E Z Go St 480 Users Manual

ST 480 to the manual 9971c782-f065-4753-a13d-795c13dfd49b

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A Textron Company

MANUAL INFORMATION
For any questions on material contained in this manual, contact a representative
for clarification.
Read and understand all labels located on the vehicle. Always replace any damaged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds
encountered on a flat surface. To prevent loss of vehicle control and possible
serious injury, speeds should be limited to no more than the maximum speed on
level ground. (See vehicle specification.) 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 re-sold.
Throughout this guide, NOTE, CAUTION and WARNING will be used.

Please 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 chemicals 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 Environmental 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.

!

!

!

A WARNING indicates a hazardous condition which could result
in severe injury or death.

!

Battery posts, terminals and related accessories contain lead and
lead compounds. Wash hands

after handling.

A NOTE indicates a condition that should be
observed.
A CAUTION indicates a condition that
may result in damage to the vehicle.

!

This spark ignition system meets all requirements
of the Canadian Interference-Causing Equipment
Regulations.

Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleur
du Canada.

OWNER’S MANUAL & SERVICE GUIDE

ST 480

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 information 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 damage that result from the use of material in this manual.

CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124
OUTSIDE USA PHONE: 010-1-706-798-4311 FAX: 010-1-706-771-4609
E-Z-GO DIVISION OF TEXTRON INC., P.O. BOX 388 AUGUSTA, GEORGIA 30903-0388 USA

i

NOTES

To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch or
the Warranty Department with vehicle serial number and manufacture date code.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void
the vehicle warranty.
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 battery.
A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75° F (-60° C).

ii

TABLE OF CONTENTS
TITLE

PAGE

MANUAL INFORMATION.......................... Inside Front Cover
NOTES ...................................................................................... i
SAFETY INFORMATION ......................................................2-1
OPERATION AND SERVICE INFORMATION .....................3-1
BEFORE INITIAL USE ................................................................................3-1
Fig. 1 Initial Service Chart ..........................................................3-2
TERRAIN .....................................................................................................3-2
VEHICLE CAPACITY ..................................................................................3-2
MODIFICATIONS TO VEHICLE ..................................................................3-3
COMMON SENSE OPERATION .................................................................3-3
POWER CONSUMPTION ...........................................................................3-3
ENVIRONMENTAL CONCERNS ................................................................3-4
OPTIONAL WINCH .....................................................................................3-4
OPERATION OF THE WINCH ...............................................................3-4
Fig. 2 Winch Mounted to Vehicle ................................................3-4
Fig. 3 Winch Remote Control .....................................................3-5
Fig. 4 Winch Clutch Knob ...........................................................3-5
WINCH APPLICATIONS ........................................................................3-5
Fig. 5 Never Operate Winch with Less Than
Five Turns Around Drum ..................................................3-6
Fig. 6 Do Not Hook Cable to Itself ..............................................3-7
Fig. 7 Use a Nylon Sling and Install a Damper when Winching .3-7
Fig. 8 Do Not Pull at Angle .........................................................3-8
CONTROLS AND INDICATORS .................................................................3-8
KEY/LIGHT SWITCH .............................................................................3-8
Fig. 9 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge 3-8
DIRECTION SELECTOR .......................................................................3-9
Fig. 10 Console Controls ............................................................3-9
CHOKE ...................................................................................................3-9
FUEL GAUGE ........................................................................................3-9
LOW OIL PRESSURE INDICATOR LIGHT ...........................................3-9
ACCELERATOR PEDAL ........................................................................3-9
Fig. 11 Accelerator, Brake and Horn ........................................3-10

TITLE

PAGE

SERVICE BRAKE PEDAL ...................................................................3-10
PARK BRAKE ...................................................................................... 3-10
HORN ...................................................................................................3-10
DIFFERENTIAL LOCK ......................................................................... 3-10
LOAD BED ................................................................................................ 3-11
ELECTRIC LIFT BED OPERATION .................................................... 3-11
Fig. 12 Electric Lift Switch ........................................................ 3-11
OPERATING THE VEHICLE ..................................................................... 3-12
RUN-IN ................................................................................................. 3-13
Fig. 13 Check Oil Level on Dipstick .........................................3-13
COLD STARTING ................................................................................ 3-13
STARTING AND DRIVING .................................................................. 3-14
STARTING THE VEHICLE ON A HILL ................................................ 3-14
COASTING .......................................................................................... 3-14
FUEL .................................................................................................... 3-15
Fig. 14 Fueling ......................................................................... 3-15
BATTERY ............................................................................................. 3-15
LABELS AND PICTOGRAMS ..............................................................3-16
SUN TOP AND WINDSHIELD ............................................................. 3-16
12 VOLT POWER OUTLET ................................................................. 3-16
Fig. 15 12 Volt Power Outlet .................................................... 3-16
TOWING A TRAILER ........................................................................... 3-16
VEHICLE CLEANING AND CARE ........................................................... 3-17
VEHICLE CLEANING .......................................................................... 3-17
VEHICLE CARE PRODUCTS ..............................................................3-17
REPAIR ..................................................................................................... 3-18
LIFTING THE VEHICLE ....................................................................... 3-18
Fig. 16 Lifting the Vehicle .........................................................3-19
WHEELS AND TIRES .......................................................................... 3-19
Tire Repair ..................................................................................... 3-19
Wheel Installation .......................................................................... 3-20
Fig. 17 Wheel Installation .........................................................3-21
LIGHT BULB REPLACEMENT ............................................................ 3-21
Fig. 18 Headlight and Turn Signal Bulb Replacement ............. 3-21
Fig. 19 Tail and Brake Light Bulb Replacement ....................... 3-21
FUSE REPLACEMENT ........................................................................ 3-21
VEHICLE WITH A DISCHARGED BATTERY ...................................... 3-22
TRANSPORTING VEHICLE ..................................................................... 3-22

1-1

TABLE OF CONTENTS
TITLE

PAGE

TOWING .............................................................................................. 3-22
NEUTRAL LOCK ................................................................................. 3-22
Fig. 20 Neutral Lock ................................................................. 3-23
HAULING ............................................................................................. 3-22
SERVICE AND MAINTENANCE .............................................................. 3-23
SERIAL NUMBER PLATE LOCATION ................................................ 3-25
Fig. 21 Serial Number Plate Location ...................................... 3-25
PERIODIC SERVICE SCHEDULE ..................................................... 3-26
Fig. 22 Periodic Service Schedule ........................................... 3-26
TIRE INSPECTION .............................................................................. 3-28
SEAT PROP ........................................................................................ 3-28
Fig. 23 Seat Prop ..................................................................... 3-29
REPLACING THE FUEL FILTER ........................................................ 3-29
CHECKING THE OIL LEVEL ............................................................... 3-29
Fig. 24 Oil Fill Cap, Dipstick and Fuel Filter ............................. 3-30
Fig. 25 Clean Entire Dipstick ................................................... 3-30
Fig. 26 Check Oil Level on Dipstick ......................................... 3-30
CHANGING THE OIL ........................................................................... 3-30
Fig. 27 Oil Viscosity Chart ....................................................... 3-31
CHANGING THE OIL FILTER ............................................................. 3-32
Fig. 28 Oil Drain and Filter ....................................................... 3-32
LUBRICATION ..................................................................................... 3-32
Fig. 29 Lubrication Points ........................................................ 3-32
AIR CLEANER INSPECTION AND REPLACEMENT ......................... 3-33
Pre-Cleaner Service ...................................................................... 3-33
Cartridge Service ........................................................................... 3-33
Fig. 30 Air Cleaner ................................................................... 3-33
REAR AXLE ......................................................................................... 3-34
Checking the Lubricant Level ........................................................ 3-34
Fig. 31 Add, Check and Drain Rear Axle Lubricant ................. 3-34
STARTER/GENERATOR BELT TENSION ......................................... 3-34
Fig. 32 Check Belt Tension with Gauge .................................. 3-35
Fig. 33 Check Belt Tension with Finger ................................... 3-35
Adjusting the Belt .......................................................................... 3-35
Fig. 34 Adjust Belt Tension ...................................................... 3-35
BATTERY CLEANING ......................................................................... 3-36
Fig. 35 Preparing Acid Neutralizing Solution ........................... 3-36
AIR INTAKE AND COOLING FINS ...................................................... 3-36
Fig. 36 Cleaning Air Intake and Cooling Fins .......................... 3-37

