E Z Go 602080 Users Manual

602080 to the manual cf091c0d-2747-4ace-bf5f-0b1511a819aa

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TM

602080

REVISED DATE: JAN. 2007

SAFETY

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

NOTES, CAUTIONS AND WARNINGS

Throughout this guide NOTE, CAUTION and WARNING

will be used.

A NOTE indicates a condition that should be

observed.

A CAUTION indicates a condition that

may result in damage to the vehicle.

A WARNING indicates a

hazardous condition that

could result in severe

injury or death.

Observe these NOTES, CAUTIONS and WARNINGS;

be aware that servicing a vehicle requires mechanical

skill and a regard for conditions that could be hazardous.

Improper service or repair may damage the vehicle or

render it unsafe.

Engine exhaust from this

product contains chemi-

cals known, in certain

quantities, to cause cancer, birth defects, or other

reproductive harm.

The exhaust emissions of this vehicles’ engine

complies with regulations set forth by the Envi-

ronmental Protection Agency (EPA) of the United States of

America (USA) at time of manufacture. Significant fines could

result from modifications or tampering with the engine, fuel,

ignition or air intake systems.

Battery posts, terminals

and related accessories

contain lead and lead

compounds. Wash hands after handling.

This spark ignition system meets all require-

ments of the Canadian Interference-Causing

Equipment Regulations.

Read and understand the following warnings

before attempting to operate the vehicle:

To prevent personal

injury or death, observe

the following:

When vehicle is to be left unattended, engage parking

brake, move direction selector to ‘F’ (forward)

position, turn key to ‘OFF’ position and remove key.

Drive vehicle only as fast as terrain and safety

considerations allow. Consider the terrain and traffic

conditions. Consider environmental factors which

effect the terrain and the ability to control the vehicle.

Avoid driving fast down hill. Sudden stops or change

of direction may result in a loss of control. Use service

brake to control speed when traveling down an incline.

Use extra care and reduced speed when driving on

poor surfaces, such as loose dirt, wet grass, gravel,

etc.

All travel should be directly up or down hills.

Use extra care when driving the vehicle across an

incline.

Stay in designated areas and avoid steep slopes. Use

the parking brake whenever the vehicle is parked.

Keep feet, legs, hands and arms inside vehicle at all

times.

Avoid extremely rough terrain.

! !

! !

! !

Ce système d'allumage par étincelle de véhicule respecte

toutes les exigences du Règlement sur le matériel brouilleu

r

du Canada.

! !

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. See APPENDIX

A.

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. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.

Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above

specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered

abuse and will not be covered under warranty.

Be sure that this manual remains as part of the permanent service record should the vehicle be sold.

For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.

Page i

Owner’s Manual and Service Guide

OWNER’S MANUAL

AND SERVICE GUIDE

GASOLINE POWERED

UTILITY VEHICLE

ST 4x4

STARTING MODEL YEAR 2005

E-Z-GO Division of TEXTRON, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the infor-

mation contained in this manual is subject to change without notice.

E-Z-GO Division of TEXTRON, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this

manual.

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

Page ii

GENERAL INFORMATION

Owner’s Manual and Service Guide

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.

Overfilling battery may void the warranty.

Tampering with or adjusting the governor to permit vehicle to operate at above factory

specifications will void the vehicle warranty.

When servicing engines, all adjustments and replacement components must be per original

vehicle specifications in order to maintain the United States of America Federal and State

emission certification applicable at the time of manufacture.

BATTERY PROLONGED STORAGE

All batteries will self discharge over time. The rate of self discharge varies depending on the

ambient temperature and the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls

below -75° F (-60° C).

Page iii

TABLE OF CONTENTS

Owner’s Manual and Service Guide

SAFETY ................................................................................................................ inside covers

GENERAL INFORMATION ....................................................................................................... ii

SAFETY INFORMATION ......................................................................................................... vii

WELCOME ................................................................................................................................. 1

BEFORE INITIAL USE .............................................................................................................. 1

Fig.1 Initial Service Chart ...........................................................................................................1

CAPABILITIES .......................................................................................................................... 1

TERRAIN .............................................................................................................................................................1

VEHICLE CAPACITY ..........................................................................................................................................1

MODIFICATIONS TO VEHICLE ..........................................................................................................................2

COMMON SENSE OPERATION ............................................................................................... 2

RUN-IN ....................................................................................................................................... 2

CONTROLS & INDICATORS .................................................................................................... 3

SERVICE BRAKE PEDAL ...................................................................................................................................3

Fig. 2 Service Brake Pedal ........................................................................................................3

Fig. 3 Park Brake and Indicator .................................................................................................3

CHOKE ................................................................................................................................................................3

Fig. 4 Choke ..............................................................................................................................4

IGNITION SWITCH ..............................................................................................................................................3

Fig. 5 Ignition Switch ..................................................................................................................4

DIRECTION SELECTOR .....................................................................................................................................4

Fig. 6 Direction Selector and Differential Locks .........................................................................4

2WD/4WD SELECTOR ....................................................................................................................................... 5

Fig. 7 2WD/4WD Selector ..........................................................................................................5

DIFFERENTIAL LOCK ........................................................................................................................................5

Fig. 8 Differential Lock ...............................................................................................................5

ACCELERATOR ..................................................................................................................................................6

Fig. 9 Accelerator Pedal ............................................................................................................6

FUEL .......................................................................................................................................... 6

FUEL GAUGE ......................................................................................................................................................6

Fig. 10 Fuel Tank and Gauge ....................................................................................................7

LOW OIL PRESSURE INDICATOR LIGHT .........................................................................................................6

Fig. 11 Low Pressure Oil Light ...................................................................................................7

LIGHT SWITCHES ..............................................................................................................................................7

Fig. 12 Light Switches ................................................................................................................7

12 VOLT POWER OUTLET .................................................................................................................................7

Fig. 13 Power Outlet ..................................................................................................................7

STARTING AND DRIVING ........................................................................................................ 8

STARTING VEHICLE ON A HILL ........................................................................................................................8

COASTING ..........................................................................................................................................................8

LOAD BED ................................................................................................................................. 8

TAILGATE ...........................................................................................................................................................9

MANUAL LIFT BED .............................................................................................................................................9

Fig. 14 Manual Lift Bed Release ................................................................................................9

ELECTRIC LIFT BED OPERATION ....................................................................................................................9

Fig. 15 Electric Lift Bed Switch ..................................................................................................9

WINCH ....................................................................................................................................... 9

WINCH APPLICATIONS .....................................................................................................................................9

Fig. 16 Do Not Pull at Angle ....................................................................................................10

WINCH MOUNTING ..........................................................................................................................................10

Fig. 17 Mounting Winch ...........................................................................................................11

WINCH OPERATION ........................................................................................................................................10

Fig. 18 Use Nylon Sling and Install a Damper when Winching ................................................11

Fig. 19 Winch Operation ..........................................................................................................12

Page iv Owner’s Manual and Service Guide

TABLE OF CONTENTS

TOP AND WINDSHIELD ..........................................................................................................12

TRANSPORTING VEHICLE ....................................................................................................12

TOWING ........................................................................................................................................................... 12

HAULING .................................................................................................................................12

TOWING A TRAILER ...............................................................................................................12

OPENING THE COWL (HOOD) ...............................................................................................13

Fig. 20 Unlatching Cowl .......................................................................................................... 13

DATA LABEL LOCATION .......................................................................................................13

MAINTENANCE .......................................................................................................................14

PERIODIC SERVICE SCHEDULE ...........................................................................................15

Fig. 21 Periodic Service Schedule .......................................................................................... 15

BASIC SERVICE PARTS .........................................................................................................16

Fig. 22 Basic Service Parts ..................................................................................................... 16

LIFTING THE VEHICLE ...........................................................................................................17

Fig. 23 Lifting the Vehicle ........................................................................................................ 17

OIL ............................................................................................................................................17

Fig. 24 Recommended Oil ...................................................................................................... 17

OIL LEVEL CHECK .......................................................................................................................................... 18

Fig. 25 Oil Fill and Level Check .............................................................................................. 18

OIL CHANGE .................................................................................................................................................... 18

Fig. 26 Oil Change .................................................................................................................. 18

OIL FILTER CHANGE ...................................................................................................................................... 18

Fig. 27 Oil Filter Change ......................................................................................................... 19

SPARK PLUGS ........................................................................................................................19

ALTERNATOR BELT ...............................................................................................................19

ADJUSTING BELT ............................................................................................................................................ 19

Fig. 28 Adjusting Alternator Belt ..............................................................................................20

AIR CLEANER .........................................................................................................................20

CANISTER TYPE AIR CLEANER .................................................................................................................... 20

CLEANING AIR FILTER ELEMENT ................................................................................................................. 20

Fig. 29 Air Cleaner .................................................................................................................. 20

FUEL FILTER ...........................................................................................................................20

Fig. 30 Fuel Filter .................................................................................................................... 21

LUBRICATION POINTS ...........................................................................................................21

Fig. 31 Lubrication Points ........................................................................................................ 21

BATTERY .................................................................................................................................21

BATTERY CLEANING ...................................................................................................................................... 22

Fig. 32 Cleaning Battery .......................................................................................................... 22

JUMP STARTING ....................................................................................................................22

Fig. 33 Jump Starting .............................................................................................................. 23

VEHICLE CLEANING AND CARE ..........................................................................................22

CLEANING ........................................................................................................................................................ 22

CARE PRODUCTS ........................................................................................................................................... 23

LABELS AND PICTOGRAMS .................................................................................................23

WHEELS AND TIRES ..............................................................................................................24

TIRE INSPECTION AND INFLATION .............................................................................................................. 24

REMOVAL AND INSTALLATION ..................................................................................................................... 24

Fig. 34 Wheel Tightening Sequence ....................................................................................... 24

Page v

TABLE OF CONTENTS

Owner’s Manual and Service Guide

LIGHT BULB REPLACEMENT ............................................................................................... 25

Fig. 35 Headlight Replacement ...............................................................................................25

FUSE REPLACEMENT ........................................................................................................... 25

SPARK ARRESTER ................................................................................................................ 25

Fig. 36 Cleaning Spark Arrester ..............................................................................................25

PROLONGED STORAGE ....................................................................................................... 25

FRONT AND REAR AXLES .................................................................................................... 26

CHECKING LUBRICANT LEVEL ......................................................................................................................26

Fig. 37 Checking Axle Lubricant ..............................................................................................26

TRANSFER CASE ................................................................................................................... 26

CHECKING LUBRICANT LEVEL ......................................................................................................................26

Fig. 38 Checking Transfer Case Lubricant ..............................................................................26

AIR INTAKE AND COOLING FINS ........................................................................................ 26

Fig. 39 Cleaning Air Intake and Cooling Fins ..........................................................................27

BRAKES .................................................................................................................................. 27

PERIODIC BRAKE TEST FOR HYDRAULIC BRAKES ....................................................................................27

CAPACITIES ............................................................................................................................ 27

Fig. 40 Capacities ....................................................................................................................27

HARDWARE ............................................................................................................................ 28

Fig. 41 Torque Specifications and Bolt Grades .......................................................................28

GENERAL SPECIFICATIONS.................................................................................................. 29

Fig. 42 Vehicle Dimensions ......................................................................................................31

Fig. 43 Vehicle Incline Specifications .......................................................................................31

Fig. 44 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance.......................32

VEHICLE WARRANTIES ......................................................................................................... 33

EMISSION CONTROL SYSTEM WARRANTY STATEMENT ................................................. 35

ENGINE OWNER WARRANTY POLICY ................................................................................. 35

INTERNATIONAL WARRANTY STATEMENT ........................................................................ 35

DECLARATION OF CONFORMITY (EUROPE ONLY)............................................................ 37

LABELS AND PICTOGRAMS.............................................................................................. A - 1

Fig. 45 Label Locations......................................................................................... Appendix A - 3

Fig. 46 Pictogram Definitions................................................................................ Appendix A - 4

Fig. 47 Pictogram Definitions................................................................................ Appendix A - 5

Fig. 48 Pictogram Definitions................................................................................ Appendix A - 6

Fig. 49 Pictogram Definitions................................................................................ Appendix A - 7

Page vi Owner’s Manual and Service Guide

TABLE OF CONTENTS

N

otes:

Owner’s Manual and Service Guide

SAFETY INFORMATION

Page vii

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:

GENERAL

Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible

to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the

place of good common sense and prudent driving practices.

Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings

and instructions combined. The manufacturer strongly suggests that all users and maintenance personnel read this

entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein.

If you have any questions regarding this vehicle, contact your closest representative or write to the address on the

back cover of this publication, Attention: Product Service Department.

The manufacturer reserves the right to make design changes without obligation to make these changes on units previ-

ously sold and the information contained in this manual is subject to change without notice.

The manufacturer is not liable for errors in this manual or for incidental or consequential damages that result from the

use of the material in this manual.

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.

Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability

or increase the speed beyond the factory specification. Such modifications can cause serious personal injury

or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may

reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and

disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the

vehicle.

Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when

used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions,

terrain and common sense.

GENERAL OPERATION

Always:

• Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.

• Read and observe all warnings and operation instruction labels affixed to the vehicle.

• Follow all safety rules established in the area where the vehicle is being operated.

• Reduce speed to compensate for poor terrain or conditions.

Owner’s Manual and Service Guide

SAFETY INFORMATION

Page viii

• Apply service brake to control speed on steep grades.

• Maintain adequate distance between vehicles.

• Reduce speed in wet areas.

• Use extreme caution when approaching sharp or blind turns.

• Use extreme caution when driving over loose terrain.

