Ezgo S4 Manuals

Manuals and User Guides for Ezgo S4. We have 5 Ezgo S4 manuals available for free PDF download: Technician's Repair And Service Manual, Service Manual, Owner's Manual

Ezgo S4 Technician's Repair And Service Manual (208 pages)

GASOLINE POWERED UTILITY VEHICLE

Brand: Ezgo | Category: Utility Vehicle | Size: 18 MB

Table of Contents

5
- Safety
  2
- General Information
  4
  - Table of Contents
    5
- Safety Information
  7
General Information & Routine Maintenance

11
- Serial Number Location
  13
- Servicing the Vehicle
  13
- Starting the Vehicle with Adischarged Battery
  13
- Fuel
  14
- Towing
  14
- Powertrain Maintenance
  15
- Routine Maintenance
  15
- Brakes
  16
- Tires
  16
- Top and Windshield
  16
- Trailering
  16
- Winter or Prolonged Storage
  16
- Care and Cleaning of the Vehicle
  17
- Hardware
  17
- Vehicle Care Products
  17
- Torque Specifications
  18
- Periodic Service Schedule
  19
- Safety
  26
Safety

31
- Body
  33
  - General
    33
  - Body Componenet Replacement
    33
- Body
  34
  - Minor Scratches
    42
    
    Larger Scratches
    42
    
    Complete Panel Repair
    42
- Wheels and Tires
  47
- Front Suspension and Steering
  51
- Speed Control
  87
- Engine
  96
Fuel System

107
- General
  109
- Carburetor Operation
  110
  - Float System
    110
  - Pilot Jet System
    110
  - Main Jet System
    110
  - Carburetor Service
    110
  - Choke System
    110
  - Choke Operation
    110
- Fuel System Component Service and Replacement
  111
  - Choke Cable and Housing Removal
    111
  - Choke Cable and Housing Installation
    111
  - Carburetor Removal
    112
  - Carburetor Disassembly
    112
  - Float Level Alignment
    113
  - Carburetor Installation
    113
- Fuel Pump
  113
Continuously Variable Transmission (Cvt)

117
- Driven Clutch
  119
- Fig. 1 Continuously Variable Transmission System (CVT)
  119
- Continuously Variable Transmission (Cvt)
  120
  - Clutches
    120
    
    Increased Load
    120
    
    Equilibrium
    120
    
    Removing the Drive Belt
    120
    
    Drive Belt Service
    120
    
    Drive Clutch Removal
    120
  - Fig. 2 Removing the Drive Belt
    120
  - Fig. 3 CVT Components
    121
    
    Drive Clutch Installation
    122
  - Storage
    122
- Direction Selector
  127
Electrical

131
- Circuits and Controls
  133
- Generator
  133
- Starter
  133
- Testing Ignition Circuit
  133
  - Testing the Magneto
    137
- Wiring
  133
- Testing Charging Circuit
  138
- Testing Starting Circuit
  138
- Inspection
  139
- Starter/Generator
  139
  - Disassembly
    139
- Battery Voltage Test
  140
- Dvom (Digital Volt Ohm Meter)
  141
- Power Supply
  141
- Storage of Battery
  141
- Troubleshooting
  141
- Mechanical Brakes
  145
- Rear Suspension
  167
- Rear Axle
  173
Troubleshooting

179
- Gasoline Vehicle Performance
  181
  - Starter Does Not Turn
    181
  - Starter Turns Slowly
    181
  - Engine Runs Rough or Loss of Power
    182
  - Poor Low Speed Performance
    183
  - Poor Midrange or High Speed Performance
    183
  - Engine Overheating
    183
  - Repeated Spark Plug Fouling
    184
  - Carburetor Floods Engine
    184
  - Excessive Smoking
    184
  - Backfiring
    184
  - Erratic, Surging, or Sudden Change in Governed Speed
    185
- Fuel Accumulation in the Crankcase
  185
  - Fuel Distribution
    185
  - Mechanical
    185
  - Operation and Application
    186
- Carburetor
  186
  - Overflow Leak
    186
  - Poor Fuel Economy
    186
  - Poor Acceleration
    186
  - Hard Starting
    186
  - Poor High Speed Operation
    187
  - Abnormal Combustion (Fuel Mixture)
    187
  - Loss of Power (Insufficient Fuel)
    187
  - Loss of Power (Insufficient Air)
    187
  - Surging
    187
- Starter/Generator
  187
  - Starter Is Noisy
    187
  - Rectification Is Imperfect
    188
  - Generator Does Not Charge
    188
- Suspension and Steering
  188
  - Uneven Tire Wear
    188
  - Stiff Steering
    188
  - Play in Steering
    188
  - Vibration
    188
  - Steering Pulls to One Side
    189
- Brake System
  189
  - Neither Wheel Locks When Park Brake Is Latched
    190
  - Neither Wheel Locks
    190
  - Grabbing Brakes (over Sensitive)
    190
  - Parking Brake Hard to Latch
    190
  - Parking Brake will Not Stay Latched
    190
  - General
    193
- General Specifications
  201