1-2

TITLE

PAGE

SPARK PLUGS ................................................................................... 3-37
BRAKES .............................................................................................. 3-37
Daily Brake Test ............................................................................ 3-37
PROLONGED STORAGE ................................................................... 3-38
HARDWARE ........................................................................................ 3-38
Fig. 37 Torque Specifications and Bolt Grades ....................... 3-39
CAPACITIES AND REPLACEMENT PARTS ..................................... 3-40
Fig. 38 Capacities and Replacement Parts ............................. 3-40

GENERAL SPECIFICATIONS.............................................. 4-1
ST 480 .................................................................................................... 4-1
Fig. 1 Vehicle Dimensions .......................................................... 4-2
Fig. 2 Vehicle Incline Specifications ........................................... 4-3
Fig. 3 Vehicle Turning Clearance Diameter................................ 4-4

LIMITED WARRANTY .......................................................... 5-1
DECLARATION OF CONFORMITY ..................................... 6-1
LABELS AND PICTOGRAMS ............................. APPENDIX A

SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
The Owner’s Manual and Service Guide has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and trouble-shooting tips will ensure the
best possible service from the product. To reduce the chance of personal injury
and/or property damage, the following instructions 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.
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 the owner-operator read this entire Owner’s
Manual and Service Guide paying particular attention to the CAUTIONS and
WARNINGS contained therein. It is further recommended that other operators
be encouraged to do the same.
If you have any questions, contact your closest representative or write to the
address on the back cover of this publication, Attention: Product Service Department.
• 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.
• 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
information contained in this manual is subject to change without notice.
• This vehicle conforms to the current applicable standard 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 communities may permit these vehicles to be operated on
their streets on a limited basis and in accordance with local ordinances.
• Vehicle capacity is limited to a maximum of two persons.
• 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.

GENERAL OPERATION
The following information is very important in the operation of the vehicle. The
operator should read, understand and always observe the following:
• Use the vehicle in a responsible manner and maintain the vehicle in safe
operating condition.
• Read, understand 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 unsuitable terrain or conditions.
• Apply service brake to control speed on steep grades.
• Reduce speed in wet areas.
• Use extreme caution and reduced speed when approaching sharp or blind
turns.
• Use extreme caution and reduced speed when driving over loose terrain.
• Use extreme caution and reduced speed in areas where pedestrians are
present.

2-1

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

MAINTENANCE
The following information is very important in the maintenance of the vehicle.
The person performing maintenance procedures should read, understand and
always observe the following:
• Maintain your vehicle in accordance with the manufacturer’s periodic service schedule.
• Ensure that mechanics performing repairs are trained and qualified to do
so.
• Follow the manufacturer’s directions if you perform maintenance on your
own 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.
• Check the polarity of each battery terminal and be sure to rewire the battery correctly.
• Use specified replacement parts. Never use replacement parts of lesser
quality.
• Use only tools recommended by the manufacturer.
• 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.
• Never attempt to perform vehicle maintenance in an area where exposed
flame is present or persons are smoking.

2-2

• Be aware that a vehicle that is not performing as designed is a potential
hazard and must not be operated until inspected and repaired.
• The manufacturer cannot anticipate all dangerous situations. People
attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential dangerous situations. These situations 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.
• Test drive the vehicle after any repairs are made or maintenance procedures performed to assure the vehicle is safe to return to service. 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.

VENTILATION
• Always store gasoline vehicles in a well ventilated area to prevent 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.

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

Service Parts Manuals, Technician’s Repair and Service Manuals and
engine Repair Manuals are available from a local Distributor, an 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
Record the four digit key number and store in a safe
place. Individual keys can only be replaced if the
key number is known. Without a key number, the entire ignition
switch will have to be replaced if keys are lost.

Thank you for purchasing a light duty utility vehicle. Before driving the
vehicle, we ask you to spend some time reading this Owner’s Manual
and Service Guide and the Operating and Maintenance Instructions
manual provided by the engine manufacturer. These manuals contain
the information that will assist you in the safe operation of the vehicle.
They will also assist you in maintaining this highly reliable vehicle.
Some illustrations may show items that are optional for your vehicle.
This vehicle has been designed and manufactured as a ‘World Vehicle’. Some countries have individual requirements to comply with their
specifications; therefore, some sections may not apply in your country.
Most of the service procedures in this guide can be accomplished
using common automotive hand tools. Contact your service representative on servicing the vehicle in accordance with the Periodic Service
Schedule.

Read, understand and follow the safety label on the instrument panel
(Ref Appendix A). Be sure you understand how to operate the vehicle,
its equipment and how to use it safely. Maintaining good performance
depends to a large extent on the operator.

Improper use of this vehicle could
result in severe injury or death. The
ST Series vehicle is a light duty utility vehicle. It is NOT an all terrain vehicle (ATV).
This vehicle is not a toy and using it while engaging in horseplay is dangerous.
Plan carefully before using the vehicle to go significant distances over questionable terrain. Remember that a one hour
drive may take many hours to walk out should you run out of
fuel or be stranded by becoming stuck on unsuitable terrain.
Hydrogen gas is generated as a natural part of the lead acid
battery charging process. A 4% concentration of hydrogen
gas is explosive and could cause severe injury or death.
Charging must take place in an area that is adequately venti-

!

!

3-1

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

lated (minimum of 5 air exchanges per hour).
To reduce the chance of battery explosion that could result in
severe injury or death, never smoke around or charge batteries in an area that has open flame or electrical equipment that
could cause an electrical arc.
Before a new vehicle is put into operation, the items shown in the INITIAL SERVICE CHART must be performed (Ref Fig. 1 on page 3-2).
ITEM

SERVICE OPERATION

Battery

Charge battery

Seats

Remove protective plastic covering

Brakes

Check operation and adjust if necessary
Check hydraulic brake fluid level

Tires

Check air pressure (see SPECIFICATIONS)

Fuel

Fill tank with correct fuel

Engine

Check oil level (Initial change after 5 - 8 hours)

Keys

Record key number and store in safe location

Fig. 1 Initial Service Chart

Vehicle battery must be fully charged before initial use.
Check for correct tire inflation. See GENERAL SPECIFICATIONS.
Check for oil or fuel leaks that could have developed in shipment from
the factory.
Check for a firm brake pedal. Determine and record braking distance
required to stop vehicle for future brake performance tests.

3-2

Record and keep key number.
Remove the protective clear plastic, that protect the seat bottom and
back rest during shipping, before placing the vehicle in service.

TERRAIN
The vehicle is designed for use on improved roads (but not on public
highways). The vehicle may also be used on established trails or open
terrain that is free from stumps, large rocks or holes.
The vehicle should not be used to cross water.

VEHICLE CAPACITY
Due to the variety of ways the vehicle may be used, it is important that
the operator consider any potential
hazards before use to prevent serious injury or death.

!

!