• Use extreme caution in areas where pedestrians are present.

MAINTENANCE

Always:

• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.

• Ensure that repairs are performed by those that are trained and qualified to do so.

• Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing

any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.

• Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the

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.

• Support the vehicle using wheel chocks and jack stands. Never get under a vehicle that is supported by a jack. Lift

the vehicle in accordance with the manufacturer’s instructions.

• Empty the fuel tank or plug fuel hoses to prevent fuel leakage.

• Maintain the vehicle in an area away from exposed flame or persons who are smoking.

• Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.

• Test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both

vehicular and pedestrian traffic.

• Replace damaged or missing warning, caution or information labels.

• Keep complete records of the maintenance history of the vehicle.

The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must

have the skill and experience to recognize and protect themselves from potential situations that could result in severe

personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury,

refer the repair or maintenance to a qualified mechanic.

Owner’s Manual and Service Guide

SAFETY INFORMATION

Page ix

VENTILATION

Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating.

Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane water

heaters and furnaces.

Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Carbon

monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

Owner’s Manual and Service Guide

SAFETY INFORMATION

Page x

Notes:

SAFETY INFORMATION

Page xi

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

GENERAL

The following text is provided as recommended by part II

of SAE J2258 DEC 2003. E-Z-GO strongly endorses the

contents of this specification.

B.1 PART II

FOR THE CONTROLLING PARTY

B.1.1 Maintenance and Operations

B.1.1.1 Introduction

B.1.1.1.1 Like other machines, light utility vehicles

can cause injury if improperly used or maintained. Part II

contains broad safety practices applicable to vehicle

operations. Before operation, the controlling party shall

follow such additional specific safety practices as may

reasonably be required for safe operation.

B.1.1.1.2 Safety Survey-The controlling party shall

perform a safety survey of their premises periodically,

and as conditions warrant, identify areas where vehicles

should not be operated and to identify possible hazards.

(a) Steep Grade-In areas where steep grades exist,

vehicle operation should be restricted to the designated

vehicle's pathways where possible, and shall be identi-

fied with a suitable warning giving the following informa-

tion: “Warning, steep grade, descend slowly.”

(b) Wet Areas-Wet areas could cause a vehicle to lose

traction and could affect steering, stability and braking.

(c) Sharp Turns, Blind Corners, Bridge Approaches-

Sharp turns, blind spots, bridge approaches, and other

potentially hazardous areas shall be identified with a suit-

able warning to the operator of the nature of the hazard

and stating the proper precautions to be taken to avoid

the hazard.

(d) Loose Terrain-Loose terrain could cause a vehicle

to lose traction and could affect steering, stability, and

braking.

B.1.1.1.3 Utility Vehicle/Pedestrian Interference

Areas-Areas where pedestrian and vehicle traffic could

interfere should be avoided by rerouting the vehicle or

the pedestrian traffic to eliminate the interference. If elim-

ination of the interference is not possible or is highly

impractical, signs shall be erected warning pedestrians

and vehicle operators of traffic conditions and to use cau-

tion.

B.1.1.1.4 The controlling party shall train vehicle

operators to adhere strictly to the operating instructions

stated in vehicle operator's manual and those additional

operating instructions provided by controlling party.

B.1.1.1.5 The controlling party shall survey specific

operating conditions and environment, establish safety

practices, and train vehicle operators to comply with

these practices.

B.1.1.2 Operation Experience has shown that vehi-

cles which comply with the provisions stated in 7.8 are

stable when properly operated in accordance with spe-

cific safety rules and practices established to meet actual

operating terrain and conditions. However, improper

operation, faulty maintenance, or poor housekeeping

may contribute to a condition of instability and defeat the

purpose of the standard. Some conditions which could

affect stability are failure of the operator to follow safety

practices, surface conditions, grade, speed, loading,

braking, turning, improper loads, towing, attachments,

dynamic forces, and the judgment exercised by the vehi-

cle operator.

B.1.1.3 Nameplates, Markings, Capacity, And Mod-

ifications.

B.1.1.3.1 The controlling party shall maintain in a legi-

ble condition all nameplates, warnings, and instructions

which are supplied by the vehicle manufacturer.

B.1.1.3.2 The controlling party shall not perform any

modification or addition which affects capacity or safe

operation, or make any change not in accordance with

the vehicle manual(s) without the vehicle manufacturer's

prior written authorization. Where authorized modifica-

tions have been made, the controlling party shall ensure

that capacity, operation, warning, and maintenance

instruction plates, tags, or decals are changed accord-

ingly.

B.1.1.3.3 As required under B.1.1.3.1 or B.1.1.3.2,

the vehicle manufacturer shall be contacted to secure

new nameplates, warnings, or instructions which shall

then be affixed in their proper place on the vehicle.

B.1.1.4 Fuel Handling

B.1.1.4.1 The controlling party shall supervise the

handling of liquid fuels (when used) to be certain that it is

in accordance with appropriate sections of ANSI/NFPA

505 and ANSI/NFPA 30 or as required by local ordi-

nance.

SAFETY INFORMATION

Page xii Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

B.1.1.4.2 The controlling party shall supervise the

handling of liquefied petroleum gas fuels (when used) to

be certain it is in accordance with appropriate sections of

ANSI/NFPA 505 and ANSI/NFPA 58 or as required by

local ordinance.

B.1.1.5 Charging Storage Batteries

B.1.1.5.1 The controlling party shall require battery-

charging procedures to be in accordance with appropri-

ate sections of ANSI/NFPA 505, ISO 3691, or local ordi-

nance and meet any other requirements such as OSHA.

B.1.1.5.2 The controlling party shall periodically

review procedures to be certain that appropriate sections

of ANSI/ NFPA 505 or local ordinance and OSHA are

strictly complied with, and shall familiarize vehicle opera-

tors with it.

B.1.1.6 Lighting For Operating Areas

B.1.1.6.1 The controlling party, in accordance with his

responsibility to survey the environment and operating

conditions, shall determine if the vehicle requires lights

and, if so, shall equip the vehicle with appropriate lights

in accordance with the vehicle manufacturer's recom-

mendations.

B.1.1.7 Warning Device(s)

B.1.1.7.1 The controlling party shall make periodic

inspections of the vehicle to be certain that the sound-

producing and visual device(s), if so equipped, are main-

tained in good operating conditioning condition.

B.1.1.7.2 The controlling party shall determine if oper-

ating conditions require the vehicle to be equipped with

additional sound-producing and/or visual devices com-

patible with the vehicle manufacturer's recommenda-

tions, and be responsible for providing and maintaining

such devices, in accordance with the vehicle manufac-

turer's recommendations.

B.1.1.8 Safety Interlocks

B.1.1.8.1 The controlling party shall make periodic

inspections of the vehicle to be certain that the safety

interlock system, if so equipped, is operating properly.

B.2 Operating Safety Rules and

Practices

B.2.1 Operator Qualifications

B.2.1.1 Only persons who are trained in the proper

operation of the vehicle shall be authorized to operate

the vehicle. Operators shall be qualified as to visual,

auditory, physical, and mental ability to safely operate the

vehicle according to Section 5 and all other applicable

parts of this document and vehicle operator's manual.

B.2.2 Operator’s Training

B.2.2.1 The controlling party shall develop and con-

duct an operator training program.

B.2.2.2 Successful completion of the operator train-

ing program by the operator shall be required before

operation of the vehicle. The program shall be presented

in its entirety to all new operators and not condensed for

those claiming previous experience.

B.2.2.3 The controlling party should include, as a

minimum, in the operator training program the following:

(a) Instructional material provided by the vehicle man-

ufacturer, including vehicle operator's manual.

(b) Emphasis on safety of passengers, vehicle opera-

tor, and other persons.

(c) Safe loading practice, including securing material

loads.

(d) General safety rules contained within this docu-

ment and the additional specific rules determined by the

controlling party in accordance with this document, and

why they were formulated.

(e) Introduction of equipment, control locations, and

functions, and explanation of how they work when used

properly and the consequences of improper use; expla-

nation of surface conditions, grade, and other conditions

of the environment which could affect vehicle operation.

(f) Operator competency evaluations.

B.2.3 Operator Responsibility

B.2.3.1 Read and follow operator's manual.

B.2.3.2 Do not operate vehicle under the influence of

drugs or alcohol.

B.2.3.3 Safeguard the pedestrians at all times. Do

not drive vehicle in a manner that could endanger other

persons.

SAFETY INFORMATION

Page xiii

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

B.2.3.4 Riding on the vehicle by persons other than

the operator is authorized only on seat(s) provided by the

vehicle manufacturer. All parts of each person's body

shall remain within the plan view outline of the vehicle

while the vehicle is in motion.

B.2.3.5 When a vehicle is to be left unattended, stop

vehicle, apply the parking brake, turn off the control or

ignition circuit, and remove the key if provided. Block the

wheels if vehicle is on an incline.

B.2.3.6 Maintain a safe distance from potential haz-

ards.

B.2.3.7 Use only approved vehicles in hazardous

locations, as defined in the appropriate safety standards.

B.2.3.8 Report all accidents involving personnel,

building structures, and equipment.

B.2.3.9 Do not add to, or modify, the vehicle.

B.2.3.10 Slow down or stop, as conditions dictate, and

activate a sound-producing warning device, if so

equipped, at intersections and when visibility is

obstructed at other locations.

B.2.3.11 Ascend or descend grades slowly, avoid

turning if possible; normally travel straight up and down.

B.2.3.12 Under all travel conditions, operate vehicle at

speeds that will permit it to be brought to a stop in a safe

manner.

B.2.3.13 Use caution and slow down when approach-

ing or on wet or slippery surfaces, loose or unfamiliar ter-

rain.

B.2.3.14 Avoid sudden starts, stops, turns, or direction

reversals so as not to shift the load, endanger passen-

gers, or lose control of the vehicle.

B.2.3.15 Do not operate vehicle in a dangerous man-

ner, such as stunt driving or horseplay.

B.2.3.16 Avoid running over loose objects, potholes,

and bumps.

B.2.4 Loading

B.2.4.1 Refer to operator's manual for loading

instructions.

B.2.4.2 Transport only stable and safely arranged

loads secured to prevent movement. Avoid loads which

cannot be centered.

B.2.4.3 Transport only loads within the gross vehicle

weight capacity.

B.2.4.4 Avoid material loads exceeding the physical

dimensions of the vehicle or as specified by the vehicle

manufacturer.

B.2.5 Operator Care of Light Utility

Vehicles

B.2.5.1 Follow Operator's Manual.

B.2.5.2 At the beginning of each operating period

during which the vehicle will be used, the operator shall

check the vehicle condition and inspect the tires, warning

devices, safety interlocks, lights, battery(s), fuel system,

speed and directional controllers, brakes, and steering

mechanism. If the vehicle is found to be in need of repair,

or in any way unsafe, the matter shall be reported imme-

diately to the controlling party and the vehicle shall not be

operated until it has been restored to safe operating con-

dition.

B.2.5.3 If during operation the vehicle becomes

unsafe in any way, the matter shall be reported immedi-

ately to the controlling party, and the vehicle shall not be

operated until it has been restored to safe operating con-

dition.

B.2.5.4 Repairs and adjustments shall only be per-

formed by specifically trained and authorized persons.

B.3 Maintenance Practices

B.3.1 Maintenance Procedures

B.3.1.1 Maintenance and inspection of all vehicles

shall be performed in conformance with the vehicle man-

ufacturer's recommendations and the following practices,

if applicable. Only trained and authorized personnel shall

be permitted to maintain, repair, adjust, and inspect vehi-

cles.

(a) A scheduled preventive maintenance, lubrication,

and inspection system shall be followed.

(b) Before undertaking maintenance or repair, follow

the vehicle manufacturer's recommendations for immobi-

lizing the vehicle.

(c) Chock wheels and block chassis before working

underneath it.

(d) Before disconnecting any part of the fuel system of

a gasoline-powered vehicle, be sure shutoff valve, if so

equipped, is closed, and run engine until fuel system is

depleted, engine stops running, and is allowed to cool.

Before disconnecting any part of the engine fuel system

of a diesel-powered vehicle, be sure shutoff valve, if so

SAFETY INFORMATION

Page xiv Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

equipped, is closed, following vehicle manufacturer's rec-

ommended practice.

(e) Before disconnecting any part of the fuel system of

LP/CNG powered vehicles, close the fuel cylinder valve

and run the engine until fuel in the system is depleted,

the engine stops running, and is allowed to cool

(f) Disconnect battery(s).

(g) Operation to check performance of the vehicle

shall be conducted in an authorized area where suitable

conditions exist, free of vehicular and pedestrian traffic.to

cool.

(h) Before returning the vehicle to service, follow the

vehicle manufacturer's recommended procedures.

(i) Avoid fire hazards and have fire protection equip-

ment present in the work area. Do not use an open flame

to check level or leakage of fuel, battery electrolyte, or

coolant.

(j) Properly ventilate the work area in accordance with

applicable regulations or local ordinances.

(k) Handle fuel cylinders carefully. Physical damage,

such as dents, scrapes, or gouges, may dangerously

weaken cylinders and make them unsafe for use.

(l) Brake mechanisms, steering mechanisms, speed

and directional control mechanisms, warning devices,

electrical systems, governors, guards, exhaust system,

and safety devices shall be inspected regularly and

maintained in accordance with the vehicle manufac-

turer's recommended procedures.

(m) Vehicles or devices designed and approved for

hazardous area operation shall be inspected to ensure

that maintenance preserves the original approved oper-

ating features.