Ezgo S4 Service Manual (192 pages)

ELECTRIC POWERED PERSONNEL VEHICLE

Brand: Ezgo | Category: Electric Vehicles | Size: 9 MB

Table of Contents

5
- General Information
  4
  - Table of Contents
    5
- Safety Information
  7
General Information & Routine Maintanence

11
- Hauling
  13
- Servicing the Electric Vehicle
  13
- Transporting Vehicle
  13
- Fig. 1 Initial Service Chart
  14
- Fig. 2 Lubrication Points
  14
- Light Bulb Replacement
  14
- Routine Maintenance
  14
- Vehicle Cleaning and Care
  14
- Sun Top and Windshield
  15
- Vehicle Care Products
  15
- Fig. 3 Torque Specifications
  16
- Hardware
  16
- Torque Specifications
  16
- Periodic Service Schedule
  17
- Safety
  19
  - Section Title
    19
  - Notices, Cautions Warnings and Dangers
    21
    
    Additional Warnings
    22
    
    Battery Removal & Installation
    23
  - Lifting the Vehicle
    24
Safety

27
- Body
  27
  - Body
    29
    
    General
    29
    
    Body Component Replacement
    29
  - Painting
    34
    
    Minor Scratches
    34
    
    Larger Scratches
    34
    
    Complete Panel Repair
    34
- Wheels and Tires
  37
Front Suspension and Steering

43
- Maintenance
  
  46
  - Lubrication
    46
  - Wheel Bearing and King Pin Bushing Inspection
    46
  - Wheel Alignment
    47
  - Wheel Bearing Adjustment
    47
  - Wheel Bearing Packing
    47
- Front Suspension
  
  49
  - Front Shock Absorber Replacement
    50
  - Front Axle Replacement
    50
  - Front Spring Replacement
    51
  - Hub Replacement
    52
  - Wheel Bearing and Race Replacement
    52
  - Axle Linkage Rod Replacement
    53
- Steering
  
  54
Electronic Speed Control

65
- General
  67
- Performance Options & Diagnostics
  67
  - Changing Performance Options
    67
  - Controller
    68
- General Troubleshooting
  70
  - Symptoms
    70
  - Testing Battery Voltage
    70
  - Continuity Check
    70
  - Testing a Switch for Continuity
    71
  - Testing a Solenoid for Continuity
    71
- Troubleshooting Diagrams
  72
- Inductive Throttle Sensor (Its) Testing and Replacement
  76
- Controller Replacement
  79
- Solenoid Replacement
  79
- Motor
  85
Batteries and Charging

91
- Battery
  93
- Battery Maintenance
  93
  - At each Charging Cycle
    94
  - Monthly
    94
  - Electrolyte Level and Water
    94
  - Cleaning Batteries
    95
  - Battery Replacement
    96
  - Prolonged Storage
    96
  - Battery Charging
    97
  - AC Voltage
    97
- Safety
  93
- Troubleshooting
  97
  - Hydrometer
    98
  - Using a Hydrometer
    98
- Battery Charger
  101
  - Rear Axle
    112
  - Brakes
    122
- Electrical System
  131
- Rear Suspension
  143
- Rear Axle
  149
- Handheld Diagnostics
  155
- Troubleshooting
  163
Lightning Protection and Grounding