The vehicle may be used to transport a maximum of two people
within the operator/passenger compartment and cargo in the load
bed. Never carry passengers in the load bed. The total payload is
800 lbs. (363 kg). The weight of the driver and passenger plus any
options or accessories must be deducted from the total payload rating
to determine the load bed capacity. Remember that towing a trailer will
reduce the payload of the vehicle itself.
Remember that volume of your load can be misleading. Loading the
vehicle to its rated capacity with dry sand, fertilizer, sod, etc. can be
handled with complete safety. The same load when wet will grossly
overload the vehicle and increase the potential for roll over and damage to the vehicle.

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

MODIFICATIONS TO VEHICLE
Changes to the weight distribution
or the center of gravity may make it
unstable or prone to roll over which
could result in injury or death to the operator or passenger.

!

!

Do not modify the vehicle in any manner that will change the weight
distribution of the vehicle. Changes to the weight distribution or the center of gravity may make it unstable or prone to roll over which could
result in injury or death to the operator or passenger.

COMMON SENSE OPERATION
This vehicle is not a toy. If not operated properly and responsibly, it
can cause severe injury or death to the operator, passenger or
bystanders. All operators should possess a valid driver’s license. Children should not be permitted to operate the vehicle. Children may not
have the skill, judgement or strength to operate this or similar vehicles.
Alcohol, drugs and many over the counter medications reduce the ability of the driver to operate the vehicle safely. Always review side effects
of any medication with a doctor or pharmacist before operating vehicle.
Protective clothing and an approved motorcycle helmet are recommended for operator and passenger at all times.
When driving at full speed on a dirt road, loose surfaces or wet grass,
vehicle stopping distance will increase. If the vehicle is fully loaded, it
will take longer to stop than with no load. When operating vehicle in wet
weather conditions, remember that the brakes may need to be lightly
applied in order to provide enough friction to dry the brake unit. If wet,
the brakes will lose much of their effect.

Slow down when in unfamiliar terrain. Slow down when cresting a hill in
an area that you are unfamiliar with.
Some hills are too steep to climb. If you attempt to climb a hill that is too
steep or if you are unable to achieve adequate traction, do not attempt
to turn around on the hill. Slowly back straight down the hill using
the service brake to control speed.

POWER CONSUMPTION
The vehicle uses a combination starter/generator to both start the
engine and charge the battery. The engine will not idle; therefore, the
battery cannot be charged while the vehicle is stopped. Do not operate
accessory items (such as accessory lights, radios, winch, etc.) excessively while the vehicle is stopped.
Overuse of accessories may drain
the battery and leave insufficient
reserve to start the vehicle.
The generator is only capable of supplying 35 amps; therefore, operation of all accessories could result in the discharge of the battery even
though the engine is running and the generator operating. Discharging
the battery is known as deep cycling. The battery is not a deep cycle
model, but is a starting battery. Multiple deep cycling of the battery will
result in the premature failure of the battery.
Vehicle battery must be fully charged before initial use.

Hydrogen gas is generated as a natural part of the lead acid battery
charging process. A 4% concentration of hydrogen gas is explosive and could cause severe

!

!

3-3

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

injury or death. Charging must take place in an area that is
adequately ventilated (minimum of 5 air exchanges per hour).
To reduce the chance of battery explosion that could result in
severe injury or death, never smoke around or charge batteries in an area that has open flame or electrical equipment that
could cause an electrical arc.

ENVIRONMENTAL CONCERNS
As a responsible user, practice respect for all wildlife and their habitat.
Respect private property and comply with all local laws and regulations
governing the use of light duty utility vehicles. Do not tamper with the
exhaust system or governor. The exhaust system has been tuned to
the engine for maximum performance. Removal or modification of the
exhaust is annoying to other people and will not improve the performance of the vehicle.

To prevent 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.
When driving, be aware of environmental hazards such as steep
slopes, overhanging limbs, etc. Be aware of the danger of fire when the
vehicle is operated over dry combustible organic material.

OPTIONAL WINCH
This vehicle may be equipped with an optional winch. Read, understand and follow all of the following information on the operation and
use of the winch before attempting to operate it.

OPERATION OF THE WINCH
The winch can be mounted at the front or rear of the vehicle and
moved to accommodate different situations. At the front, it is mounted
under the center of the front cowl to a bracket attached to the front axle
as shown (Ref Fig. 2 on page 3-4). At the rear, the winch is mounted
upside down in the hitch receiver.
If mounting winch at rear of vehicle, the winch must
be mounted upside down.
Winch shown mounted at front of vehicle
Front Axle

Spring Pin

Clevis Pin

Fig. 2 Winch Mounted to Vehicle

3-4

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Before moving the winch, unplug the winch connector from the wire
harness. To move the winch from one end of the vehicle to the other,
remove the spring pin, pull out the clevis pin and remove the winch
mount tube from the receiver. Move to opposite end of vehicle and
install by inserting clevis pin and securing with spring pin. Plug the
winch connector into wire harness.
The winch remote control plugs into the receptacle on the driver side of
the seat support (Ref Fig. 3 on page 3-5).

operate winch while sitting in passenger seat. Read the following section (Winch Applications) before attempting to operate winch.
ENGAGED

LOCKED OUT

Pull out
Turn 90 0

Clutch Knob

Fig. 4 Winch Clutch Knob
Remote Control

WINCH APPLICATIONS
The winch may be used for a number of purposes, including pulling the
vehicle if it loses traction on unsuitable terrain.

Receptacle

Fig. 3 Winch Remote Control

To unwind the cable, locate the clutch knob on the winch. 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. Re-engage drum by
turning clutch knob 90°, returning it to original position (Ref Fig. 4 on
page 3-5).
To wind cable, use handsaver bar to keep tension on the cable while
activating remote. When winding cable, make sure the cable winds
tightly and evenly onto the drum leaving no gaps that could cause premature wear to the cable. When using winch under a load, operate the
remote control from as far to the side of the vehicle as possible. Do not

Improper use of the winch could
result in a number of conditions that
could cause severe injury or death
to operator, occupants of vehicle or bystander.

!

!

It is impossible to predict all conditions that the winch could be used,
therefore the following warnings should not be considered as complete.
Before operating the winch, consider the possible dangers and take
precautions to protect yourself, your passenger and any bystanders.

To prevent severe injury or death to
operator, occupants or bystanders,
select the object to which the cable
is attached with the following considerations:
Make sure the object cannot be pulled over or otherwise
damaged.

!

!

3-5

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

The object the winch is attached to could fall on the vehicle
and it’s occupants.
If attaching the winch to a dead tree, a section could fall.
When pulling vehicle with winch, pull straight only. Do not permit the
cable to contact the side of the drum.

Replace frayed wire cable with a direct factory replacement only.
Never operate the winch with less than five (5) full turns of
cable around the drum (Ref Fig. 5 on page 3-6).

Do not pull vehicle at angle. If the
vehicle is pulled at an angle, it could
turn over causing severe injury or
death to anyone in the area. The winch cable could also
become overstressed and break causing severe injury or
death to anyone struck by the cable.

!

!

If the vehicle becomes stuck or ‘hung up’ on an obstruction, the vehicle
may be moved using the winch.
The winch may be installed in either the front or rear receiver and held
in place with the locking pin provided.

To prevent severe injury or death,
read and understand the following
before attempting to use the winch:
The winch is not intended to be used in any hoisting operation.
The rolling load capacity of the winch decreases with the
steepness of the slope.
The winch is designed for intermittent duty only. The electric motor should not be allowed to become excessively
hot. If the motor becomes uncomfortably hot to the touch,
stop winching and allow the motor to cool.
Always wear thick leather gloves when handling the wire
cable.

!

3-6

!