(n) Fuel systems shall be checked for leaks and condi-

tion of parts. If a leak is found, action shall be taken to

prevent the use of the vehicle until the cause of the leak

has been repaired.

(o) The vehicle manufacturer's capacity, operation,

and maintenance instruction plates, tags, and safety

labels shall be maintained in legible condition.

(p) Batteries, motors, speed and directional control-

lers, limit switches, protective devices, electrical conduc-

tors/insulators, and connections shall be inspected and

maintained in accordance with vehicle manufacturer's

recommended procedures.

(q) Vehicles shall be kept in a clean condition to mini-

mize fire hazards and facilitate the detection of compo-

nents needing service.

(r) Hydraulic systems, if so equipped, shall be

checked for leaks and condition of parts. Keep body and

hands away from pin hole leaks or nozzles that eject

hydraulic fluid under high pressure. Use paper or card-

board, not hands, to search for leaks.

(s) Modifications and additions which affect capacity

and safe machine operation shall not be performed with-

out vehicle manufacturer's prior written authorization.

Where authorized modifications have been made, the

controlling party shall ensure that capacity, operation,

warning, and maintenance instruction plates, tags, and

safety labels are changed accordingly.

(t) Care shall be taken to ensure that all replacement

parts are interchangeable with the original parts and of a

specification at least equal to that provided in the original

equipment.

End of SAE J2258 DEC 2003, Part II

OPERATION AND SERVICE INFORMATION

Page 1

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

WELCOME

Thank you for purchasing this utility vehicle. Before driv-

ing vehicle, we ask you to spend some time reading this

Owner’s Manual and Service Guide and the Owner’s

Manual provided by Honda Motor Co., Ltd. These manu-

als contain information to assist you in safe operation of

vehicle. They will also assist you in maintaining vehicle.

Some illustrations may show items that are optional.

Most service procedures in this guide can be accom-

plished using common automotive hand tools. Other-

wise, contact your service representative to schedule

maintenance performed by a technician. Any servicing

must be done per the Periodic Service Schedule found in

this manual and the Maintenance Schedule found in the

engine manual.

Service Parts Manuals, Technician’s Repair and Service

Manuals and engine Repair Manuals are available from a

local Distributor, an authorized Branch or the Service

Parts Department. When ordering parts or requesting

information for your vehicle, provide vehicle model, serial

number and manufacture date code.

BEFORE INITIAL USE

Read, understand and follow safety label on driver side

fender well (Ref Appendix A). Be sure you understand

how to safely operate vehicle and its equipment.

Maintaining good performance depends, to a large

extent, on owner/operator.

To reduce possibility of

severe injury or death,

do not use vehicle

improperly such as engaging in horseplay or attempt-

ing to perform tasks for which it is not designed.

This vehicle is a utility vehicle. It is NOT a toy or an all

terrain vehicle (ATV).

Before new vehicle is put into operation, items shown in

INITIAL SERVICE CHART must be performed (Ref. Fig.

1 on page 1).

CAPABILITIES

TERRAIN

To reduce possibility of

severe injury or death

while driving, be aware

of the following:

Environmental hazards such as steep slopes,

overhanging limbs, etc.

Danger of fire when vehicle is operated over dry

combustible organic material.

Vehicle is designed for: improved roads (not public high-

ways), established trails, open terrain free from stumps,

large rocks or holes, crossing water no deeper than 8

inches (20 cm).

Slow down when: traveling unfamiliar terrain, cresting a

hill.

Be aware of hazards such as: steep slopes, overhanging

limbs, danger of fire when vehicle is operated over dry

combustible organic material.

On steep slopes: do not turn vehicle or stop and turn

around, always travel straight up and down, control

speed with service brake when going downhill.

Vehicle stopping distance increases: when driving on wet

grass, dirt roads or loose surfaces, when crossing

streams or bodies of water that soak the brakes.

Remember to lightly apply brakes and use friction to dry

braking surfaces.

VEHICLE CAPACITY

To reduce possibility of

severe injury or death

due to the variety of

ITEM SERVICE OPERATION

Seats Remove protective plastic covering

Brakes Check operation and brake fluid level

Tires Check air pressure (see SPECIFICATIONS)

Fuel Fill tank with correct fuel

Engine Check oil level

Keys Record key number and store in a safe location

Fig. 1 Initial Service Chart

Ref Int 1

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OPERATION AND SERVICE INFORMATION

Page 2 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

ways the vehicle may be used, it is important the

operator consider any potential hazards before use to

prevent serious injury or death.

See GENERAL SPECIFICATIONS section of this man-

ual for load and seating capacity.

Never carry passengers in load bed.

The weight of driver and passenger plus any options or

accessories must be deducted from total payload rating

to determine load bed capacity.

Stopping distance increases as vehicle load increases.

Load weight can be misleading. Loads consisting of dry

sand, fertilizer, sod, etc. will, when wet, grossly overload

vehicle and increase potential for roll over and vehicle

damage.

Towing a loaded trailer reduces capacity of vehicle load

bed. (Ref. TOWING A TRAILER on page 12)

MODIFICATIONS TO VEHICLE

Changes to weight distri-

bution or center of gravi-

ty may make vehicle

unstable or prone to roll over which could result in

injury or death to operator or passenger.

Do not modify vehicle in any manner that will change

weight distribution.

Changes to weight distribution or center of gravity may

make it unstable or prone to roll over which could result

in injury or death to operator or passenger.

Do not tamper with governor. It is set for maximum safe

vehicle speed.

Do not tamper with exhaust system. It is matched with

engine for optimum performance.

Removal of muffler or other modifications to exhaust sys-

tem will: annoy others, not improve performance of vehi-

cle, increase possibility of starting a fire.

COMMON SENSE OPERATION

To reduce possibility of

severe injury or death to

operator, passenger or

bystanders, do not operate vehicle improperly and/or

irresponsibly.

If vehicle is operated improperly and/or irresponsibly,

severe injury or death to operator, passenger or bystand-

ers can occur.

All operators should possess a valid driver’s license.

Children may not have the skill, judgement or strength to

operate this or similar vehicles and should not be permit-

ted to do so.

Alcohol, drugs and many over-the-counter medications

reduce ability of driver to operate vehicle safely. Always

review side effects of any medication with a doctor or

pharmacist before operating vehicle.

If the vehicle is to be used in areas where steep slopes,

overhanging limbs or other adverse conditions may be

encountered, protective clothing and an approved motor-

cycle helmet are recommended for both operator and

passenger.

Plan carefully before using vehicle to go significant dis-

tances over questionable terrain. Remember that a one

hour drive may take many hours to walk out should vehi-

cle run out of fuel or be stranded by becoming stuck on

unsuitable terrain.

Respect private property and comply with all local laws

and regulations governing use of utility vehicles.

RUN-IN

Check for oil or fuel leaks that could have developed in

shipment from factory. Avoid full throttle starts and rapid

acceleration until engine has achieved operating temper-

ature.

All engines consume more oil than normal during the first

hours of operation. As internal moving parts are run-in,

oil consumption should gradually decrease until rate of

consumption stabilizes.

Check oil level See OIL LEVEL CHECK on page 18. Add

oil if level on dipstick is at lower hole.

Do not overfill engine. Too much oil

may cause smoking or allow oil to enter

the air filter enclosure.

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 becoming contam-

inated and/or being discharged into the engine compartment.

Oil should be changed, while engine is warm, at end of

run-in period (Ref. Periodic Service Schedule on page

15).

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OPERATION AND SERVICE INFORMATION

Page 3

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

CONTROLS & INDICATORS

SERVICE BRAKE PEDAL

The service brake is a hydraulic front disc/rear drum

brake system.

Push foot operated service brake pedal to activate wheel

brakes, slowing or stopping vehicle (Ref. Fig. 2 on page

3).

PARKING BRAKE

Drive vehicle with park brake fully

released. Failure to do so will prema-

turely wear rear brakes.

The park brake is a mechanical system using rear drum

service brakes.

To engage, pull park brake handle up. An indicator light

will illuminate in gauge cluster reminding operator to

release park brake before driving (Ref. Fig. 3 on page 3).

To disengage, pull up slightly and push in release button

at end of handle, then fully lower park brake handle.

CHOKE

Starting a cold engine may require use of choke. To use,

pull choke knob out and hold while starting engine (Ref.

Fig. 4 on page 4). Once started and engine begins to

warm, release choke knob.

Do not allow starter to operate continu-

ously for more than 10 seconds. Allow

30 seconds between starting attempts. If vehicle does not start

on third attempt, turn key switch off, set park brake and deter-

mine cause of problem.

IGNITION SWITCH

Ignition switch has three positions: ‘OFF’, ‘ON’ and

‘START’ (Ref. Fig. 5 on page 4).

Insert key into switch and turn clockwise to ‘ON’ to

enable starting system.

Continue to turn clockwise to “START” to activate starter.

Once engine starts, release key allowing return to ‘ON’.

To prevent inadvertent operation of vehicle when left

unattended, turn key to ‘OFF’ position and remove key.

Fig. 2 Service Brake Pedal

Ref Sbp 1 Fig. 3 Park Brake and Indicator

Front of Vehicle

P

HOURS

8 16 0 4/4

Ref Pbh 2

OPERATION AND SERVICE INFORMATION

Page 4 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

If vehicle is equipped with factory installed cus-

tom accessories, some accessories remain

operational with key switch in ‘OFF’ position.

To prevent draining the battery, always

place differential lock switches in the

‘unlocked’ position, turn the key switch to ‘off’ and remove the

key.

If one or both of the differential locks is engaged and the

key left in the ‘on’ position, the differential lock sole-

noid(s) will be activated (Ref. Fig. 6 on page 4) and (Ref.

Fig. 8 on page 5). Over time the solenoids will drain the

battery to a point where the vehicle will be unable to be

started.

DIRECTION SELECTOR

To reduce possibility of drivetrain dam-

age, vehicle must completely stop

before moving direction selector (Ref. Fig. 6 on page 4).

Direction selector offers choice of three positions: for-

ward, neutral and reverse (Ref. Fig. 6 on page 4).

Selector must be in neutral to start engine. Always bring vehicle to a complete stop before changing

selection.

Fig. 4 Choke

R

ef Chk 4

Choke

Pull

Out

Fig. 5 Ignition Switch

Fig. 6 Direction Selector and Differential Locks

Ref Kes 5

OFF

ON

START

73767G01

73777G01

Ref Dsl 5

Neutral Disengaged

Forward Engaged

Reverse

OPERATION AND SERVICE INFORMATION

Page 5

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

Place direction selector in forward and set park brake

when leaving vehicle unattended.

2WD/4WD SELECTOR

To reduce possibility of drivetrain dam-

age, vehicle must completely stop

before switching between two wheel and four wheel drive.

This lever allows choice of two wheel or four wheel drive

(Ref. Fig. 7 on page 5).

Always bring vehicle to a complete stop before changing

selection.

When four wheel drive is selected, an indicator light in

gauge cluster will illuminate to verify engagement.

Vehicle should be left in two wheel drive when unat-

tended.

DIFFERENTIAL LOCK

To reduce possibility of

severe injury or death

from loss of control

while vehicle is in motion, do not engage front differ-

ential lock while turning steering wheel. Lock engage-

ment may abruptly force steering wheel to center

causing loss of grip on wheel.

Front and rear differentials are equipped with electrically

actuated locks (Ref. Fig. 8 on page 5). With a differential

unlocked, if one tire looses traction, the vehicle will likely

become stuck. With a differential locked, power is dis-

tributed to both tires at all times and greatly increases

traction. Locks are not intended to be engaged at all

times. They are intended to free or prevent vehicle from

being stuck as terrain demands, ideally for short runs at

slow speeds. Always disengage differential locks as ter-

rain and conditions allow.

Differential locks should only be used when

additional traction is required. Continued use of

rear differential lock may cause excessive wear to tires. Contin-

ued use of front differential lock may increase steering effort.

Vehicle must be completely stopped

before engaging or disengaging differ-

ential lock. Failure to stop may damage differential.

Fig. 7 2WD/4WD Selector

73777G01

Two Wheel Drive

Four Wheel Drive

Ref 4wd 1

P

HOURS

8 16 0 4/4

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Fig. 8 Differential Lock

73777G01

Ref Dif 1

P

HOURS

8 16 0 4/4

Rear Differential

Lock Switch

Front Differential

Lock Switch Disengaged

Engaged

OPERATION AND SERVICE INFORMATION

Page 6 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

To prevent draining the battery, always place differential lock

switches in the ‘unlocked’ position, turn the key switch to ‘off’

and remove the key.

To engage rear differential lock, stop vehicle and push

upper portion of rear differential lock switch. To engage

front and rear differential lock, stop vehicle and push

upper portion of both differential lock switches. Indicator

lights in gauge cluster illuminate to remind operator when

locks are engaged.

To disengage differential locks, stop vehicle and push

lower portion of switches. After unlocking, the differential

may remain locked if driving is resumed in a straight line.

This is a normal occurrence caused by pressure remain-

ing against the gears and not allowing the locking mech-

anism to release. To avoid this, simply turn vehicle as

acceleration begins or accelerate in reverse.

ACCELERATOR

With engine running, push accelerator pedal to acceler-

ate in direction selected (Ref. Fig. 9 on page 6). Release

pedal to slow vehicle and engine will idle. To stop vehicle

quickly, apply service brake.

FUEL

To reduce possibility of

severe injury or death

from improper fuel han-

dling:

Do not smoke near the fuel tank.

Do not refuel near open flame or electrical items,

including cellular phones, which could produce a

spark.

