Ezgo WorkHorse ST 480 Manuals

Ezgo WorkHorse ST 480 Manuals

Manuals and User Guides for Ezgo WorkHorse ST 480. We have 1 Ezgo WorkHorse ST 480 manual available for free PDF download: Technician's Repair And Service Manual

Ezgo WorkHorse ST 480 Technician's Repair And Service Manual

Ezgo WorkHorse ST 480 Technician's Repair And Service Manual (165 pages)

GASOLINE POWERED UTILITY VEHICLE

Brand: Ezgo | Category: Utility Vehicle | Size: 15 MB

Table of Contents

Notes, Cautions and Warnings
2
Safety
2
Notes
4
Table of Contents
5
General
7
General Operation
7
Safety Information
7
Maintenance
8
Ventilation
9
General Information & Routine Maintenance
11
Starting the Vehicle with a Discahrged Battery
13
Servicing the Vehicle
13
Serial Number Plate Location
13
Neutral Lock
14
Powertrain Maintenance
14
Routine Maintenance
14
Towing
14
Brakes
15
Care and Cleaning of the Vehicle
15
Tires
15
Vehicle Care Products
15
Trailering
16
Top and Windshield
16
Prolonged Storage
16
Bolt Grades
17
Hardware
17
Torque Specifications
17
25 Hours
18
50 Hours
18
8 Hours or Daily
18
Periodic Service Schedule
18
100 Hours
19
250-300 Hours or Yearly
19
500 Hours
20
Fuel Handling and Storage
23
General Safety Practices
23
Lighting for Operating Areas
23
Stability
23
Control of Noxious Gases and Fumes
24
Operating Safety Rules and Practices
24
Personnel and Burden Carrier Operator Responsibility
24
Warning Device
24
Operator Care of Personnel and Burden Carriers
25
Traveling
25
Maintenance Practices
25
Loading
25
Maintenance Procedures
26
General Maintenance
27
Important Safety Warning
27
Modifications to Vehicle
27
Before Servicing the Vehicle
28
Battery Removal and Installation
29
Lifting the Vehicle
29
Body and Truckbed
31
Drive Rivet Removal
33
Drill out Metal Rivet
33
Component Replacement
33
Instrument Panel Replacement
34
Tool List
34
Cowl Replacement
35
Front Bumper Replacement
35
Rocker Panel Replacement
36
Seat Back Replacement
36
Seat Bottom Replacement
36
Seat Components
36
Body Components (Rear)
37
Side Panel Replacement
38
Seat Filler Panel Replacement
38
Seat Support Panel Replacement
38
Electric Lift Toggle Switch and Winch Receptacle
38
Electric Lift Actuator
39
Rear Fender Replacement
39
Rear Panel Replacement
39
Truck Bed Replacement
39
Truckbed Components
40
Hitches
41
Hydraulic Brake System Components
45
Part of Frame
45
- Wheel Brake
  46
- Daily Brake Performance Test
  46
- How the Hydraulic System Works
  46
- Brake System Inspection
  46
- Brake Fluid
  47
- Master Cylinder
  47
- Master Cylinder Replacement
  47
- Replacing Master Cylinder
  47
- Table of Contents
  47
Master Cylinder

48
Brake Fluid

48
- Brake Linkage
  48
- Brake Pedal Bumper Adjustment
  48
- Crowfoot Wrench, 1", 3/8" Drive
  48
- Lock Nut
  48
- Teflon Tape
  48
Tool List Qty. Required