Fig. 5 Never Operate Winch with Less Than
Five Turns Around Drum

If the winch motor stalls from overloading, do not continue
to activate the winch remote control. The wire cable may
become overstressed.
Do not attempt to pull loads exceeding 1500 lbs. (680 kg).
To pull out the cable, the free spool clutch knob must be
used. Pull out and rotate the knob. If the cable is under any
load the clutch may not release easily. Jog out some of the
cable to release the tension and operate clutch. Pull out
the desired amount of cable and secure. Engage the drum
by rotating the knob until it snaps in place. Never operate
the winch unless the clutch is engaged.
Have all persons and pets leave the area while operating
winch. Never allow anyone to remain in the vehicle.

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

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

Damper
Nylon
Sling
Ref Wcd 2

Fig. 7 Use a Nylon Sling and Install a Damper when Winching

Ref Wca 2

Fig. 6 Do Not Hook Cable to Itself

Stay clear of the winch, the cable and the cable hook.
Place a heavy cloth, jacket or blanket over the cable to act
as a damper should the cable break when operating the
winch (Ref Fig. 7 on page 3-7).
Remember that the winch operation will drain the battery
and may leave insufficient power to start the vehicle.
When operating the winch, keep the entire area in view.
Never release the free spool clutch while the cable is
under load.
Never work around the winch drum or the winch cable
while it is under tension.

Unplug the winch switch before working on the winch
drum in order to prevent inadvertent operation.
When operating winch, take up slack slowly. Stop winch
before cable becomes tight and inspect all winching connections. Check winch attachment, hook attachment,
nylon sling (if required) and load attachment.
Do not pull at an angle. This will cause the wire cable to
pile up on one end of the winch. This may jam the winch
causing damage to the cable and/or the winch. Pulling the
vehicle at an angle can cause damage to the front suspension and may cause the vehicle to overturn. When pulling
vehicle, pull straight only (Ref Fig. 8 on page 3-8).
If the vehicle is being used as an anchor to winch a load, it
should have the parking brake set and chocks installed on

3-7

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

CONTROLS AND INDICATORS
Correct

Incorrect

Vehicle controls and indicators consist of:
• key/light switch
• direction selector
• choke
• fuel gauge
• low oil pressure light
• accelerator pedal
• brake pedal
• park brake
• horn
• differential lock

KEY/LIGHT SWITCH
Ref Wps 2

Fig. 8 Do Not Pull at Angle

all wheels.
Never use the winch to lift people or other overhead loads.
Do not use the winch to secure loads. Use a tie down
designed for the job.
Do not apply shock loads to the winch.
Do not attempt to modify or weld the winch.

Located on the dash panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key. To prevent
inadvertent operation of the vehicle when left unattended, the key
should be turned to the ‘OFF’ position and removed (Ref Fig. 9 on page
3-9).
If the vehicle is equipped with lights, the key switch has a position to
operate them, indicated by the light icon.
If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’ position.

DIRECTION SELECTOR
To reduce the possibility of

3-8

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Fuel
Gauge

Key/Light Switch

OFF ON

Parking
Brake

Choke

F
E
FUEL

Low Oil Pressure
Indicator Light

Direction
Selector
Differential
Locked

Fig. 9 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge

component damage, the vehicle must be completely
stopped before moving the direction selector.

Differential
Lock Lever
(Stop Vehicle
Before Moving
Lever)

Located on the console between the seats, this lever permits the selection of either forward or reverse (Ref Fig. 10 on page 3-9). The vehicle
should be left in forward when unattended.

CHOKE
The choke is used to aid cold starting (Ref Fig. 10 on page 3-9).
See ‘Cold Starting’ (Refer to page 3-14) for instructions on using
the choke properly.

FUEL GAUGE
An electric fuel gauge is located to the right side of the key/light switch.
It indicates the amount of fuel in the tank (Ref Fig. 9 on page 3-9).

LOW OIL PRESSURE INDICATOR LIGHT
A low oil pressure indicator light is located on the dash panel (Ref Fig. 9
on page 3-9). If oil pressure drops below 1 - 4 psi (.1 - .2 kg/cm2), the oil
pressure switch will activate the light. Check oil level (Refer to page 3-

Differential
Unlocked
75694G01

Fig. 10 Console Controls

29). If oil level is between ADD and FULL mark on dipstick, a mechanical problem exists within the engine and the vehicle must not be
driven. Contact a local Distributor or authorized Branch.
To prevent 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 the air filter
enclosure.

3-9

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
If oil level is below ADD mark on dipstick, add oil to bring level to FULL
mark (Refer to page 3-29). Drive vehicle a short distance and check oil
pressure. If oil pressure light does not come on, continue to use vehicle.

SERVICE BRAKE PEDAL

ACCELERATOR PEDAL
Unintentional movement of the
!
! accelerator pedal may cause the
vehicle to move which could result
in severe injury or death.

PARK BRAKE

With the key switch ‘ON’, depressing the accelerator pedal starts the
engine and the vehicle begins to move in the direction selected. When
the pedal is released, the engine will stop (Ref Fig. 11 on page 3-10).
To stop the vehicle more quickly, depress the service brake.

H

The hand operated park brake is located on the console between the
front seats (Ref Fig. 10 on page 3-9). The brake is engaged when the
handle is raised and disengaged when the handle is in the full down
position.
When leaving the vehicle unattended, engage the park brake by raising
the handle until it locks in place. To release the park brake, depress the
release button in the end of the handle while slightly raising the handle,
then lower the park brake handle.

HORN

Horn
ORN

Depressing the foot operated service brake pedal activates the
wheel brakes, slowing or stopping the vehicle (Ref Fig. 11 on page
3-10).

Service
Brake

Accelerator

The horn is operated by pushing the horn button located on the upper
floorboard to the left of the brake pedal (Ref Fig. 11 on page 3-10).

DIFFERENTIAL LOCK

Fig. 11 Accelerator, Brake and Horn

The rear drive axle is equipped with a manually operated locking differential. With the differential unlocked, if one drive wheel looses traction,
all available power is transferred to that wheel until it regains traction.
With the differential locked, power is distributed to both drive wheels at
all times. Always disengage the differential lock after traction is
regained. With the differential locked, steering effort and tire wear is
increased due to the outside tire dragging during turns.
The differential lock should only be used when
additional traction is required. Continued use of the

3-10

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
differential lock may cause excessive wear to the rear tires.

The vehicle must be completely
stopped before engaging or
disengaging the differential lock. Failure to stop will
damage the differential.
To engage the differential lock, stop vehicle and push the lock lever forward towards the red ‘locked’ symbol (Ref Fig. 10 on page 3-9).
To disengage the differential lock, stop the vehicle and push the differential lock lever backward towards the green ‘unlocked’ symbol. After
unlocking, the differential may remain locked if driving is resumed in a
straight line. This is a normal occurrence caused by pressure remaining against the gears and not allowing the locking mechanism to
release. To avoid this, simply turn the vehicle as acceleration begins or
accelerate in reverse.

LOAD BED
To reduce the possibility of severe
injury or death, read, understand
and follow the Danger label affixed
to the front of the load bed.

!

!

The electric lift bed is the standard bed for the ST480.
A load bed warning label is affixed to the front of the bed. See Appendix
A. For safe operation of the vehicle, this label must be understood. See
the load bed warning label for maximum load. The load must be positioned in the bed as far forward as possible, distributed 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, damage the vehicle and/or cause the vehicle to tip over. Use
extra care when operating loaded vehicle.
Do not permit any one to ride in the bed.
Do not drive the vehicle with the load bed raised or with the tailgate
unsupported.
When using the electric lift on the ST 480, be sure to 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 the vehicle falling backwards.
Before operating load bed, check to ensure no one is behind the vehicle.

!

!