Never fill a gas can in the bed of a vehicle. Static

discharge could ignite gasoline vapor and cause

an explosion.

Always handle gasoline in a well ventilated area.

Always wear eye protection to protect against

splashed fuel and fuel vapors.

Always allow adequate space for the expansion of

gasoline. Leave at least 1" (2.5 cm) space below

bottom of filler neck.

Inspect fuel cap, tank and other components for

leaks or deterioration that could cause a hazard-

ous condition.

Fuel cap is located on passenger side panel of vehicle

beside seat (Ref. Fig. 10 on page 7). Fuel tank is located

under passenger side of seat. Fill tank with fresh, clean,

automotive grade gasoline. High altitude or heavy use/

load applications may benefit from higher octane gaso-

line.

Do not use gasoline which contains Methanol.

Some fuels, called oxygenated or reformu-

lated gasoline, are gasoline blended with

alcohols or ethers. Excessive amounts of these blends can damage the

fuel system or cause performance problems. If any undesirable operat-

ing symptoms occur, use gasoline with a lower percentage of alcohol or

ether.

Do not overfill the fuel tank. Allow adequate space for the expan-

sion of gasoline. Leave at least 1" (2.5 cm) space below bottom

of filler neck.

FUEL GAUGE

An electric fuel gauge is located left of steering wheel in

gauge cluster (Ref. Fig. 10 on page 7). It indicates

amount of fuel in tank.

! !

Fig. 9 Accelerator Pedal

Ref Acl 1

OPERATION AND SERVICE INFORMATION

Page 7

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

LOW OIL PRESSURE INDICATOR LIGHT

Low oil pressure indicator light is located in gauge cluster

at left of dash panel. Indicator light is activated if oil pres-

sure drops below 1.5 psi (.11 kg/cm2) (Ref. Fig. 11 on

page 7). Check oil level See ‘OIL LEVEL CHECK’ on

page 18. If oil level is between ADD and FULL mark on

dipstick, a mechanical problem exists within engine and

vehicle must not be driven. Contact a local Distributor

or authorized Branch.

To reduce possibility of engine damage,

do not operate engine until oil pressure

is corrected. Do not overfill engine. Too much oil may cause

smoking or allow oil to enter air filter enclosure.

If oil level is below ADD mark on dipstick, add oil to bring

level to FULL mark. Drive vehicle a short distance and

check oil pressure. If oil pressure light does not come on,

continue to use vehicle.

LIGHT SWITCHES

Headlight switch is located to left of steering wheel on

dash panel (Ref. Fig. 12 on page 7). Headlights operate

independently of ignition switch.

Accessory switch is located to right of headlight switch. It

may operate accessory items, (if equipped), indepen-

dently of headlights and ignition switch.

12 VOLT POWER OUTLET

Fig. 10 Fuel Tank and Gauge

Fig. 11 Low Pressure Oil Light

P

HOURS

8 16

04/4

Ref Ftl 4

P

HOURS

816 04/4

Ref Opl 1

Fig. 12 Light Switches

Fig. 13 Power Outlet

Ref Lsw 1

Headlight Accessory

Switch

Re

f

Pow 2

OPERATION AND SERVICE INFORMATION

Page 8 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

Overuse of accessories may drain bat-

tery and leave insufficient reserve to

start vehicle.

A 12 volt power outlet, rated at 15 amps, is located left of

ignition switch (Ref. Fig. 13 on page 7). It provides con-

stant power for accessories equipped with a 12 volt plug

STARTING AND DRIVING

To reduce possibility of

roll-back which could

result in severe injury or

vehicle damage, do not release service brake until

engine has started.

To operate vehicle:

•Apply service brake.

•Place direction selector in neutral.

•Insert key into ignition switch and turn it to ‘ON’

position.

•Apply choke if needed and turn key to ‘START’

position just long enough for engine to start.

•Release choke once engine runs smoothly.

•Place direction selector in forward or reverse.

If equipped, a warning signal will sound while

direction selector is in reverse.

•Release park brake.

•Release service brake and apply accelerator.

•When accelerator pedal is released, engine will

idle.

•Apply service brake pedal to slow or stop vehicle.

•Move direction selector only after vehicle has

completely stopped.

STARTING VEHICLE ON A HILL

To reduce possibility of

roll-back which could

result in severe injury or

vehicle damage, do not release service brake until

engine has started.

Do not hold vehicle on hill by using

accelerator and engine. This will cause

premature and excessive wear to drive train components.

To reduce the possibility of permanent damage to the

drive system, it is important to prevent excessive roll-

back when starting the vehicle on a hill.

Release park brake while depressing accelerator with

right foot and release the service brake by lifting left foot.

COASTING

To reduce possibility of

severe injury or death

from coasting at above

recommended speeds, limit speed with service brake.

On steep hills, it is possible for the vehicle to coast at

greater than normal speeds encountered on a flat sur-

face. To reduce possibility of drivetrain damage or loss of

vehicle control, speeds should be limited to no more than

the maximum governed speed on level ground (See

GENERAL SPECIFICATIONS). Limit speed by applying

service brake.

LOAD BED

A manual lift bed is standard. An electric lift is optional.

To reduce possibility of

severe injury or death,

read, understand and fol-

low Warning label affixed inside load bed. See Appen-

dix A.

Failure to follow label may result in vehicle tipping

over.

Operate vehicle with awareness of load.

Do not permit anyone to ride in load bed.

Before operating, verify no one is behind vehicle.

Never fill a gas can while it is in load bed. Static dis-

charge could ignite gasoline vapor causing an explo-

sion.

A load bed warning label is affixed to inside front of bed.

See Appendix A. For safe operation of vehicle, this label

must be understood.

See load bed warning label for maximum load. Load

must be positioned in bed as far forward as possible, dis-

tributed in such a way that its center of gravity must not

be higher than height noted on label, and secured.

Failure to follow these instructions may result in severe

injury and/or vehicle damage resulting from rollover. Use

extra care when operating loaded vehicle.

Do not permit anyone to ride in load bed.

Do not drive vehicle with load bed raised or tailgate

unsupported.

Avoid backing up to the edge of a drop off, such as a

loading dock or ravine. A misjudgment of distance or an

unstable surface could result in vehicle falling back-

wards.

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OPERATION AND SERVICE INFORMATION

Page 9

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

Before operating, verify no one is behind vehicle.

Always place a gas can on ground for filling. Never fill a

gas can in load bed of vehicle. Built up static electricity

could discharge during fueling process and ignite gaso-

line vapor.

TAILGATE

To open tailgate (Early Production): Lift taillgate straight

up with a sharp upward pull to lift out of closed position

and swing out. Maximum load is 100 lbs. (45 kg).

To open tailgate (Late Production): Pull latches out from

recess in tailgate. Slide both latch handles toward the

center of the tailgate and pivot tailgate out to open posi-

tion. Maximum load is 100 lbs. (45 kg).

To remove tailgate, remove side cables from load bed

and lower tailgate until it is straight down, lift tailgate

straight up to remove from pins and remove from load

bed. Assemble in reverse order.

MANUAL LIFT BED

To reduce possibility of

severe injury, exercise

caution while manually

lifting or lowering load bed. Fingers or other body

parts could be trapped under falling bed.

To raise manual lift bed, locate latch handle at front left

side of bed, pull handle up with one hand to release and

lift bed with other hand (Ref. Fig. 14 on page 9).

A gas strut located underneath will assist in raising bed

when empty and will keep it raised when empty.

Over time, the gas strut may allow the truck

bed to slowly lower. If this condition is evident,

replacement of gas strut is required.

To lower manual lift bed, push down on bed until latch

catches. Be sure hands are not trapped by load bed.

ELECTRIC LIFT BED OPERATION

To reduce possibility of

severe injury, exercise

caution while lifting or

lowering load bed. Fingers or other body parts could

be trapped under bed.

The electric lift toggle switch is located at left side of dash

panel (Ref. Fig. 15 on page 9). Push top part of switch to

raise load bed and bottom part to lower.

WINCH

An optional winch is available. Read, understand and fol-

low all following information on operation and use of

winch before attempting to operate it.

WINCH APPLICATIONS

To reduce possibility of

severe injury or death,

the following must be

observed:

Have all persons and pets leave area while operat-

ing winch. Never allow anyone to remain in vehi-

cle.

Make sure object to which cable is attached can-

not be damaged or pulled over onto vehicle and

it’s occupants. If attaching winch to a dead tree, a

section or limb could fall.

Fig. 14 Manual Lift Bed Release

! !

Front of Vehicle

Manual Load Bed

Latch Handle

Pull Up To Release

And Lift Bed

Ref Mbl 4

Fig. 15 Electric Lift Bed Switch

! !

Ref Lbs 2

Up

Down

! !

OPERATION AND SERVICE INFORMATION

Page 10 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

Do not pull at an angle (Ref. Fig. 16 on page 10).

This will cause cable to pile up on one end, jam-

ming and damaging winch. The winch cable could

also break from being overstressed and strike

someone. Pulling vehicle at an angle can cause

damage to front suspension and may cause vehi-

cle to overturn. When pulling vehicle, pull straight

only.

If vehicle is being used as an anchor to winch a

load, it should have park brake set and wheels

chocked.

Never use winch to lift people or other overhead

loads. The winch is not intended to be used in any

hoisting operation.

Do not use winch to secure loads. Use a tie down

designed for the job.

Do not apply shock loads to winch.

Do not attempt to modify or weld winch.

Rolling load capacity of winch decreases with

steepness of slope.

Winch is designed for intermittent duty only. The

electric motor should not be allowed to become

excessively hot. If motor becomes uncomfortably

hot to touch, stop and allow motor to cool.

Winch may be used for a number of purposes, including

pulling vehicle if it loses traction on unsuitable terrain or

becomes stuck or ‘hung up’ on an obstruction.

It is impossible to predict all conditions a winch could be

used; therefore, the following warnings should not be

considered as complete. Before operating winch, con-

sider possible dangers and take precautions to protect

yourself, your passenger and any bystanders.

When pulling vehicle with winch, pull straight only. Do

not permit cable to contact side of drum.

WINCH MOUNTING

Winch can be mounted at front, or rear (if vehicle is

equipped with optional rear hitch) of vehicle to accommo-

date different situations. At front, winch is mounted in

receiver of frame below cowl (Ref. Fig. 17 on page 11).

At rear, winch is mounted in hitch receiver below load

bed.

Unplug winch remote

control before working

on winch drum in order

to prevent inadvertent operation.

Before moving winch, unplug winch connector from wire

harness. To move winch from one end of vehicle to other,

remove spring pin, pull out clevis pin and pull winch

mount tube out of receiver. Move to opposite end of vehi-

cle and install winch mount tube in receiver. Secure by

inserting clevis pin and securing with spring pin. Plug

winch connector into wire harness.

WINCH OPERATION

To reduce possibility of

severe injury or death,

the following warnings

must be observed before attempting to operate

winch:

Always wear thick leather gloves when handling

wire cable.

Replace frayed wire cable with a direct factory

replacement only.

Never operate winch with less than five (5) full

turns of cable around drum (Ref. Fig. 19 on page

12).

If winch motor stalls from overloading, do not

continue applying power to winch. The wire cable

may become overstressed.

Do not attempt to pull loads exceeding 1500 lbs.

(680 kg).

To pull out cable, free spool clutch knob must be

used. Pull out and rotate knob. If cable is under

any load, clutch may not release easily. Jog out

some cable to release tension and operate clutch.

Fig. 16 Do Not Pull at Angle

Correct

Incorrect

Ref Wps 2

! !

! !

OPERATION AND SERVICE INFORMATION

Page 11

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

Pull out desired amount of cable and secure.

Engage drum by rotating knob until it snaps in

place. Never operate winch unless clutch is

engaged.

To prevent damage to wire cable, never hook

cable to itself. Always use a nylon sling (Ref. Fig.

18 on page 11).

Stay clear of winch, cable and cable hook. Place a

heavy cloth, jacket or blanket over cable to act as

a damper should cable break when operating

winch (Ref. Fig. 18 on page 11).

Remember that winch operation with engine off

will drain battery and may leave insufficient power

to start vehicle. Always let engine idle while using

winch.

When operating winch, keep entire area in view.

Never release free spool clutch while cable is

under load.

Never work around winch drum or cable under

tension.

Unplug winch remote control before working on

winch drum in order to prevent inadvertent opera-

tion.

Take up slack in cable slowly. Stop winch before

cable becomes tight and inspect all attachments

such as winch attachment, hook attachment,

nylon sling (if required) and load attachment.

Plug winch remote control into receptacle located on

dash panel (Ref. Fig. 19 on page 12).

To unwind cable, locate clutch knob on winch (Ref. Fig.

19 on page 12). Pull out knob and rotate 90° to lock out.

Using handsaver bar, pull cable from winch drum. Leave

at least five turns of cable on drum. Engage drum by

turning clutch knob 90°, returning it to original position.

To wind cable, use handsaver bar to keep tension on

cable while activating remote. When winding cable,

make sure it winds tightly and evenly onto drum leaving

no gaps that could cause premature wear to cable. When

using winch under a load, operate remote control as far

Fig. 17 Mounting Winch

Clevis

Pin

Spring

Pin

Winch shown mounted at front of vehicle

Ref Wmt 2

Fig. 18 Use Nylon Sling and Install a Damper when

Winching

Ref Wca 3

Nylon

Sling

Damper

OPERATION AND SERVICE INFORMATION

Page 12 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

as possible from side of vehicle. Do not operate winch

while sitting in passenger seat. Read ‘Winch Applica-

tions’ section before attempting to operate winch.