169
- Equipment Fault and Personal Safety System
  171
- Ground Network Requirements
  171
- Ground Systems
  171
- Grounding Requirements
  171
- External Grounding Requirements
  172
- Lightning Protection System
  172
- Materials
  172
- 10. Equipment Fault and Personal Safety System
  173
- Weather Protection
  175
- General Specifications
  183

Ezgo S4 Owner's Manual (58 pages)

72V ELECTRIC VEHICLE

Brand: Ezgo | Category: Electric Vehicles | Size: 4 MB

Table of Contents
5
Introduction

9
Safety Labels

11
- Operation Warning Label (662185)
  11
- Rear-Facing Seat / Load Deck Warning (P/N 610631)
  11
Safety

11
- Maximum Cargo Load / Maximum Weight Capacity
  13
- Tire Pressure
  13
- Operator Safety
  13
  - Unauthorized Operation
    14
  - Operating Without Instruction
    14
  - Alcohol or Drugs
    14
  - Passenger
    14
  - Before Operating
    14
  - Load Operation
    15
  - Driving in Reverse
    15
  - Driving a Damaged Vehicle
    15
  - Driving at Maximum Speeds
    15
  - Driving on Pavement
    15
  - Driving on Public Roads
    15
  - Turning
    15
  - Driving Uphill
    15
  - Driving Downhill
    15
  - Stalling on a Hill
    15
  - Tires
    16
  - Slippery Terrain
    16
- Battery Charging
  16
- Vehicle Lifting
  16
- Vehicle Modification
  16
- Maintenance Safety
  16
Features and Controls

19
- Key Switch
  19
- State of Charge / Hour Meter
  19
- Max Speed / Range Switch
  19
- Cup Holder
  19
- Headlight Switch
  19
  - Halogen
    19
  - LED (if Equipped)
    19
- Usb Port
  19
Table of Contents

20
- Steering Wheel
  20
- Brake Pedals
  20
  - Brake Pedal
    20
  - Parking Brake Pedal
    20
- Accelerator Pedal
  20
- Hip Restraints
  20
- Seat Bottom
  20
- Glove Box / Storage Compartments
  20
- Charger Receptacle
  20
- Canopy Top and Windshield (if Equipped)
  20
- Flip Seat/Load Deck
  21
Operation

23
- Safety
  23
- Before Initial Use
  23
- Pre-Ride Inspection
  23
- Environmental Awareness
  24
- Battery Charger
  24
- Performance Features
  24
  - Speed Control
    24
  - Pedal-Up Braking
    25
  - Walk-Away Feature
    25
  - Anti-Roll Back Feature
    25
  - Anti-Stall Feature
    25
  - High Pedal Disable Feature
    25
  - Diagnostic Mode Feature
    25
- Starting and Stopping the Vehicle
  26
  - Starting on a Hill
    26
- Accelerating
  26
- Braking
  27
  - Coasting
    27
- Driving with a Passenger
  27
- Slippery Surfaces
  27
- Driving Uphill
  28
- Traversing Hillsides
  28
- Driving Downhill
  28
- Stalling on a Hill
  28
- Driving in Reverse
  29
- Parking the Vehicle
  29
- Hauling Cargo
  29
  - Maximum Cargo Load / Maximum Weight Capacity
    30
- Flip Seat/ Load Deck Operation
  30
Vehicle Maintenance

31
- Maintenance Safety
  31
- Scheduled Maintenance
  32
  - Severe Use Conditions
    32
- Scheduled Maintenance Chart
  32
- Recommended Lubricants and Fluids
  33
- Replacement of Maintenance Items
  33
- Lifting the Vehicle
  34
  - Lifting Front
    34
  - Lifting Rear
    34
  - Lowering Vehicle
    34
- Vehicle Cleaning and Care
  35
  - Washing the Vehicle
    35
  - Polishing the Vehicle
    35
- Tires
  35
  - Tire Pressure
    36
  - Tire Repair
    36
  - Tire Replacement
    36
- Wheels
  36
  - Wheel Removal
    36
  - Wheel Installation
    37
- Lights
  37
- Fuse Replacement
  38
- Controller System Test
  38
- Rear Axle
  39
  - Checking the Lubricant Level
    39
- Lubrication
  39
- Brakes
  40
  - Periodic Brake Test
    40
- Battery
  41
- Battery Disposal
  41
- Battery Cleaning
  42
- Battery Charging and Maintenance
  42
  - At each Charging Cycle
    42
  - Monthly
    42
  - Electrolyte Level and Water
    43
- Battery Replacement
  44
- Battery Storage
  45
- Battery Charging
  46
  - AC Voltage
    46
- Troubleshooting
  46
  - Using a Hydrometer
    47
- Transporting the Vehicle
  48
  - Hauling the Vehicle
    48
  - Towing the Vehicle
    48
Specifications