Never fill a gas can in the bed of a
vehicle. Static discharge could ignite
gasoline vapor and cause an explo-

sion.
Always place a gas can on the ground before filling. Never fill a gas can
in the bed of the vehicle. Static electricity is built up during the fueling
process and could discharge causing the gasoline vapor to ignite.

ELECTRIC LIFT BED OPERATION
Exercise caution while operating the
!
! electric lift bed to ensure clothing is
not caught during lifting or lowering
procedure. Severe injury could result if bed is lowered and
traps fingers or other body parts.
The electric lift switch is located on the driver side of the front seat
panel. Move the switch lever up to raise the load bed and down to
lower (Ref Fig. 12 on page 3-12).

3-11

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

Rais

e

Low

er

Fig. 12 Electric Lift Switch

OPERATING THE VEHICLE
Improper use of the vehicle or the
lack of proper maintenance may
result in damage or decreased performance.
Read and understand the following warnings before attempting to
operate the vehicle.

!

!

To reduce the possibility of severe
injury or death resulting from loss of
vehicle control, the following warn-

ings must be observed:
When driving vehicle, consider the terrain, traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle.
Use extra care and reduced speed when driving on poor
surfaces, such as loose dirt, wet grass, gravel, etc.
Stay in areas suitable for a light duty utility vehicle. Avoid
rough, unimproved trails, areas with large rocks, stumps

3-12

or holes and avoid steep slopes.
Maintain a safe speed when driving down hill. Use service
brake to control speed when traveling down an incline. A
sudden stop or change of direction may result in loss of
control.
Slow down before and during turns. All turns should be
made at reduced speed.
Never drive vehicle up, down, or across an incline that
exceeds 14° (25% grade).
When driving the vehicle on unfamiliar terrain, drive the
vehicle slowly, especially when cresting a hill.
If the vehicle is unable to climb a hill, do NOT attempt to
turn it around. Turning the vehicle sideways on a hill could
result in the vehicle rolling over. Slowly back down the hill
using the service brake to control speed.
When operating the electric dump, do not back up to a
drop off, such as a loading dock or ravine. Misjudgment or
an unstable surface could cause the vehicle to fall backward into the drop off.
To reduce the possibility of severe
i n j u r y o r d e a t h r e s u l t i ng f r o m
improper vehicle operation, the following warnings must be observed:
The vehicle is a light duty utility vehicle. It is not an ATV
(All Terrain Vehicle).
The vehicle is not a toy and engaging in horseplay is dangerous.
The vehicle should not be operated on public highways. It

!

!

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

is not designed to comply with any DOT requirements.
The vehicle should be operated by persons with a valid
driver’s license. Children should not operate this vehicle.
Refer to GENERAL SPECIFICATIONS for seating capacity.
Use the park brake when the vehicle is parked.
To prevent inadvertent movement when the vehicle is to
be left unattended, engage the park brake, move direction
selector to forward position, turn key to ‘OFF’ position and
remove key.
Make sure that the direction selector is in correct position
before attempting to start the vehicle.
Always bring the vehicle to a complete stop before shifting
the direction selector and/or differential lock.
Do not take vehicle out of ‘gear’ while in motion (coast).
Check the area behind the vehicle before operating in
reverse.
All occupants must be seated. Keep entire body inside
vehicle and hold on while vehicle is in motion.
The vehicle is not equipped with seat belts and is not
designed with roll over protection. The top and windshield
do not provide protection from falling or flying objects.
A motorcycle helmet and protective clothing are recommended for operator and passenger at all times.
Do not permit anyone in the load bed while vehicle is in
motion.
Use caution when operating the electric dump. Do not
allow anyone behind the vehicle when operating the unit.
When operating the winch, observe all warnings and safe-

ty decals on the vehicle. Read, understand and follow the
instructions located in the front part of this manual.
Do not winch at an angle. Do not exceed winch capacity.
RUN-IN
Check for oil or fuel leaks that could have developed in shipment from
the factory. Avoid full throttle starts and rapid acceleration until the
engine has achieved operating temperature.
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 the rate of consumption stabilizes.
Check the oil level per the Periodic Service Schedule. Add oil if the
level on the dipstick indicates that oil is in the add oil range (Ref Fig. 13
on page 3-13).
Maximum oil level
DO NOT OVERFILL
ADD

FULL

Fig. 13 Check Oil Level on Dipstick

Never overfill the engine with oil,
foaming may result and oil may
enter the breather system.
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 contaminated and/
or oil being discharged into the engine compartment.

3-13

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
The oil should be changed in accordance with the Periodic Service
Schedule while the engine is warm. See SERVICE AND MAINTENANCE for checking oil level and changing oil procedures.

COLD STARTING
Starting a cold engine may require use of the choke. Depress the
accelerator approximately 1" (2.5 cm) or until the starter just begins to
operate. Pull the choke out if required. Accelerate slowly and push the
choke in completely when the engine runs smoothly.
Do not allow the starter to operate
continuously for more than 10
seconds. Allow 30 seconds between starting
attempts. If the vehicle does not start on the third
attempt, turn the key switch off, set the park brake and
determine the cause of the problem.
If the vehicle had been running and the engine does not start within 10
seconds, use the choke.

STARTING AND DRIVING
To reduce the possibility of roll-back
!
! which could result in severe injury
or vehicle damage, do not release
the service brake until engine has started.
To operate vehicle:
• Apply the service brake, place the key in the key switch and turn it
to the ‘ON’ position.
• Move the direction selector to the direction desired.
• Release the park brake by pressing the release button in the end
of the handle while slightly raising the handle. Then lower the

3-14

parking brake handle.
• Slowly depress the accelerator pedal to start the engine. Release
service brake when engine starts.
• When the accelerator pedal is released, the ignition circuit is deenergized and the engine stops. To stop the vehicle more quickly,
depress the service brake pedal.
When the direction selector is in the reverse position, a warning signal will sound to indicate that the
vehicle is ready to run in reverse.

STARTING THE VEHICLE ON A HILL
To reduce the possibility of roll-back
!
! which could result in severe injury
or vehicle damage, do not release
the service brake until engine has started.
Do not hold vehicle on hill by using
the 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.
Place left foot on service brake and release the park brake. Depress
accelerator with right foot and release the service brake by lifting left
foot.

COASTING

!

!

To reduce the possibility of severe
injury or death from coasting at

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

above recommended speeds, limit speed with service brake.
On steep hills, it is possible for the vehicle to coast at greater than normal speeds encountered on a flat surface. To reduce the possible loss
of vehicle control and severe drivetrain damage, speeds should be limited to no more than the maximum governed speed on level ground
(see GENERAL SPECIFICATIONS). Limit speed by applying service
brake.

FUEL
To reduce the possibility of severe
injury or death from improper fuel
handling:
Do not smoke near the fuel tank.
Do not refuel near open flame or electrical items which
could produce a spark.
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 hazardous condition.

!

Some fuels, called oxygenated or
reformulated 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 operating
symptoms occur, use gasoline with a lower percentage of
alcohol or ether.
Do not overfill the fuel tank. Allow adequate space for
the expansion of gasoline. Leave at least 1" (2.5 cm)
space below bottom of filler neck.

!

The fuel tank is located under the seat on the passenger side of the
vehicle (Ref Fig. 14 on page 3-15). Fill the tank with fresh, clean, automotive grade gasoline (Ref Fig. 38 on page 3-40). High altitude or
heavy use/load applications may benefit from higher octane gasoline.

Fuel
1" Min.
(2.5 cm)

Fig. 14 Fueling

BATTERY
Excessive use of accessories may
drain the battery and leave
insufficient reserve to start the vehicle.

Do not use gasoline which contains Methanol.