TOP AND WINDSHIELD

The sun top does not

provide protection from

falling objects.

The windshield does not provide protection from tree

limbs or flying objects.

Sun top and windshield can only be used with ROPS

(Roll Over Protection System) equipped vehicles.

Sun top and windshield provide some protection from the

elements; however, they will not keep operator and pas-

senger dry in a downpour. An optional Cab provides pro-

tection from the weather, utilizes an optional windshield

wiper which is also available with the windshield

equipped ROPS unit.

The sun top has been designed to provide roll over pro-

tection and requires the ROPS system to be installed. In

addition, the sun top does not protect against falling

objects nor does the windshield protect against flying

objects and tree limbs. Keep arms and legs inside of

vehicle while it is moving.

TRANSPORTING VEHICLE

TOWING

This vehicle is not

designed to be towed.

It is recommended that

vehicle be moved by placing entire vehicle on a trailer,

flatbed truck or other suitable transport.

HAULING

To reduce possibility of

severe injury or death

while transporting vehi-

cle:Secure vehicle and contents.

Never ride on vehicle being transported.

Always remove windshield before transporting.

Maximum speed with sun top installed is 50 mph

(80 kph).

If vehicle is to be transported at highway speeds, the sun

top must be removed. When transporting vehicle below

highway speeds, check for tightness of hardware and

cracks in sun top at mounting points. It is recommended

that the windshield be removed when transporting.

Always verify vehicle and contents are adequately

secured before transporting. Rated capacity of trailer or

truck must exceed weight of vehicle (see GENERAL

SPECIFICATIONS for vehicle weight) and load. Lock

park brake and secure vehicle using ratchet tie downs.

TOWING A TRAILER

To reduce possibility of

severe injury or death,

trailer weight is never to

exceed 1500 lbs. (680 kg).

To reduce possibility of vehicle dam-

age, do not exceed 1500 lbs. (680 kg)

trailer weight nor 150 lbs. (68 kg) tongue weight.

Fig. 19 Winch Operation

Winch Remote Plug

Ref Wop 1

Pull Out

ENGAGED

Clutch Knob

LOCKED

OUT

Turn 90˚

Minimum of 5 Turns

Of Cable On Drum

! !

! !

! !

! !

OPERATION AND SERVICE INFORMATION

Page 13

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

Vehicle may be equipped with a receiver that accepts a

standard 2" ball hitch. Trailer range of motion is limited by

the ball and hitch and should not be used on rough trails

or over objects such as logs, large rocks, holes, etc.

Never install non-factory baskets or extensions in hitch

receivers (front or rear). Such items change performance

characteristics of vehicle and result in unsafe handling,

possible roll over or vehicle damage.

Remember a loaded trailer always reduces overall

capacity of vehicle.

At no time should tongue weight be more than 150 lbs

(68 kg).

The maximum weight that can be towed on a trailer is

1500 lbs. (680 kg).

OPENING THE COWL (HOOD)

To lift cowl (Ref. Fig. 20 on page 13):

•Pull down and out on both latches to clear receiv-

ers mounted to frame

•Lift cowl up fully to allow catch to rest on cross-

member and release cowl

To lower cowl:

•Lift cowl up fully with one hand to remove weight

from catch

•Pull catch away from crossmember with other

hand

•Lower cowl until catch clears crossmember and

continue lowering cowl with both hands

•Once seated on rubber bumpers, secure with

latches

DATA LABEL LOCATION

Serial number label is located on body just below air

intake louvers near choke knob.

Manufacture date code and repeat of serial number are

on data labels located on frame crossmember under bed.

See LOAD BED on page 8.

Design changes take place on an ongoing basis. In order

to obtain correct components for vehicle, manufacture

date code, serial number and vehicle model must be pro-

vided when ordering service parts.

Fig. 20 Unlatching Cowl

Ref Lco 1

Latches

Catch

Latch

Receiver

OPERATION AND SERVICE INFORMATION

Page 14 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

MAINTENANCE

To reduce possibility of

severe injury or death

from improper servicing

techniques:

Do not attempt any type of servicing operations

before reading and understanding all notes, cau-

tions and warnings in this manual.

Wear eye protection when working on

vehicle. Use extra care when working

around batteries, or using solvents or

compressed air.

Turn off all electrical loads from battery before

removing battery wires.

Wrap wrenches with vinyl

tape to reduce possibility of a

dropped wrench ‘shorting

out’ a battery, which could result in an explosion.

Remove and ground spark plug wires and discon-

nect battery at negative terminal before servicing.

Treat all electrolyte spills to body and eyes with

extended flushing with clear water. Contact a phy-

sician immediately. Any electrolyte spills should

be neutralized with a solution of 2 teaspoons (10

ml) sodium bicarbonate (baking soda) dissolved

in 1 quart (1 liters) of water and flushed with

water.

Insulate metal aerosol containers of battery termi-

nal protectant to reduce chance of contacting bat-

tery terminals which could result in an explosion.

Always place entire vehicle on jack stands, disen-

gage four (4) wheel drive and unlock front and

rear differentials when performing a procedure

requiring engine to run with vehicle in place and

tires off ground. Failure to do so will allow vehicle

to pull itself off when supported by only two jack

stands.

It is in the best interest of both vehicle owner and service

technician to carefully follow procedures recommended

in this manual. Preventative maintenance, applied at rec-

ommended intervals, is the best guarantee for keeping

vehicle both dependable and economical.

This vehicle will give years of satisfactory service, provid-

ing it receives regular maintenance. For appropriate ser-

vice intervals: See PERIODIC SERVICE SCHEDULE on

page 15. For appropriate locations See ‘LUBRICATION

POINTS’ on page 21.

To prolong vehicle life, some mainte-

nance items must be serviced more fre-

quently on vehicles used under severe driving conditions such

as extreme temperatures, extreme dust/debris conditions, fre-

quent use with maximum load.

To reduce possibility of vehicle damage when servicing:

•Do not lift vehicle by placing jack under front or

rear aluminum differential cases: See ‘Lifting the

Vehicle’ on page 17.

•Always place entire vehicle on jack stands, select

two (2) wheel drive and unlock both differentials

when performing procedures requiring engine to

run with vehicle in place and tires off ground. Fail-

ure to do so will allow vehicle to pull itself off when

supported by only two jack stands.

•Do not operate engine with CVT drive belt

removed since engine speed is governed by the

transfer case. Doing so allows engine to exceed

its maximum revolutions per minute (RPM).

To access powertrain for routine maintenance, lift seat.

Additional access may be obtained by raising or remov-

ing load bed. For major repair, refer to appropriate Tech-

nician’s Repair and Service Manual.

Some service procedures may require vehicle to be

lifted. For proper lifting procedure and safety information:

See ‘LIFTING THE VEHICLE’ on page 17.

! !

OPERATION AND SERVICE INFORMATION

Page 15

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

PERIODIC SERVICE SCHEDULE

ITEM

BEFORE

EACH

USE WEEKLY

EVERY

20

HOURS

EVERY

50

HOURS

EVERY

100

HOURS

EVERY

200

HOURS

EVERY

300

HOURS

EVERY

500

HOURS

Service Brake

(Pedal Pressure) Check X

(Fluid Level) Check X

(Pads & Shoes) Inspect X

(Rotors & Drums) Clean X

Park Brake Clean X X

Tires Check X X

Overall Vehicle Condition Check X

Wheels Check X

Fuel Gauge Check X

Alternator Belt Check X

Engine Fan and Cooling Fins Clean X

CVT Enclosure

(Blockage) Clean X

(Damage) Repair/

Replace X

Wiring Check X

Accelerator Check X

Choke Check X

Carburetor Linkage Check X

Direction Selector Check X

Engine Oil Check X

Change X ** X

Engine Oil Filter Replace X ** X

Air Filter Check X

Clean X#

Replace X#

Spark Plugs Check X

Replace X

Idle Speed Check X**

Valve Clearance Check X** X

Fuel Filter Check X

Replace X

Combustion Chamber Clean X

Steering Check X

Fig. 21 Periodic Service Schedule

OPERATION AND SERVICE INFORMATION

Page 16 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

** First occurrence only # More frequently in dusty conditions

To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative

or see Repair and Service Manual for this vehicle.

Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.

BASIC SERVICE PARTS

To order parts, SERVICE PARTS Department contact

information is as follows:

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., 1451 Marvin Griffin

Road, Augusta, Georgia USA 30906-3852

ITEM

BEFORE

EACH

USE WEEKLY

EVERY

20

HOURS

EVERY

50

HOURS

EVERY

100

HOURS

EVERY

200

HOURS

EVERY

300

HOURS

EVERY

500

HOURS

Tie Rods/Linkages Check X

Rear Axle Check X** X

Replace X

Muffler/Exhaust Check X

Spark Arrester Clean X

Front Axle Check X** X

Front Knuckles Check X

Front Struts Check X

Front Wheel Alignment Check X

Rear Shock Absorbers Check X

Fuel Tank Clean X

Throttle/Governor Linkage Check X

Hardware And Fasteners Check X

Tighten X

Battery Clean X

Drive Belt Check X

Front Wheel Bearings Check X

Drive shafts Lubricate X

C.V.Joints and Boots Check X

Fig. 21 Periodic Service Schedule

Air Filter Element 72944-G01

Oil Filter 15400-POH-305PE

Spark Plugs ZGR5A (NGK)

J16CR-U (DENSO)

Optional Alternator Belt 73561-G01

CVT Belt 73965-G01

Fuse 15 amp (P/N 35212-G01)

20 amp (P/N 35212-G02)

7.5 amp (P/N 35212-G05)

Headlight Bulb 20209-G3

Tail Light Bulb #1157 (P/N 21759-G1)

Fig. 22 Basic Service Parts

OPERATION AND SERVICE INFORMATION

Page 17

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

LIFTING THE VEHICLE

Tool List Qty. Required

Floor jack .................................................................... 1

Jack stands ................................................................. 4

Chocks ........................................................................ 4

To prevent possible inju-

ry or death resulting

from vehicle falling off

jack, be sure vehicle is on a firm and level surface.

Never get under vehicle while it is supported by a

jack. Use jack stands and test vehicle stability on

stands. Always place chocks in front and behind the

wheels not being raised. Use extreme care since vehi-

cle is extremely unstable during lifting process.

To prevent possible injury or

death from operating engine

while vehicle is raised, disengage 4 wheel drive and

unlock front and rear differentials. To reduce possibil-

ity of vehicle damage:

Do not raise vehicle by placing jack under front or rear aluminum

differential cases.

Do not operate engine with 4 wheel drive or either differential

locks engaged.

Never operate engine with CVT drive belt removed.

Some servicing operations may require entire vehicle to

be raised (Ref. Fig. 23 on page 17).

Install chocks in front and behind each front wheel. Cen-

ter jack under flange on long axle tube. Raise vehicle and

locate a jack stand under outer ends of rear axle tubes.

Lower jack and test stability of vehicle on two jack

stands.

Center jack under front of frame. Raise vehicle and posi-

tion jack stands under frame as shown.

Lower jack and test stability of vehicle on four jack

stands.

Lower vehicle by reversing lifting sequence.

OIL

Use detergent motor oil designed for 4 stroke engines.

The oil must be of high quality and meet API SF, SG

standards.

For most conditions, 10W30 oil is recommended (Ref.

Fig. 24 on page 17).

See chart for viscosity allowed in extreme temperatures

(Ref. Fig. 24 on page 17).

! !

Fig. 23 Lifting the Vehicle

Fig. 24 Recommended Oil

Ref Liv 5 View From Underside of Vehicle

-20 0 20 40 60 80 100

-30 -20 -10 0 10 20 30 40

C

F 0

30

30

(Air Temperature)

10W-30

10W-30

5W-30

5W-30

0

Ref Ovc 3

OPERATION AND SERVICE INFORMATION

Page 18 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

OIL LEVEL CHECK

To reduce possibility of engine damage,

do not run engine with oil level too low.

Park vehicle on level surface, shut off engine and wait a

minute for oil to settle.

Lift seat, remove dipstick and wipe clean (Ref. Fig. 25 on

page 18).

Replace dipstick and remove again. Observe level indi-

cated and:

if it is between upper and lower holes, oil level is correct

if it is at or below the lower hole, remove oil fill cap and

add oil until level reaches upper hole

When finished, return dipstick and oil fill cap and lower

seat.

OIL CHANGE

With engine warm, park vehicle on level surface, shut off

engine, remove key, set park brake and wait a minute for

oil to settle.

Lift seat, wipe oil fill cap clean with a cloth and remove fill

cap (Ref. Fig. 25 on page 18).

Place drain pan under engine.

Remove drain plug from base of engine (Ref. Fig. 26 on

page 18).

Once oil has drained, replace drain plug and, if due,

change oil filter at this time (Ref. OIL CHANGE on page

18).

Fill engine to upper hole on dipstick with appropriate oil

(Ref. Fig. 24 on page 17).

Return oil fill cap and dipstick and lower seat.

OIL FILTER CHANGE

Drain oil (Ref. OIL CHANGE on page 18).

Clean oil filter and its mount (Ref. Fig. 27 on page 19).

Place drain pan under engine and, being careful not to

damage oil pressure switch, remove oil filter.

Wipe sealing surface of filter mount clean.

Apply clean, fresh oil to seal of new filter and screw filter

on by hand until seal contacts filter mount. Tighten 7/8 of

a turn more. Torque specification is 16 ft. lbs. (22 Nm).