49
- Express S4 72V- Vehicle Specifications
  49

Ezgo S4 Owner's Manual (82 pages)

48 V ELECTRIC POWERED VEHICLE

Brand: Ezgo | Category: Electric Vehicles | Size: 3 MB

Table of Contents

5
- Safety
  7
  - Safety
    8
  - Notices, Cautions, Warnings, and Dangers
    9
  - General
    10
  - General Operation
    11
  - Maintenance
    11
  - Ventilation
    12
  - Labels and Pictograms
    13
- General Specifications
  19
Introduction

27
- Accelerator Pedal
  29
- Direction Selector
  29
- Features
  29
- General Information
  29
- Key Switch / Headlight Switch
  29
- State of Charge Meter
  29
- Brake and Park Brake
  31
- Brake Light/Turn Signal
  31
- Cup Holder
  31
- Front Seats
  31
- Glove Box
  31
- Grab Handles - Front Passenger
  31
- Hip Restraint
  31
- Horn
  31
- Rear View Mirror
  31
- Weather Enclosure
  31
- Battery Compartment
  32
- Charger Receptacle
  32
- Charger with DC to DC Converter
  32
- Ash Tray
  33
- Convertible Seat
  33
- Run/Tow Switch
  33
- Cargo Platform
  34
- Handrail - Rear
  34
- Hour Meter
  34
Operating Procedures

37
- Serial Number Location
  
  38
- Before Initial Use
  
  39
- Poratable Charger Installation
  
  40
  - Using the Charger
    41
  - Understanding the Charger
    41
  - LED Operation Codes
    42
  - LED Fault Codes
    42
  - Maintenance Instructions
    43
- Operating the Vehicle
  
  43
- Trucourse Technology
  
  44
  - General
    44
  - Changing Performance Options
    45
  - Operation
    45
  - Regenerative Braking
    46
  - Pedal-Up Braking
    47
  - Terrain
    47
  - Walk-Away Feature
    47
  - Anti-Roll Back Feature
    47
  - Anti-Stall Feature
    47
  - High Pedal Disable Feature
    48
  - Diagnostic Mode Feature
    48
- Starting and Driving
  
  48
  - Starting Vehicle on a Hill
    48
  - Coasting
    49
  - Labels and Pictograms
    49
  - Sun Top and Windshield
    49
Maintenance

51
- Vehicle Cleaning and Care
  
  53
  - Vehicle Cleaning
    53
- Environmental Concerns
  
  54
- Common Sense Operation
  
  54
- Repair
  
  55
  - Lifting the Vehicle
    55
- Wheels and Tires
  
  56
  - Tire Repair
    56
  - Wheel Installation
    57
- Light Bulb Replacement
  
  58
- Fuse Replacement
  
  58
- Service and Maintenance
  
  59
- Transporting Vehicle
  
  59
  - Towing
    59
  - Hauling
    59
- Routine Maintenance
  
  60
  - Tire Inspection
    60
  - Brakes
    60
- Periodic Brake Test for Mechanical Brakes
  
  61
- Rear Axle
  
  61
  - Checking the Lubricant Level
    61
- Lubrication
  
  62
- Hardware
  
  62
- Periodic Service Schedule
  
  63
- Battery Charging and Maintenance
  
  64
  - Safety
    64
  - Battery
    65
  - Battery Maintenance
    65
  - At each Charging Cycle
    65
  - Monthly
    65
  - Electrolyte Level and Water
    65
  - Battery Cleaning
    67
  - Battery Replacement
    68
  - Battery Charging
    69
  - AC Voltage
    69
  - Troubleshooting
    69
- Hydrometer
  
  70
  - Using a Hydrometer
    71
  - Battery Cgarger Maintenance
    71
- Prolonged Storage
  