3-15

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
The vehicle uses a combination starter/generator to both start the
engine and charge the battery. The engine will not idle; therefore, the
battery cannot be charged while the vehicle is stopped. Do not operate
accessory items (such as accessory lights, radios, winch, etc.) excessively while the vehicle is stopped.
The generator is capable of supplying 35 amps; therefore, operation of
all accessories could result in the discharge of the battery even though
the engine is running and the generator operating. Discharging the battery is known as deep cycling. The battery is not a deep cycle model,
but is a starting battery. Multiple deep cycling will result in the premature
failure of the battery.
If the vehicle battery has become discharged, it must be charged using
a 12 Volt charger that is rated at 10 amps or less and in accordance
with all instructions provided by the manufacturer of the charger.

downpour. This vehicle is not equipped with seat belts and the sun top
has not been designed to provide roll over protection. 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.

12 VOLT POWER OUTLET
Overuse of accessories may drain
the battery and leave insufficient
reserve to start the vehicle.
A 12 volt power outlet, rated at 15 amps, is located to the left side of the
key/light switch (Ref Fig. 15 on page 3-16). It provides constant power
for accessories equipped with a 12 volt plug.

LABELS AND PICTOGRAMS
OFF ON

Vehicles may be labeled with pictograms as a method of conveying
information or warnings. Appendix A illustrates and explains pictograms that may appear on the vehicle. Not all pictograms shown in
Appendix A will be found on your vehicle.

F
E
FUEL

SUN TOP AND WINDSHIELD
The sun top does not provide pro!
! tection from roll over or falling
objects.
The windshield does not provide protection from tree limbs
or flying objects.

TOWING A TRAILER

The sun top and windshield provide some protection from the elements; however, they will not keep the operator and passenger dry in a

The vehicle is equipped with a receiver that can be fitted with a standard 1 7/8" ball. The trailer and its load must not exceed 500 lbs (227

3-16

12V Power
Outlet

Fig. 15 12 Volt Power Outlet

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
kg) and no more than 50 lbs (23 kg) tongue weight may be attached to
the hitch. Remember that the overall capacity of the vehicle, operator,
passenger, contents of load bed and accessories must be reduced to
compensate for the trailer and load.
The range of motion of the trailer is limited by the ball and hitch. The
trailer should not be used on rough trails or over objects such as logs,
large rocks, holes, etc.
Never install baskets or extensions using the hitch receivers (front or
rear). Such items will change the performance characteristics of vehicle
and result in unsafe handling, possible roll over or vehicle damage.

VEHICLE CLEANING AND CARE
VEHICLE CLEANING
To reduce the possibility of severe
injury or vehicle damage, read and
understand all instructions supplied
by manufacturer of pressure washer.

!

!

When pressure washing exterior of
vehicle, do not use pressure in
excess of 700 psi. To reduce the possibility of
cosmetic damage, do not use any abrasive or reactive
solvents to clean plastic parts.
It is important that proper techniques and cleaning materials be used.
Using excessive water pressure may cause severe injury to operator or
bystander, damage to seals, plastics, seat material, body finish or electrical system. Do not use pressure in excess of 700 psi to wash exterior
of vehicle.

Clean windshield with lots of water and a clean cloth. Minor scratches
may be removed using a commercial plastic polish or Plexus® plastic
cleaner available from the service parts department.
Normal cleaning of vinyl seats and plastic or rubber trim requires the
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 the use of a
commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive appearance and
durable protection. Frequent washing with lukewarm or cold water and
mild detergent is required to preserve the painted surfaces.
Occasional cleaning and waxing with non-abrasive products 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
the underbody of the vehicle. These materials will cause corrosion of
underbody parts unless flushed occasionally 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 the engine does not start or runs improperly after
washing, remove the spark plug wires (by pulling
the spark plug boots, never the wires). Dry all connections with
forced air. Reinstall the wires.

3-17

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

VEHICLE 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 vehicle colors for
use on both metal and molded plastic 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, nontacky, dry coating that will not crack, peel or flake over a wide temperature range. (P/N 75500-G01)
• White Lithium Grease designed to provide lubrication protection in
areas where staining or discoloring is a problem, or in areas of
extreme temperature ranges. (P/N 75502-G01)
• Penetrant/Lubricant, a 4-in-1 product that penetrates seized parts,
lubricates leaving a light lubricating 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 contains 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)

3-18

aerosol cans of Battery Protector, Penetrant/Lubricant, White Lithium Grease, and Carburetor and Choke Cleaner. (P/N 75508G01)
• Plexus® plastic cleaner and polish removes minor scratches from
windshield. (P/N 28433-G**)

REPAIR
LIFTING THE VEHICLE
Tool List

Qty. Required

Floor jack ...............................................................................1
Jack stands............................................................................4
Chocks...................................................................................4

To prevent possible injury or death
resulting from a vehicle falling from
a jack, be sure the vehicle is on a
firm and level surface. Never get under a vehicle while it is
supported by a jack. Use jack stands and test the stability of
the vehicle on the stands. Always place chocks in front and
behind the wheels not being raised. Use extreme care since
the vehicle is extremely unstable during the lifting process.

!

!

Some servicing operations may require the rear wheels or the entire
vehicle be raised.
Install chocks in front and behind each front wheel (Ref Fig. 16 on page
3-19). Center jack under rear bumper. Raise vehicle and locate a jack
stand under the outer end of each rear axle.
Lower jack and test the stability of the vehicle on the two jack stands.

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Place the jack at the center of the front axle. Raise the vehicle and position jack stands under the frame crossmember as indicated.
Lower jack and test the stability of vehicle on the four jack stands.
If only front or rear of vehicle is to be raised, place the chocks in front
and behind each wheel not being raised in order to stabilize the vehicle.
Lower the vehicle by reversing the lifting sequence.

WHEELS AND TIRES
Standard tires for this vehicle are uni-directional
and should never be moved from one side of vehicle to the other.

This vehicle comes standard with uni-directional tires. Left side tires
should always remain on the left side of the vehicle. Right side tires
should always remain on the right side of the vehicle. Uni-directional
tires have an arrow on the sidewall indicating direction of rotation when
moving forward. Tire condition should be inspected per the Periodic
Service Schedule (Ref Fig. 22 on page 3-26). Inflation pressures
should be checked when the tires are cool. Be sure to install valve dust
cap after checking or inflating.

Tire Repair
Tool List

Qty. Required

Lug wrench, 3/4"....................................................................1
Impact socket, 3/4", 1/2" drive ...............................................1

View from Underside of Vehicle

Impact wrench, 1/2" drive ......................................................1
Torque wrench, 1/2" drive ......................................................1

Fig. 16 Lifting the Vehicle

3-19

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

A tire explosion can cause severe
injury or death. Never exceed inflation pressure rating on tire sidewall.
To reduce the possibility of tire explosion, pressurize tire
with small amount of air applied intermittently to seat
beads. Due to the low volume of the small tires, overinflation can occur in seconds. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face
and eyes from escaping air when removing valve core.
To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets
designed for impact wrench use.
Use caution when inflating tires. Overinflation could cause
the tire to separate from the wheel or cause the tire to
explode, either of which could cause severe injury.

!

!

Use caution when inflating tires. Due to the low volume of the small
tires, overinflation can occur in seconds. Overinflation could cause the
tire to separate from the wheel or cause the tire to explode.
Tire inflation will depend on the type of tires fitted but under no condition
should inflation pressure be higher than recommended on the tire sidewall. Standard and optional tires should be inflated to pressure designated in GENERAL SPECIFICATIONS on page 4-1. If pressure is
not designated in GENERAL SPECIFICATIONS, inflate to pressure
designated on tire sidewall. All four tires should have the same pressure for optimum handling characteristics. Be sure to install the valve
dust cap after checking or inflating.
The vehicle is fitted with low pressure tubeless tires mounted on one
piece rims. When removing wheels with an impact wrench, use

3-20

only impact sockets. Regular sockets are not designed for
impact pressures exerted by power tools.
Generally, the most cost effective way to repair a puncture in the tread
is to use a commercial tire plug.
Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not
requiring the tire be removed from the wheel.