Fig. 25 Oil Fill and Level Check

Ref Olc 1

Oil Fill Cap

Dip Stick

Fig. 26 Oil Change

Ref Odp 1

Front of Vehicle

Drain

Plug

OPERATION AND SERVICE INFORMATION

Page 19

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

Fill engine to upper hole on dipstick with appropriate oil

(Ref. OIL CHANGE on page 18).

Return oil fill cap and dipstick and lower seat.

Start engine and check for leaks.

Shut engine off, check oil level and add, if necessary, to

bring level to upper hole on dipstick.

SPARK PLUGS

To reduce possibility of engine damage:

Only use recommended spark plugs.

Tighten spark plugs as instructed. Too loose can overheat

engine and too tight can damage threads in cylinder head.

Inspect and replace spark plugs at intervals indicated in

Periodic Service Schedule. See ‘PERIODIC SERVICE

SCHEDULE’ on page 15.

Remove plug wires and clean area around plugs to pre-

vent debris falling into cylinders. Use a 13/16” spark plug

wrench to remove plugs.

Inspect electrodes for wear and insulator for cracks or

chips. Fouled spark plugs are indicated by a wet, black

appearance. This could be caused by a dirty air filter ele-

ment or other restrictions in air intake system. Incorrectly

adjusted valves, spark plug wires which are in poor con-

dition or poor quality fuel could also contribute.

If reusing spark plugs, clean with wire brush.

Check gap. Gap should measure .028 - .031" (.70 - .80

mm). If necessary, adjust gap being careful not to dam-

age plug.

If replacing spark plugs, use only recommended type.

(Ref. Fig. 22 on page 16). New plugs must be properly

gapped before installation.

Install plugs by hand to reduce chance of cross-thread-

ing.•When plug seats against engine:

•Tighten used plugs an additional 1/8 to 1/4 turn.

•Tighten new plugs an additional 1/2 turn.

ALTERNATOR BELT

Vehicle may be equipped with an optional hi-output alter-

nator (Ref. Fig. 28 on page 20). It provides power neces-

sary to run a variety of equipment such as electric

powered tools, hi-intensity lighting, radio and winch.

ADJUSTING BELT

Hardware involved: 1/2" and 9/16" hex

Special Tools Required Qty.

Torque wrench, ft. lbs. ................................................. 1

Belt tension gauge....................................................... 1

Inspect belt for cracking or wear. Replace if required.

Loosen top nut.

Loosen bottom bolt.

By hand or using a pry bar, pull alternator belt tight and

hand tighten bottom bolt.

Check belt tension. Tighten to (Ref. Fig. 28 on page 20):

75 - 80 lbs. (34 - 36 kg) tension for an existing belt or 90

- 110 lbs. (41 - 50 kg) tension for a new belt when using a

belt tension gauge. Apply gauge half way between the

two pulleys.

-or-

a maximum deflection of 1/2" (13 mm) for an existing

belt or 3/8" (1 cm) for a new belt when gauging by hand.

Tighten bolt to 9 - 11 ft. lbs. (12 - 15 Nm) torque and nut

to 18 - 20 ft. lbs. (25 - 27 Nm).

Fig. 27 Oil Filter Change

Ref Ofi 1

Front of Vehicle

OPERATION AND SERVICE INFORMATION

Page 20 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

AIR CLEANER

CANISTER TYPE AIR CLEANER

Air cleaner element is accessible by unsnapping two

clips on air canister and removing cover and air filter ele-

ment (Ref. Fig. 29 on page 20).

Clean inside of cover and canister.

Install element and cover the same way they were

removed. Be sure positioning arrow on cover is pointing

up and all clips are fastened securely.

CLEANING AIR FILTER ELEMENT

Do not use compressed air to clean air

filter; doing so will damage filter which

may result in damage to engine.

If element is in acceptable condition, loose dirt may be

removed by tapping filter lightly. Do not use oil on filter

element or any part of unit.

FUEL FILTER

To reduce possibility of

an explosion, do not

smoke near fuel tank or

in an area where gasoline is being handled. Do not

perform procedures involving fuel system near open

fire or electrical items which could produce a spark.

Do not handle gasoline in an area that is not ade-

quately ventilated.

Always wear safety glasses to prevent possible eye

injury from gasoline or gasoline vapor.

Fuel filter is located at front of engine above fan cover

(Ref. Fig. 30 on page 21).

Inspect it for dirt and/or water. Replace if significant

amount is found.

To replace, use a pair of pliers to move clamps off ends

of filter.

Remove hose coming from fuel tank first and plug.

Remove filter from hose going to fuel pump and discard.

Orient direction of new fuel filter according to

FLOW arrow on side of filter.

Install new fuel filter and reposition clamps over inlet and

outlet.

Fig. 28 Adjusting Alternator Belt

Ref Abt 3

3/8" (1 cm) Max. Deflection for New Bel

t

1/2" (1.3 cm) Max. Deflection for Existing

Belt

Fig. 29 Air Cleaner

Air Cleaner

Cover

Air Cleaner

Canister

Air Filter

Element

R

ef Air 4

Clip

! !

OPERATION AND SERVICE INFORMATION

Page 21

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

LUBRICATION POINTS

Do not use more than three (3) pumps

of grease in any grease fitting at any

one time. Excess grease may cause grease seals to fail or

grease migration into areas that could damage components.

Add no more than two or three pumps of grease to fit-

tings shown (Ref. Fig. 31 on page 21). More than three

pumps in a grease fitting could damage seals allowing

contamination of grease-sensitive components.

BATTERY

To reduce possibility of discharging

battery and leaving insufficient reserve

to start vehicle, do not use accessories excessively while engine

is off.

Failure to promptly charge a discharged battery will shorten its

life span.

Unless equipped with optional high output alternator, the

vehicle uses a charge coil to charge battery. Battery is

charged while engine is running. Do not operate acces-

sory items (such as accessory lights, radios, winch, etc.)

excessively while engine is off. The charge coil is capa-

ble of supplying 20 amps; therefore, operation of all

accessories could result in discharge of battery even

though engine is running.

Discharging and recharging a battery is known as deep

cycling. The battery is not a deep cycle model, but is a

starting battery that is intended to maintain a full charge

from the charging circuit. Multiple deep cycles will result

in premature failure of battery.

If battery becomes discharged, vehicle can be jump

started. See JUMP STARTING on page 22. After starting,

promptly charge battery using a 12 volt charger rated at

10 amps or less and in accordance with all instructions

provided by the manufacturer of charger.

Fig. 30 Fuel Filter

Ref Ffi 1

Fig. 31 Lubrication Points

Ref Lub 5

Slip Joints

& U-Joint

Yokes

View From Underside of Vehicle

OPERATION AND SERVICE INFORMATION

Page 22 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

BATTERY CLEANING

To reduce possibility of damage to

vehicle or floor, neutralize acid before

rinsing battery.

To reduce possibility of damage to electrical components while

cleaning, do not use a pressure washer.

Cleaning should take place per PERIODIC SERVICE

SCHEDULE See ‘PERIODIC SERVICE SCHEDULE’ on

page 15.

When cleaning outside of battery and terminals, first

spray with a solution of sodium bicarbonate (baking

soda) and water to neutralize any acid deposits before

rinsing with clear water.

Use of a water hose without first neutralizing any acid,

will move acid from top of battery to other parts of vehicle

or storage facility where it will attack metal, concrete or

asphalt. Additionally, a conductive residue will remain on

battery and will contribute to its discharge.

To reduce possibility of

battery explosion that

could result in severe

injury or death, do not use metallic spray wand to

clean battery and keep all smoking materials, open

flame or sparks away from battery.

Correct cleaning technique is to spray top and sides of

battery with solution of sodium bicarbonate (baking soda)

and clear water (Ref. Fig. 32 on page 22). Solution

should consist of amounts shown in diagram and is best

applied with a garden type sprayer equipped with a non

metallic spray wand or a plastic spray bottle. In addi-

tion, special attention should be paid to metal compo-

nents adjacent to battery which should also be sprayed

with solution. Allow solution to sit for at least three min-

utes. Use a soft bristle brush or cloth to wipe battery;

removing any residue that could contribute to self dis-

charge of battery. Rinse entire area with clean water. Do

not use a pressure washer.

JUMP STARTING

To reduce possibility of

severe injury or death,

follow jump starting

instructions explicitly.

To reduce possibility of permanent damage to battery, promptly

charge a discharged battery.

Turn key switch to OFF.

Place direction selector in neutral.

Attach one end of red positive cable to positive post of

weak battery and other end to positive post of strong bat-

tery (Ref. Fig. 33 on page 23).

Attach one end of black negative cable to negative post

of strong battery and other end to vehicle frame.

Start vehicle as usual. Once started, disconnect cables in

reverse order.

Charge battery as soon as possible (Ref. BATTERY on

page 21).

VEHICLE CLEANING AND CARE

CLEANING

To reduce possibility of

severe injury or vehicle

damage, read and under-

stand all instructions supplied by manufacturer of

pressure washer.

To reduce possibility of damage, do not

use pressure in excess of 700 psi (4826

kPa) when pressure washing exterior of vehicle and do not use

any abrasive or reactive solvents to clean plastic parts.

It is important that proper techniques and cleaning mate-

rials be used. Using excessive water pressure may

cause severe injury to operator or bystander, damage to

seals, plastics, seat material, body finish or electrical sys-

! !

! !

Fig. 32 Cleaning Battery

1 1/2 gallons

(6 liters)

Clear Water

1/4 Cup (60 ml)

Sodium Bicarbonate

(Baking Soda)

2 Gallon

(7.5 liter)

Garden

Sprayer

R

ef Pns 1

1 quart

(1 liter)

Clear Water

2 Teaspoons

(10 ml)

Sodium

Bicarbonate

(Baking Soda)

Plastic

Spray

Bottle

OR

Non

Metallic

Wand

! !

OPERATION AND SERVICE INFORMATION

Page 23

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

tem. Do not use pressure in excess of 700 psi (4800 kPa)

to wash exterior of vehicle.

Clean windshield with lots of water and a clean cloth.

Normal cleaning of vinyl seats and plastic or rubber trim

requires use of a mild soap solution applied with a

sponge or soft brush and wipe with a damp cloth.

Removal of oil, tar, asphalt, shoe polish, etc. will require

use of a commercially available vinyl/rubber cleaner.

Painted surfaces require frequent washing with luke-

warm or cold water and mild detergent.

Occasional cleaning and waxing with non-abrasive prod-

ucts designed for ‘clear coat’ automotive finishes will

enhance the appearance and durability of the painted

surfaces.

Corrosive materials used as fertilizers or for dust control

can collect on underbody of vehicle. These materials will

cause corrosion of underbody parts unless flushed occa-

sionally with plain water. Thoroughly clean any areas

where mud or other debris can collect. Sediment packed

in closed areas should be loosened to ease it’s removal,

taking care not to chip or otherwise damage paint.

If engine does not start or runs improperly after

washing, remove spark plug wires (by pulling

the spark plug boots, never the wires). Dry all connections with

forced air. Reinstall wires.

CARE PRODUCTS

To help maintain the vehicle there are several products

available through local Distributors, authorized

Branches, or the Service Parts Department.

•Touch-up paint specially formulated to match vehi-

cle colors for use on both metal and molded plas-

tic bodies. (P/N 28140-G** and 28432-G** for

solid colors; 75831-G** for camouflage colors)

•Battery Protectant formulated to form a long-term,

flexible, non-tacky, dry coating that will not crack,

peel or flake over a wide temperature range. (P/N

75500-G01)

•White Lithium Grease designed to provide lubrica-

tion protection in areas where staining or discolor-

ing is a problem, or in areas of extreme

temperature ranges. (P/N 75502-G01)

•Penetrant/Lubricant, a 4-in-1 product that pene-

trates seized parts, lubricates leaving a light lubri-

cating film, reduces corrosion by adhering to wet

or dry surfaces and displaces moisture, sealing

against future moisture return. (P/N 75503-G01)

•Multi-purpose Cleaner and Degreaser that con-

tains natural, environmentally safe solvents. (P/N

75504-G01)

•Multi-purpose Hand Cleaner is an industrial

strength cleaner containing no harsh solvents, yet

gently lifts grease off hands. May be used with or

without water. (P/N 75505-G01)

•Battery Cleaner that neutralizes battery acids and

dissolves terminal corrosion and can be rinsed

with water. (P/N 75506-G01)

•Biodegradable Cleaner that breaks down grease

to be easily wiped or rinsed away. (P/N 75507-

G01)

•Multi-purpose Value Pack sampler includes 4

ounce (118 ml) aerosol cans of Battery Protector,

Penetrant/Lubricant, White Lithium Grease, and

Carburetor and Choke Cleaner. (P/N 75508-G01)

LABELS AND PICTOGRAMS

Vehicles are labeled with pictograms as a method of con-

veying information or warnings. Appendix A illustrates

and explains pictograms that appear on vehicle. Not all

pictograms shown in Appendix A will be used on vehicle.

Fig. 33 Jump Starting

Ref Jmp 1

+

-

+

-

Strong

Battery

Weak

Battery

Front o

f

Vehicle

OPERATION AND SERVICE INFORMATION

Page 24 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

WHEELS AND TIRES

Tires are uni-directional and should never be

moved from one side of vehicle to the other.

This vehicle comes standard with low pressure, tubeless,

uni-directional tires mounted on one piece wheels (Ref.

Fig. 34 on page 24). Left side tires should always remain

on left side of vehicle. Right side tires should always

remain on right side of vehicle. Uni-directional tires have

an arrow on their sidewall indicating direction of rotation

when moving forward.