48
- Torque Wrench, In. Lbs., 3/8" Drive
  48
- Wrench, 9/16
  48
- Socket, 7/16", 3/8" Drive
  51
- Socket, 9/16", 3/8" Drive
  51
  - Wheel Brake Service
    51
  - Belleville Washer Installation
    52
  - Replacing an Adjuster
    52
  - Bleeding and Flushing
    53
  - Bleeding Sequence
    53
  - Wheel Brake Assembly Replacement
    53
  - Bleeder Valve
    54
  - Brake Pedal Removal and Installation
    54
  - Flushing
    54
  - Cable Replacement
    55
  - Parking Brake
    55
  - Parking Brake System Components
    56
  - Continuously Variable Transmission
    57
  - Clutches
    59
  - Drive Clutch
    59
  - Driven Clutch
    59
  - CVT Components
    60
  - Drive Clutch Removal
    60
  - Equilibrium
    60
  - Increased Load
    60
  - Drive Clutch Installation
    61
  - Driven Clutch Removal
    61
  - Driven Clutch Repair
    61
  - Torque Ramp Buttons
    61
  - Drive Belt Service
    62
  - Driven Clutch Installation
    62
  - Removing the Drive Belt
    62
  - Storage
    62
  - Direction Selector
    63
  - Direction Selector Components
    65
  - Removing Direction Selector
    65
  - Replacing a Micro Switch
    66
  - Replacing the Reverse Warning Buzzer
    66
  - Shift Cable Adjustment
    66
  - Electrical
    67
  - Electrical System Components
    69
  - Circuits and Controls
    70
  - Electrical Plate Assembly
    70
  - Digital Volt Ohm Meter
    71
  - Generator Mode
    71
  - Starter Mode
    71
  - Starter/Generator
    71
  - Testing Charging Circuit
    72
  - Starting and Charging System Wiring Diagram
    73
  - Starter/Generator Disassembly
    74
  - Battery Voltage Test
    75
  - Bearing Removal
    75
  - Starter/Generator Brush Removal
    75
  - Starter/Generator Inspection
    75
  - Check for Loose or Bare Wires
    76
  - Power Supply
    76
  - Storage of Battery
    76
  - Troubleshooting
    76
  - Accessory Wiring Diagram
    77
  - Accessory Wiring
    78
  - Check Fuse
    78
  - Check Power Wire
    78
  - Light Bulb Replacement
    78
  - Horn and Fuse Block
    79
  - Headlight, Turn Signal and Taillight
    81
  - Hour Meter
    82
  - Engine
    83
  - Oil Capacity
    86
  - Oil Recommendations
    86
  - Power Train Maintenance
    86
  - Removing Debris
    86
  - Changing the Oil
    87
  - Check Oil Level on Dipstick
    87
  - Clean Entire Dipstick
    87
  - Cleaning the Top of the Engine
    87
  - Air Cleaner Maintenance
    88
  - Cartridge Service
    88
  - Pre-Cleaner Service
    88
  - Starter/Generator Belt Tension
    88
  - Adjusting Belt Tension
    89
  - Checking Belt Tension with Finger
    89
  - Gapping the Spark Plug
    89
  - Spark Plugs
    89
  - Engine Description
    90
  - Engine Operation
    90
  - Engine Specifications
    90
  - Vehicle Preparation to Test Engine Condition
    90
  - Disconnect Accelerator, Governor, and Choke Cables
    91
  - Engine Removal
    91
  - Disconnect Differential Lock Cable
    92
  - Disconnect Starter and Ground Cables
    93
  - Disconnect White Engine Stop Wire
    93
  - Engine Installation
    93
  - Ignition Control Module and Fuel Line
    93
  - Starter/Generator Installation
    94
  - Starter/Generator Removal
    94
  - Starter/Generator Mounting
    95
  - Starter/Generator Wiring
    95
  - Front Suspension and Steering
    97
  - Front Axle Replacement
    99
  - Front Shock Absorber Replacement
    99
  - Front Suspension
    99
  - Shock Boot Removal and Replacement
    99
  - Front Axle Alignment
    100
  - Front Spring Replacement
    100
  - Suspension Components
    100
  - Tie Rod Replacement
    101
  - Tie Rod, Wheel Bearing and King Pin Inspection
    101
  - Hub Cover Removal
    102
  - Steering
    102
  - Steering Shaft Replacement
    102
  - Steering Wheel Replacement
    102
  - Steering Components
    103
  - Steering Housing Assembly Replacement
    103
  - Idler Arm Replacement
    104
  - Rack Ball Joint Removal
    104
  - Rack Replacement
    104
  - Rack Tensioner Replacement
    104
  - Lubrication
    105
  - Rack Ball Joint Installation
    105
  - Steering Pinion and Bearing Replacement
    105
  - Wheel Bearing Inspection/Packing
    105
  - Bearing Adjustment
    106
  - Lubrication Points
    106
  - Seal Installation
    106
  - Wheel Bearing Replacement
    106
  - Front Spindle and Bearing
    107
  - King Pin Bushing Replacement
    107
  - Wheel Alignment
    107
  - Front End Alignment
    108
  - Fuel System
    109
  - Fuel System Components
    111
  - Fuel
    112
  - Fuel System Component Service and Replacement
    112
  - Fuel Tank Location
    112
  - Choke System
    113
  - Fuel Lines and Filters
    113
  - Fuel Pump
    113
  - Fuel Tank
    113
  - Carburetor
    114
  - Choke Cable Installation and Adjustment
    114
  - Paint
    115
  - Complete Panel Repair
    117
  - Larger Scratches
    117
  - Minot Scratches
    117
  - Painting
    117
  - Rear Axle and Suspension
    119
  - Checking the Lubricant Level
    121
  - Rear Axle and Suspension Components
    121
  - Rear Axle Maintenance
    121
  - Check, Add or Drain Rear Axle Lubricant
    122
  - Differential Lock Cable Adjustment
    122
  - Rear Axle Removal
    122
  - Disconnect Brake Lines
    123
  - Disconnect Parking Brake Cables
    123
  - Detach Differential Link
    124
  - Disconnect Accelerator Cable and Governor
    124
  - Disconnect Direction Selector Cables
    124
  - Rear Axle Installation
    124
  - Rear Spring Removal
    125
  - Rear Suspension
    125
  - Shock Absorber Installation
    125
  - Shock Absorber Removal
    125
  - Speed Control
    127
  - Accelerator, Governor and Carburetor Linkage
    129
  - Governor Operation
    129
  - Accelerator/Governor Cable Adjustment
    130
  - Cable Adjustment
    130
  - General Cable Adjustment Procedure
    130
  - Accelerator Pedal Arm Adjustment
    131
  - Access to Pedal Box
    131
  - Micro Switch Adjustment
    131
  - Pedal Box Adjustments
    131
  - Accelerator Linkage
    132
  - Control Arm Link
    132
  - Governor Compression Spring Adjustment
    133
  - Road Test
    133
  - Gasoline Vehicle Performance
    137
  - Weather Protection
    143
  - Front Strut Installation
    145
  - Rear Strut Installation
    145
  - Sun Top
    145
  - Sun Top Installation
    145
  - Fold down Windshield
    147
  - One-Piece Windshield
    148
  - Wheels and Tires
    149
  - Tire Repair
    151
  - Wheel and Tire Service
    151
  - Wheel Installation
    151
  - Options/Accessories
    155
  - Standard Equipment
    155
  - Vehicle Dimensions
    156
  - Vehicle Incline Specifications and Turning Clearance Diameter
    157
  - Intersecting Aisle Clearance
    158

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