pictograms: Pictograms:...
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LABELS AND PICTOGRAMS WARNING WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL READ MANUAL SECURE LOAD AS FAR FORWARD xxx lbs . AS POSSIBLE. xxx kg MAXIMUM LOAD BED WARNING CAPACITY USE CAUTION IN INCLEMENT WEATHER DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE...
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LABELS AND PICTOGRAMS DO NOT CLEAN UP GASOLINE 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...
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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 DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY LOCKED...
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LABELS AND PICTOGRAMS MAXIMUM TAILGATE LOAD Ref Pic 1-4 Owner’s Manual and Service Guide Appendix A - 6...
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Read and understand the following warnings Some components are heavy, spring loaded, highly cor- before attempting to operate the vehicle: rosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide, prevent personal battery acid and hydrogen gas could result in serious injury or death, observe bodily injury to the technician/mechanic and bystanders if the following:...
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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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