TIRE INSPECTION AND INFLATION

To reduce possibility of

severe injury or death

from tire separating from

wheel or exploding, use caution when inflating tires

and never exceed maximum pressure rating on side-

wall of tire. Overinflation can occur quickly.

Tire condition should be inspected per the PERIODIC

SERVICE SCHEDULE See ‘PERIODIC SERVICE

SCHEDULE’ on page 15. Examine for cuts, punctures

and excessive wear. Repair or replace as necessary.

Air pressure should be checked when tires are cool. If air

needs to be added, see GENERAL SPECIFICATIONS

section of this manual. Standard and optional tires should

be inflated to pressure designated. If pressure is not des-

ignated, inflate to pressure recommended on sidewall of

tire. Under no condition should inflation pressure be

higher than maximum pressure listed on sidewall of tire.

All four tires should have the same pressure for opti-

mum handling characteristics.

Use caution when inflating tires. Due to low volume of

small tires, overinflation can occur in seconds. Overinfla-

tion could cause tire to separate from wheel or cause tire

to explode.

Be sure to install valve dust cap after checking.

REMOVAL AND INSTALLATION

To reduce possibility of

severe injury caused by

a broken socket when

removing wheels, use only sockets designed for

impact wrench use.

Hardware involved: 3/4" hex lug nut

To remove, loosen lug nuts. If using an impact wrench,

use only impact sockets with it. Regular sockets are not

designed for impact pressures exerted by power tools.

Raise vehicle. See LIFTING THE VEHICLE on page 17.

Remove lug nuts and wheel.

To reduce possibility of damage, tight-

en lug nuts to no more than 85 ft. lbs.

(115 Nm) torque.

Use ‘cross sequence’ pattern when tightening

lug nuts to assure even seating of wheel

against hub.

Special Tools Required Qty.

Torque wrench, ft. lbs. .................................................1

To install, place wheel onto studs with valve stem facing

away from hub (Ref. Fig. 34 on page 24). Be sure to

position wheel on hub correctly with arrow on tire indicat-

ing direction of rotation when moving forward.

Add lug nuts and finger tighten.

Secure wheel by tightening lug nuts in a ‘cross sequence’

pattern to 50 - 85 ft. lbs. (70 - 115 Nm) torque in 20 ft. lbs.

(30 Nm) increments.

Lower vehicle

.

! !

! !

Fig. 34 Wheel Tightening Sequence

Tire style may vary

1

2

3

4

'Cross Sequence'

Front of

Vehicle

R

o

t

a

t

i

o

n

Ref Whi 4

OPERATION AND SERVICE INFORMATION

Page 25

Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

LIGHT BULB REPLACEMENT

Replacement bulbs are available from a local Distributor,

an authorized Branch or the Service Parts Department

(Ref. Fig. 22 on page 16).

Locate two screws on backside of cowl that secure head-

light (Ref. Fig. 35 on page 25).

Remove screws, pull headlight out and disconnect wires.

Connect wires to new headlight, install in cowl and

secure with screws previously removed.

FUSE REPLACEMENT

Fuses are available from a local Distributor, an autho-

rized Branch or the Service Parts Department (Ref. Fig.

22 on page 16).

To replace fuses, locate fuse block or individual water

resistant fuses mounted to plate under cowl (late produc-

tion).

Pull out failed fuse and replace with a fuse of same type

and load rating.

SPARK ARRESTER

To reduce possibility of

severe injury or death,

allow muffler to cool

before servicing and never operate vehicle without

spark arrester in good condition and in place.

Raise load bed.

Remove screw securing spark arrester and pull arrester

from muffler (Ref. Fig. 36 on page 25).

Brush off carbon deposits from arrester screen without

damaging screen. Screen must be intact. Replace spark

arrester if screen is breached.

Install arrester on muffler and secure with screw.

PROLONGED STORAGE

To reduce possibility of

severe injury or death

resulting from a possi-

ble explosion:

Do not handle fuel in an area that is not adequately

ventilated. Do not smoke near fuel tank or refuel near

open flame or electrical items which could produce a

spark.

Store vehicle in a clean, dry area. Do not store in

same area as a stove, furnace, water heater, or other

appliance that uses a pilot light or has a device that

can create a spark.

When refueling, inspect fuel cap for leaks or breaks

that could result in fuel spillage.

Always wear safety glasses while refueling to prevent

possible eye injury from gasoline or gasoline vapor.

Keep hands, clothing and jewelry away from moving

parts. Use care not to contact hot objects.

Preparing vehicle for a prolonged storage period (30

days or more) calls for a few simple steps to prevent a

build up of varnish and gum in carburetor and corrosion

in engine.

•Clean body, chassis and engine of debris, mud,

chaff or grass (Ref. AIR INTAKE AND COOLING

FINS on page 26).

•Disconnect fuel hose at fuel tank and plug hose.

•With proper ventilation, start engine and allow it to

run until it stops due to lack of fuel.

Fig. 35 Headlight Replacement

Headlight

Bulb

Inside

of Cowl

R

ef Hdr 4

! !

Fig. 36 Cleaning Spark Arrester

Ref Csa 1

! !

OPERATION AND SERVICE INFORMATION

Page 26 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

•Add fuel stabilizer to fuel tank following instruc-

tions on stabilizer container.

•Attach fuel line to tank and drive vehicle for sev-

eral minutes to circulate fuel stabilizer through car-

buretor.

•While engine is still warm, change oil (Ref. OIL

CHANGE on page 18).

•Remove spark plugs (Ref. SPARK PLUGS on

page 19) and pour about 1 oz. (30 ml) of engine oil

into each cylinder. Replace spark plugs, ground

spark plug wires and use starter to turn engine

over a few seconds to distribute oil.

FRONT AND REAR AXLES

Rear axle is provided with a lubricant level check/fill plug

located on side of differential case. Unless leakage is evi-

dent, an annual lubricant check is sufficient.

CHECKING LUBRICANT LEVEL

Hardware involved: 7/16" hex head plug

Clean check/fill plug and area around it (Ref. Fig. 37 on

page 26).

Remove plug.

Correct lubricant level is just below bottom of threaded

hole. If lubricant is to be added, use a funnel and add

correct type lubricant slowly until it starts to seep from

hole See ‘Checking Axle Lubricant’ on page 26.

Install plug and tighten to 18 ft. lbs. (25 Nm).

To replace lubricant, a drain plug is provided at bottom of

differential case.

TRANSFER CASE

The transfer case is provided with an oil level check/fill

plug located on passenger side at rear of case. Unless

leakage is evident, an annual check is sufficient.

CHECKING LUBRICANT LEVEL

Hardware involved: 9/16" hex head plug

Clean check/fill plug and area around it (Ref. Fig. 38 on

page 26).

Remove plug.

Correct lubricant level is just below bottom of threaded

hole. If lubricant is to be added, use a funnel and add

correct type lubricant slowly until it starts to seep from

hole See ‘Checking Transfer Case Lubricant’ on page

26..

Install plug and tighten to 20 - 25 ft. lbs. (27 - 34 Nm).

To replace lubricant, a drain plug is provided at bottom of

transfer case.

AIR INTAKE AND COOLING FINS

To reduce possibility of

fire, engine parts should

be kept clean to reduce

risk of overheating and ignition of accumulated

debris.

Fig. 37 Checking Axle Lubricant

Check/Fill Plug

Drain Plug

Ref Raf 4

Fig. 38 Checking Transfer Case Lubricant

Drain Plug

Check/Fill Plug

Ref Tcf 1

! !

OPERATION AND SERVICE INFORMATION

Page 27

Owner’s Manual and Service Guide

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

build up of dirt and debris in air intake and cooling fins

(Ref. Fig. 39 on page 27). Dirt and debris may clog the

engine’s air cooling system.

Clean areas shown to prevent engine damage.

Keep linkages, springs and controls clean.

Keep area around muffler free of any combustible mate-

rial.

BRAKES

PERIODIC BRAKE TEST FOR HYDRAULIC

BRAKES

To reduce possibility of

severe injury or death,

always evaluate pedal

travel before operating a vehicle to verify some brak-

ing function is present.

It is important to periodically check and maintain proper

brake fluid level in master cylinder (Ref. BRAKES on

page 27). Master cylinder is located under cowl. When

checking fluid, wipe off any dirt from fill cap before

removing it to reduce possibility of contamination. Fluid

level should be maintained at mark molded into reservoir.

If fluid must be added, use only DOT 3 brake fluid and

inspect system for fluid leaks.

Push brake pedal. Pedal should have some free travel

and then become hard. A brake pedal that has no free

travel, excessive free travel or a spongy feel indicates

that a brake inspection is required. A brake pedal that

offers little resistance after it is applied indicates a leak in

system.

CAPACITIES

Fig. 39 Cleaning Air Intake and Cooling Fins

Air

Intake

Cooling

Fins

R

ef Cai 2

! !

Fuel Tank 6.7 gal (25.4 liters) unleaded, 87 octane or higher

Engine Oil 1.59 quarts (1.5 liters) crankcase only

1.90 quarts (1.8 liters) crankcase and filter

10W30 usually. See OIL on page 17.

Front Differential 15.2 ± 1 oz. (450 ml) of 80 - 90W GL5

Rear Axle 15.2 ± 1 oz. (450 ml) of 80 - 90W GL5

Transfer Case 24 oz. (700 ml) MOBILFLUID 424

Fig. 40 Capacities

OPERATION AND SERVICE INFORMATION

Page 28 Owner’s Manual and Service Guide

Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings

HARDWARE

Periodically, vehicle should be inspected for loose fasten-

ers. Fasteners should be tightened in accordance with

the Torque Specifications table (Ref. Fig. 41 on page 28).

Use care when tightening fasteners and refer to Techni-

cian’s Repair and Service Manual for specific torque val-

ues.

Generally, three grades of hardware are used in vehicle.

Grade 5 hardware can be identified by three marks on

the hexagonal bolt head and grade 8 by six marks.

Unmarked hardware is Grade 2.

Fig. 41 Torque Specifications and Bolt Grades

ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)

BOLT SIZE

Grade 2

1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"

Unless otherwise noted in text, tighten all hardware in accordance with this chart.

This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when

installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.

4

(5)

8

(11)

15

(20)

24

(33)

35

(47)

55

(75)

75

(102)

130

(176)

125

(169)

190

(258)

Grade 5

Grade 8

6

(8)

13

(18)

23

(31)

35

(47)

55

(75)

80

(108)

110

(149)

200

(271)

320

(434)

480

(651)

6

(8)

18

(24)

35

(47)

55

(75)

80

(108)

110

(149)

170

(230)

280

(380)

460

(624)

680

(922)

BOLT SIZE

Class 5.8

(Grade 2)

M4 M5 M6 M8 M10 M12 M14

1

(2)

2

(3)

4

(6)

10

(14)

20

(27)

35

(47)

55

(76.4)

Class 8.8

(Grade 5)

2

(3)

4

(6)

7

(10)

18

(24)

35

(47)

61

(83)

97

(131)

Class 10.9

(Grade 8)

3

(4)

6

(8)

10

(14)

25

(34)

49

(66)

86

(117)

136

(184)

5.8

8.8

10.9

Ref Tsp 1

Page 29

GENERAL SPECIFICATIONS

Owner’s Manual and Service Guide

GENERAL SPECIFICATIONS

Page 30 Owner’s Manual and Service Guide

GENERAL SPECIFICATIONS

ST 4X4

STANDARD EQUIPMENT:

CHASSIS Welded steel, hot-dip galvanized, front hitch receiver

BODY (Front) Flexible, Impact Resistant DuraShield™ Injection Molded TPE

(Thermoplastic Elastomer) with Base Coat/Clear Coat

BODY (Rear) Lightweight, replaceable steel panels, plastic rear fenders

BATTERY One 12 Volt Maintenance Free (340 CCA, 38 Minute Reserve)

ENGINE Honda 18 H.P. (13.4 kW) 37.5 ci (614 cc) Twin Cylinder, Air Cooled, Overhead Valve,

Replaceable Oil Filter, Replaceable Dry Cartridge Air Filter with Remote Air Intake,

Transistorized Magneto, Fixed Jet Bowl Carburetor, Pulse Fuel Pump

TRANSFER CASE Helical geared with Forward, Reverse and Ground Speed Governor

TRANSMISSION Automatic Continuously Variable Transmission (CVT)

FUEL TANK 6.7 Gallon (25.4 Liters) Tank

BRAKES (FRONT) Dual Front Wheel, Hydraulic 8" (203 mm) Disc Brakes

BRAKES (REAR) Dual Rear Wheel, Hydraulic 6.3" (160 mm) Drum Brakes

PARK BRAKE Hand Operated Lever with Indicator Light

FRONT SUSPENSION Independent with Hydraulic Struts

REAR SUSPENSION Leaf Springs with Hydraulic Shock Absorbers

STEERING Single Reduction Rack & Pinion

SEATING Cushion Foam/Vinyl Cover, Hip Restraint/Hand Hold

SEATING CAPACITY Operator & 1 Passenger

TOTAL LOAD CAPACITY 1500 lbs. (545 kg) Including Operator, Passenger, Accessories & Cargo

SPEED 25 mph (40 kph)

STANDARD COLOR Recon Green

DASH PANEL Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin) with 2 Drink Holders

TIRE Carlisle AT489, 25 x 11 - 12 (Uni-directional)

TIRE PRESSURE 16 - 20 psi (110 - 138 kPa)

WEIGHT (Without fuel) 1250 lbs. (567 kg)

BED Rotomolded Load Bed, Inside Dimensions: 42 3/4" L X 54" W X 11" H (109 X 137 X 27 cm)

OPERATING CONTROLS & Removable Key, Direction Selector, Electric Fuel Gauge, 4WD/2WD Selector with Indicator Lights,

INSTRUMENTATION Electric Front & Rear Differential Locks with Indicator Lights, Hour Meter, Volt Meter

MAXIMUM TRAILER WEIGHT 1500 lbs. (680 kg)

Page 31

GENERAL SPECIFICATIONS

Owner’s Manual and Service Guide

Fig. 42 Vehicle Dimensions

Fig. 43 Vehicle Incline Specifications

Front

43 3/8" (110 cm)

Rear

43 3/4" (111 cm)

76" (193 cm)

112" (285 cm)

50"

(127 cm)

16" (40.6 cm)

8 3/8" (21.3 cm)

Clearance At Lowest Point

Of Vehicle (On Rear Axle)

31.5"

(80 cm)

54" *

(137 cm)

50"

(127 cm)

11"

(28 cm)

(Inside)

11 1/2"

(29 cm)

12 3/4" *

(32 cm)

18 1/4"

(46 cm)

9 1/2" (24 cm)

Clearance At Lowest

Point On Frame

Ref Dim 3-1 Late 2005 Production Loadbed shown. Early Production Similar

* Indicates Late 2005 Production Dimension

Maximum Recommended Side Tilt

25% or 14˚ Max.