If the tire is flat, raise vehicle and remove wheel. Refer to ‘Lifting the
Vehicle’ for proper lifting procedure and safety information. Inflate tire to
maximum recommended pressure. Immerse the tire in water to locate
the leak and mark with chalk. Insert tire plug in accordance with manufacturer’s specifications.

To reduce the possibility of severe
injury, be sure mounting/demounting machine is anchored to floor.
Wear OSHA approved safety equipment when mounting/
demounting tires.

!

!

If the tire is to be removed or mounted, the tire changing machine manufacturer’s recommendations must be followed in order to reduce possibility of severe injury. Be sure to position tire on wheel correctly. Arrow
on tire indicates rotation when moving forward.

Wheel Installation
To reduce the possibility of
component damage, do not tighten
lug nuts to more than 85 ft. lbs. (115 Nm) torque.
It is important to follow the ‘cross sequence’ pattern
when installing lug nuts. This will assure even seating of the wheel against the hub.

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
With the valve stem to the outside, mount the wheel onto the hub with
lug nuts. Be sure to position the wheel on hub correctly with arrow indicating direction of rotation when moving forward. Finger tighten lug nuts
in a ‘cross sequence’ pattern (Ref Fig. 17 on page 3-21). Tighten lug
nuts to 50 - 85 ft. lbs. (70 - 115 Nm) torque in 20 ft. lbs. (30 Nm) increments following the ‘cross sequence’ pattern.

1

Inside
of Cowl

Headlight
Bulb

'Cross Sequence'
3

Turn Signal
Housing

on

Rota
ti

Turn Signal Lens

Fig. 18 Headlight and Turn Signal Bulb Replacement

Front of
Vehicle

4

2

Tire style may vary

Fig. 17 Wheel Installation

LIGHT BULB REPLACEMENT
For vehicles with headlights mounted in cowl, locate the two screws on
backside of cowl that secure headlight (Ref Fig. 18 on page 3-21).
Remove screws, pull headlight out and disconnect wires. Connect
wires to new headlight, install in cowl and secure with screws previously removed.
To replace the turn signal light bulb, support turn signal housing from
backside of cowl while removing two screws securing lens (Ref Fig. 18
on page 3-21). Install new bulb and replace lens.

To replace the tail and brake light bulb, roll the rubber bezel from
around the edge of the taillight and remove lens (Ref Fig. 19 on page 322). Install replacement bulb and replace lens.

FUSE REPLACEMENT
To replace fuses, locate the fuse block under the driver side seat. Pull
out old fuse and replace with a new automotive type fuse. Headlight
and taillight bulbs and fuses are available from a local Distributor, an
authorized Branch or the Service Parts Department.

VEHICLE WITH A DISCHARGED BATTERY
To reduce the possibility of severe
!
! injury or death from inadvertent
motion, do not attempt to ‘jump
start’ a vehicle.

3-21

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

TRANSPORTING VEHICLE
Roll Rubber
Bezel Away
From Body

Tail/Brake
Light

TOWING

!
Rear
Fender

!

This vehicle is not designed to be
towed.

It is recommended that the vehicle be moved by placing the entire vehicle on a trailer, flatbed truck or other suitable transport.

NEUTRAL LOCK
To prevent the driven clutch from turning the rear wheels during service
operations, a neutral lock is located under the passenger side of the
console panel (Ref Fig. 20 on page 3-23).
To operate:
Fig. 19 Tail and Brake Light Bulb Replacement

The vehicle is equipped with a starter/generator and does not idle.
When starting the engine, the starter/generator functions as a starter
and with the engine running, it functions as a generator.
With the short running times associated with this kind of vehicle, the
generator is more than adequate to maintain the battery charge level.
The generator is not designed to charge a discharged battery.
When engine starts, the clutches engage and cause vehicle to move
making ‘jump starting’ both dangerous and impractical.
If the vehicle battery has become discharged, it must be charged using
a 12 Volt charger that is rated at 10 amps or less. Read and understand
all instructions provided by the manufacturer of the charger.

3-22

Turn the key switch to ‘OFF’ and raise the passenger seat. Place the
direction selector in the forward position. Reach under the passengers
side of console panel and rotate the neutral lock lever clockwise until it
snaps into the slot in the direction selector bracket as shown. Next, pull
the direction selector handle to the rear until it locks in place in the neutral position. When in this position, the direction selector remains locked
in the neutral position. To activate the direction selector, pull the neutral
lock lever out of the slot and rotate counter-clockwise until it snaps into
the detent position in the direction selector bracket.

HAULING
To reduce the possibility of severe
injury or death while transporting
vehicle:
Secure the vehicle and contents.

!

!

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
for tightness of hardware and cracks in sun top at mounting points.
Always remove windshield when transporting. Always check that the
vehicle and contents are adequately secured before transporting. The
rated capacity of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load.
Lock the park brake and secure the vehicle using ratchet tie downs.

Direction
Selector
Console

Front of
Vehicle

Direction
Selector
Bracket

cked
tion

Locked
Position

Slot
2

Detent

Neutral
Lock

ut and
rotate 90˚
to lock

out and
rotate 90˚
to unlock

Fig. 20 Neutral Lock

Never ride on vehicle being transported.
Always remove windshield before transporting.
Maximum speed with sun top installed is 50 mph (80 kph).
If the vehicle is to be transported at highway speeds, the sun top must
be removed. When transporting vehicle below highway speeds, check

SERVICE AND MAINTENANCE
To reduce the possibility of severe
injury or death from improper servicing techniques:
Do not attempt any type of servicing operations before
reading and understanding all notes, cautions and warnings in this manual.
Any servicing requiring adjustments to be made to the
powertrain while the engine is running must be made with
both drive wheels raised and vehicle properly supported
on jack stands.
To reduce the possibility of engine damage, never operate
vehicle at full throttle for more than 4 - 5 seconds while
vehicle is in a ‘no load’ condition.
Wear eye protection when working on the vehicle. Use extra care when working around batteries, or using solvents or compressed air.

!

!

To reduce the possibility of causing an electrical arc,
which could result in a battery explosion, turn off all electrical loads from the battery before removing battery
wires.

3-23

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

Wrap wrenches with vinyl tape to
reduce the possibility of a dropped
wrench ‘shorting out’ a battery, which
could result in an explosion.
Reduce the possibility of accidental starting by removing
and grounding spark plug wires and disconnecting battery
at negative terminal before servicing.
The electrolyte in a battery is an acid solution which can
cause severe burns to the skin and eyes. Treat all electrolyte spills to the body and eyes with extended flushing
with clear water. Contact a physician immediately.
Any electrolyte spills should be neutralized with a solution
of 1/4 cup (60 ml) sodium bicarbonate (baking soda) dissolved in 1 1/2 gallons (6 liters) of water and flushed with
water.
Aerosol containers of battery terminal protectant must be
used with extreme care. Insulate metal container to reduce
the possibility of can contacting battery terminals which
could result in an explosion.
Always install a positive stop to prevent load bed from
unexpectedly falling.
It is in the best interest of both vehicle owner and service technician, to
carefully follow the procedures recommended in this manual. Preventative maintenance, applied at recommended intervals, is the best
guarantee for keeping the vehicle both dependable and economical.
This vehicle will give years of satisfactory service, providing it receives
regular maintenance. Refer to the Periodic Service Schedule for appropriate service intervals (Ref Fig. 22 on page 3-26). Refer to Lubrication
Points for appropriate lubrication locations (Ref Fig. 29 on page 3-32).