  72
  - Declaration of Conformity
    77

Ezgo S4 Owner's Manual (62 pages)

Brand: Ezgo | Category: Offroad Vehicle | Size: 4 MB

Table of Contents
5
Safety

9
- General
  9
- Notices, Cautions, Warnings, and Dangers
  9
- General Operation
  11
- Maintenance
  12
- Ventilation
  13
- Labels and Pictograms
  14
General Specifications

15
Introduction

19
- Features
  19
  - General Information
    19
  - Steering Wheel
    19
  - Brake Pedal
    19
  - Park Brake
    19
  - Accelerator Pedal
    19
  - Cupholder
    19
  - Key Switch / Light Switch (if Equipped with Lights)
    20
  - State of Charge Meter (if Equipped)
    20
  - Direction Selector
    20
  - Fuse Block (if Equipped)
    20
  - Charger Receptacle
    21
  - Run - Tow/Maintenance/Storage Switch
    21
  - Seat
    22
  - Hip Restraints
    22
  - Sweater Basket
    22
  - Bag Well
    22
  - Glove Box Compartments and Ball Holders
    22
  - Sun Top (if Equipped)
    22
  - Battery Compartment
    22
Operating Procedures

25
- Serial Number Location
  25
- Before Initial Use
  26
- Portable Charger Installation
  27
- Understanding the Charger
  28
  - LED Operation Codes
    28
  - LED Fault Codes
    28
- Using the Charger
  29
- Charger Maintenance
  29
- Operating the Vehicle
  29
  - Performance
    30
  - Speed Control
    30
  - Pedal-Up Braking
    31
  - Terrain
    31
  - Walk-Away Feature
    31
  - Anti-Roll Back Feature
    31
  - Anti-Stall Feature
    31
  - High Pedal Disable Feature
    32
  - Diagnostic Mode Feature
    32
- Starting and Driving
  32
  - Starting Vehicle on a Hill
    32
  - Coasting
    33
- Labels and Pictograms
  33
- Sun Top and Windshield (if Equipped)
  33
Maintenance

35
- Vehicle Cleaning and Care
  35
- Common Sense Operation
  35
- Environmental Concerns
  36
  - Battery Disposal
    36
- Lifting the Vehicle
  36
- Wheels and Tires
  37
  - Tire Repair
    38
  - Wheel Installation
    38
- Light Bulb Replacement (if Equipped)
  39
  - Headlight
    39
  - Taillight
    39
- Fuse Replacement (if Equipped)
  39
- Transporting Vehicle
  40
  - Towing
    40
    
    Hauling
    40
  - Service and Maintenance
    40
  - Routine Maintenance
    41
  - Tire Inspection
    41
  - Brakes
    42
    
    Periodic Brake Test
    42
  - System Test
    42
  - Rear Axle
    43
    
    Checking the Lubricant Level
    43
  - Lubrication
    43
  - Capacities and Replacement Parts
    43
  - Hardware
    44
  - Battery Charging and Maintenance
    44
    
    Safety
    44
    
    Battery Disposal
    45
    
    Battery
    45
    
    Battery Maintenance
    45
    
    At each Charging Cycle
    46
    
    Monthly
    46
    
    Electrolyte Level and Water
    46
    
    Battery Cleaning
    48
    
    Battery Replacement
    49
    
    Prolonged Storage
    50
    
    Battery Charging
    50
    
    AC Voltage
    51
    
    Troubleshooting
    51
    
    Hydrometer
    51
Periodic Service Schedule

55
Appendix A

57
- Declaration of Conformity
  57

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Ezgo S4 Owner's Manual (58 pages)

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Ezgo S4 Owner's Manual (82 pages)

Table of Contents

Table of Contents

Introduction

Operating Procedures

Serial Number Location

Before Initial Use

Poratable Charger Installation

Operating the Vehicle

Trucourse Technology

Starting and Driving

Maintenance

Vehicle Cleaning and Care

Environmental Concerns

Common Sense Operation

Repair

Wheels and Tires

Light Bulb Replacement

Fuse Replacement

Service and Maintenance

Transporting Vehicle

Routine Maintenance

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Ezgo S4 Owner's Manual (62 pages)

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