Maximum Recommended Ramp Grade

25% or 14˚ Max.

Ref Dim 3-2

Page 32 Owner’s Manual and Service Guide

GENERAL SPECIFICATIONS

Fig. 44 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance

TURNING CLEARANCE DIAMETER

Approx. 25'-6" (7.8 m)

Ref Dim 3-3

Page 33

Owner’s Manual and Service Guide

VEHICLE WARRANTIES

VEHICLE WARRANTIES

Page 34 Owner’s Manual and Service Guide

VEHICLE WARRANTIES

Page 35

VEHICLE WARRANTIES

Owner’s Manual and Service Guide

EMISSION CONTROL SYSTEM WARRANTY STATEMENT

(Owner’s Defect Warranty Rights and Obligations)

Refer to the HONDA Emission Control System Warranty sheet, provided with vehicle, for information.

ENGINE OWNER WARRANTY POLICY

Refer to the Warranty sheet, provided with vehicle, for Engine Warranty information.

INTERNATIONAL WARRANTY STATEMENT

Refer to the International Warranty sheet, provided with vehicle, for information.

Page 36 Owner’s Manual and Service Guide

VEHICLE WARRANTIES

N

otes:

Page 37

Owner’s Manual and Service Guide

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

(EUROPE ONLY)

Declaration of Conformity is packaged with vehicle. For additional information, contact:

Ransomes Jacobsen Limited

West Road, Ransomes Europark,

Ipswich, England, IP3 9TT

Page 38 Owner’s Manual and Service Guide

DECLARATION OF CONFORMITY

N

otes:

Appendix A - 1

LABELS AND PICTOGRAMS

Owner’s Manual and Service Guide

LABELS AND PICTOGRAMS

Appendix A - 2 Owner’s Manual and Service Guide

LABELS AND PICTOGRAMS

Notes:

Appendix A - 3

LABELS AND PICTOGRAMS

Owner’s Manual and Service Guide

Fig. 45 Label Locations

75696G01

74099G01

See Following

Pages For

Explanation

Of These

Pictograms:

(14)

74099-G01

72939G01

(Lift Cowl)

To release cowl,

raise and hold

cowl, lift lever

and lower cowl

carefully

72939G01

H O

2

123

P

P

P

P

P

P

74093-G01

74093G01

24880G1

75696G01

See Following Pages

For Explanation Of These

Pictograms: (1,23,27,18,20,

22,17,15)

See Following Pages

For Explanation Of These

Pictograms: (1)

See Following

Pages For

Explanation

Of These

Pictograms:

(1,35)

73603G01

73601G01

73605G01

73607G01

See Following

Pages For

Explanation

Of These

Pictograms:

(61,45,62,63)

See Following Pages

For Explanation Of

These Pictograms:

(43,44,51)

73767G01

73771G01

See Following

Pages For

Explanation

Of These

Pictograms:

(1,2,3,4,6,9,29,

36,37,54,55)

< 14

˚

25%

< 14

˚

25%

73771G01

OFF

ON

START

73767G01

73769 G01

See Following

Pages For

Explanation

Of These

Pictograms:

(52,53)

P

12

3

73769G01

35493G01

See Following Pages

For Explanation Of

This Pictogram:

(28)

(Lift Cowl)

P

b

35493-G01

74821G04 See Following

Pages For

Explanation

Of These

Pictograms:

(1,2,12,10,8,

11,50,7,5)

MA

X

14

o

/ 25

%

!

MA

X

1100 l

b

s.

500 k

g

MA

X

5 i

n

.

12 c

m

P

P

MA

X

100 l

b

s.

45 k

g

74821G04

See Following

Pages For

Explanation

Of These

Pictograms:

(56,57,58,59,60)

73777G01

73777G01

71489G01

See Following Pages

For Explanation Of

These Pictograms:

(1,2)

Appendix A - 4 Owner’s Manual and Service Guide

LABELS AND PICTOGRAMS

Fig. 46 Pictogram Definitions

1.

2.

4.

MAX

MAX

14 ° / 25 %

14 ° / 25 %

5.

!

< 14 ° 25 %

< 14 ° 25 %

6.

P

P

12.

x in

x in

xx cm

xx cm

MAX LOAD

MAX LOAD

XXX LBS

XXX LBS

XXX KG

XXX KG

13.

!

< 14 ° 25 %

< 14 ° 25 %

9.

11.

7.

MAX

MAX

xxx lbs.

xxx lbs.

xxx kg

xxx kg

10.

MAX

MAX

xx in

xx in

xx cm

xx cm

8.

!

3.

WARNING

DO NOT OPERATE

UNDER THE INFLUENCE

OF DRUGS OR ALCOHOL

14.

WARNING

READ MANUAL

WARNING

USE CAUTION

IN INCLEMENT

WEATHER

MAXIMUM CROSS

HILL/RAMP ANGLE

AS SPECIFIED

WARNING

MAXIMUM CROSS

HILL/RAMP ANGLE

AS SPECIFIED

LOAD WITH

HIGH CENTER

OF GRAVITY

COULD RESULT

IN TIP OVER

LOAD

CENTER

OF GRAVITY,

MAXIMUM

HEIGHT

WARNING

READ MANUAL

FOR MAXIMUM

LOAD BED

CAPACITY.

MAXIMUM

RAMP/HILL

SECURE LOAD

AS FAR FORWARD

AS POSSIBLE

MAXIMUM LOAD

BED CAPACITY

DO NOT RIDE IN

LOAD BED

DANGER OF

EXPLOSION

DO NOT FILL

GAS CAN

IN LOAD BED

WARNING MAXIMUM LAOD & CENTER OF GRAVITY.

KEEP LOAD AS FAR FORWARD AS POSSIBLE.

DO NOT RIDE IN LOAD BED

KEEP HANDS & FINGERS AWAY FROM DUMP BED.

DO NOT STAND BEHIND DUMP BED

Appendix A - 5

LABELS AND PICTOGRAMS

Owner’s Manual and Service Guide

Fig. 47 Pictogram Definitions

26.

27.

13

H O

2

P

P

15.

2

P

P

16.

P

P

18.

P

P

17.

23.

21.

22.

24.

25.

19.

20.

28.

29.

30.

31.

32.

33.

34.

35.

CLEAN UP GASOLINE SPILLS WITH WATER BEFORE

STARTING ENGINE

UNLEAD

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

SHORTING BATTERY

TERMINALS MAY

CAUSE EXPLOSION

NO

TAMPERING.

KEEP HANDS

OUT

WARNING

CORROSIVE

WARNING

EXPLOSIVE

WARNING

LETHAL

VOLTAGE

DO NOT

EXPOSE

TO FLAME

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

WEAR EYE

PROTECTION

NO SMOKING

HOT SURFACE

Appendix A - 6 Owner’s Manual and Service Guide

LABELS AND PICTOGRAMS

Fig. 48 Pictogram Definitions

36.

37.

F

38.

42.

R

39.

P

F

40.

P

N

41.

ON

43.

OFF

44.

45.

46.

47.

48.

49.

50.

51.

START

52.

P

53.

12

3

OPERATE

FROM

DRIVER’S SIDE

ONLY

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

* AN AUDIBLE DEVICE WILL SOUND

* DEPRESS ACCELERATOR PEDAL

AND ACCELERATE SMOOTHLY

TO LEAVE A GASOLINE POWERED

VEHICLE IN PARK:

* APPLY PARKING BRAKE

* TURN KEY TO OFF

* MOVE DIRECTION SELECTOR TO

FORWARD

TO LEAVE AN ELECTRIC POWERED

VEHICLE IN PARK:

* APPLY PARKING BRAKE

* TURN KEY TO OFF

* MOVE DIRECTION SELECTOR TO

NEUTRAL

PULL HANDLE UP,

PUSH BUTTON IN,

PUSH HANDLE DOWN

TO RELEASE PARK BRAKE

PULL HANDLE UP

TO ENGAGE PARK

BRAKE

ENGINE

CRANKING

POSITION

MAXIMUM

TAILGATE

LOAD

WARNING

KEEP ENTIRE BODY

INSIDE CAR

DIFFERENTIAL

LOCKED

LOCKED

UNLOCKED

KEEP CLEAR

HAND OR

FINGERS CAN

BE TRAPPED

ON

POSITION

OFF

POSITION

HEADLIGHTS

Appendix A - 7

LABELS AND PICTOGRAMS

Owner’s Manual and Service Guide

Fig. 49 Pictogram Definitions

62.

63.

56.

57.

58.

59.

60.

61.

55.

54.

WARNING

READ OWNER’S MANUL

BEFORE OPERATING

VEHICLE IN FORWARD

OR REVERSE

WARNING

READ OWNER’S MANUAL

BEFORE PARKING

VEHICLE AND LEAVING

IT UNATTENDED

FORWARD

NEUTRAL

REVERSE

WARNING

READ OWNER’S MANUAL

BEFORE ENGAGING TWO

OR FOUR WHEEL DRIVE

PUSH TOP OF SWITCH

TO LOCK DIFFERENTIAL

PUSH BOTTOM OF

SWITCH TO UNLOCK

DIFFERENTIAL

FRONT DIFFERENTIAL

LOCK SWITCH.

WARNING

READ OWNER’S MANUAL

BEFORE ENGAGING

FRONT DIFFERENTIAL

LOCK.

DO NOT ENGAGE LOCK

WHILE FRONT WHEELS

ARE TURNED AND

VEHICLE IS AT SPEED.

PUSH TOP PART OF

SWITCH TO RAISE LOAD

BED

PUSH BOTTOM PART OF

SWITCH TO LOWER LOAD

BED

REAR DIFFERENTIAL

LOCK SWITCH

AUXILIARY LIGHTS

HORN BUTTON

Appendix A - 8 Owner’s Manual and Service Guide

LABELS AND PICTOGRAMS

Notes:

Check area behind the

vehicle before operating

in reverse.

Make sure the direction selector is in correct position

before attempting to start the vehicle.

Slow down before and during turns. All turns should

be executed at reduced speed.

Always bring vehicle to a complete stop before

shifting the direction selector.

See GENERAL SPECIFICATIONS for vehicle load and

seating capacity.

Read and understand the following text and

warnings before attempting to service vehicle:

In any product, components will eventually fail to perform

properly as the result of normal use, age, wear or abuse.

It is virtually impossible to anticipate all possible compo-

nent failures or the manner in which each component

may fail.

Be aware that a vehicle requiring repair indicates that the

vehicle is no longer functioning as designed and there-

fore should be considered potentially hazardous. Use

extreme care when working on any vehicle. When diag-

nosing, removing or replacing any components that are

not operating correctly, take time to consider the safety of

yourself and others around you should the component

move unexpectedly.

Some components are heavy, spring loaded, highly cor-

rosive, explosive or may produce high amperage or

reach high temperatures. Gasoline, carbon monoxide,

battery acid and hydrogen gas could result in serious

bodily injury to the technician/mechanic and bystanders if

not treated with the utmost caution. Be careful not to

place hands, face, feet or body in a location that could

expose them to injury should an unforeseen situation

occur.

Always use the appropriate tools listed in the tool list and

wear approved safety equipment.

To prevent personal

injury or death, observe

the following:

Before working on the vehicle, remove all jewelry

(rings, watches, necklaces, etc.)

Be sure that no loose clothing or hair can contact

moving parts.

Use care not to touch hot objects.

Raise entire vehicle and support on jack stands before

attempting to run or adjust powertrain.

Wear eye protection when working on or around

vehicle. In particular, use care when working around

batteries, using solvents or compressed air.

Hydrogen gas is formed when charging batteries. Do

not charge batteries without adequate ventilation.

Do not permit open flame or anyone to smoke in an

area that is being used for charging batteries. A

concentration 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. Carbon monoxide is a dangerous

gas that can cause unconsciousness and is

potentially lethal.

The following are symptoms of carbon monoxide

inhalation:

• Dizziness

• Vomiting

• Intense headache

• Muscular twitching

• Weakness and sleepiness

• Throbbing in temples

If any of these symptoms are experienced, get fresh air

immediately. Never work around or operate a vehicle

in an environment that does not ventilate exhaust

gases from the area.

! !

! !

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.

Technical Communications Department

Starting Model Year 2005

P/N 602080

ISSUED: April 2005

E-Z-GO Division Of Textron, Inc.,

1451 Marvin Grin 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