3-24

In any product, components will fail to perform properly as the result of
normal use, age, wear or abuse.
A vehicle requiring repair indicates the vehicle is no longer functioning
as designed and should be considered potentially hazardous. Use
extreme care when working on any vehicle. When diagnosing, removing or replacing any components that are not operating properly, consider the safety of yourself and those around you, should the
component move unexpectedly.
Some components are heavy, spring loaded, highly corrosive, explosive, may produce 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 utmost caution. Be careful not to place hands, face, feet or
body in a location that could expose them to injury should an unforeseen dangerous situation occur.

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.
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

!

!

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

of 4% hydrogen gas or more is explosive.
Engine exhaust gas (carbon monoxide) is deadly. Carbon
monoxide is an odorless, colorless gas that is formed as a
natural part of incomplete combustion of hydrocarbon
fuels. 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.

OFF
ON
E
F
FUEL

Fig. 21 Serial Number Plate Location

maintenance items must be serviced more frequently
on vehicles used under severe driving conditions
such as extreme temperatures, extreme dust/debris
conditions, frequent use with maximum load.

SERIAL NUMBER PLATE LOCATION

To access powertrain for routine maintenance, lift seats. Additional
access may be obtained by raising or removing the load bed. For major
repair, refer to appropriate Technician’s Repair and Service Manual.

The serial number and manufacturing date code are located on a plate
on the passenger side of the dash housing of the vehicle (Ref Fig. 21
on page 3-25).

Some service procedures may require the vehicle to be lifted. Refer to
LIFTING THE VEHICLE for proper lifting procedure and safety information.

Design changes take place on an ongoing basis. In order to obtain correct components for the vehicle, the manufacturing date code, serial
number and vehicle model must be provided when ordering service
parts.
T o p r o lo ng ve hi cl e l if e , so me

3-25

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

PERIODIC SERVICE SCHEDULE
✓ Check
♦ Clean, Adjust, etc.
▲ Replace
To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for
this vehicle.
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions

DAILY
BEFORE USE:
✓ Check oil level (Refer to page 3-29), see Note 1 on Pg. 3-40
✓ Check service brake general operation
✓ Check park brake function
✓ Check warning device function in reverse
✓ Check tire condition
✓ Check overall vehicle condition
♦ Clean fins and inside blower housing (Refer to page 3-36), see Note 3 on Pg. 3-40

WEEKLY
TIRES
WHEELS
FUEL GAUGE
STARTER/GENERATOR BELT

✓
✓
✓
✓

Examine for cuts, excessive wear and pressure, see GENERAL SPECIFICATIONS
Check for bent rims, missing or loose lug nuts
Check for proper operation (at fueling), and fuel cap vent is free of dirt
Check for tension, wear, cracks (Refer to page 3-34)

25 HOURS (includes items listed in previous table & the following)
WIRING
ACCELERATOR
BRAKE FLUID (HYDRAULIC BRAKES)
PARK BRAKE
CHOKE CABLE
CARBURETOR LINKAGE
DIRECTION SELECTOR
ENGINE

✓
✓
✓
✓
✓
✓
✓

Check all wiring for loose connections and broken/missing insulation
Check for smooth movement - DO NOT LUBRICATE CABLE
Check level, add if required (DOT 3) and check for leakage (Refer to page 3-37)
Check brake performance and adjust if required
Check for smooth movement and adjustment - DO NOT LUBRICATE CABLE
Check attachment, adjust as required
Check for smooth movement and attachment, adjust as required

♦

Clean foam pre-cleaner (Refer to page 3-33), see Note 3 on Pg. 3-40

✓

Check for unusual noise, vibration, acceleration, oil leaks

Fig. 22 Periodic Service Schedule

3-26

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
STEERING ASSEMBLY
TIE RODS/LINKAGES
REAR AXLE

✓
✓
✓

Check for abnormal play, tightness of all hardware
Check for excessive play, bent components or loose connections
Check for leakage, add SAE 30 oil as required (Refer to page 3-34)

50 HOURS (includes items listed in previous tables & the following)
▲ Change oil, DO NOT OVERFILL (Refer to page 3-30), see Note 1 and Note 2 on Pg. 3-40

ENGINE
EXHAUST
FRONT AXLE
FRONT SHOCK ABSORBERS
FRONT SPRINGS
FRONT WHEEL ALIGNMENT
PARKING (PARK) BRAKE
REAR SHOCK ABSORBERS
ENGINE ELECTRICAL SYSTEM
FUEL SYSTEM
THROTTLE/GOVERNOR LINKAGE
HARDWARE AND FASTENERS

✓ Check spark plug wires for cracks/loose connections
✓ Inspect/clean spark arrester
✓ Check for damage to axle and loose or missing hardware
✓ Check for oil leakage and loose fasteners
✓ Check for loose hardware, cracks at attachments
✓ Check for unusual tire wear, align if required
✓ Check for binding cables
✓ Check for damage or wear
♦ Lubricate as required, use light oil. DO NOT LUBRICATE CABLES
✓ Check for oil leakage, loose mounting hardware
✓ Check coil/spark plug wires for cracks/loose connections
✓ Check for leaks at tank, cap, system lines, filters, pump, carburetor
✓ Check system lines for cracks/deterioration
✓ Check operation and governed speed
✓ Check for loose or missing hardware and components
♦ Tighten or replace missing hardware

100 HOURS (includes items listed in previous tables & the following)
BATTERY

♦

ENGINE

▲ Change oil filter (Refer to page 3-32), see Note 1 on Pg. 3-40

DIRECTION SELECTOR
KING PINS
STEERING ASSEMBLY

▲
✓
✓
♦
♦

Clean battery & terminals
Change air cleaner cartridge if damaged or dirty (Refer to page 3-33), see Note 3 on Pg. 3-40
Check for wear and smooth movement (lubricate shaft with light oil if required)
Check for excessive play and tightness of retaining nuts
Lubricate, use wheel bearing grease
Lubricate unit and idler arm, use wheel bearing grease

Fig. 22 Periodic Service Schedule

3-27

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
RACK END BALL JOINT
REAR AXLE
DRIVE BELT

♦ Lubricate, use wheel bearing grease
✓ Check for unusual noise and loose or missing mounting hardware
✓ Check for cracks, fraying and excessive wear

250-300 HOURS or YEARLY (includes items listed in previous tables & the following)

FUEL FILTER
SPARK PLUGS
MUFFLER/EXHAUST

✓ Check and adjust as required, see Technician’s Repair and Service Manual
✓ Check lubricant, add lubricant (SAE 30 oil) as required (Refer to page 3-34)
♦ Clean, see Technician’s Repair and Service Manual
✓ Check brake shoe linings, see Technician’s Repair and Service Manual
♦ Replace (Refer to page 3-29)
♦ Replace, gap new plugs (Ref. Capacities and Replacement Parts on page 3-40)(Refer to page 3-37)
✓ Check mounting hardware; check for leaks at head and muffler gaskets

VALVES

✓

FRONT WHEEL BEARINGS
REAR AXLE
SERVICE BRAKES

Check valve clearance, refer to Briggs & Stratton® Repair Manual (P/N 272144) for VANGUARD™ V-Twin
Overhead Valve Engines

500 HOURS
REAR AXLE
CYLINDER HEAD AND PISTONS

▲ Replace lubricant
♦ Clean combustion chamber deposits, refer to Briggs & Stratton® Repair Manual (P/N 272144) for
VANGUARD™ V-Twin Overhead Valve Engines

Fig. 22 Periodic Service Schedule

TIRE INSPECTION
Note 1 - Change oil after first 8 hours, then after every 50 hours.
Note 2 - Change oil every 25 hours when operating under heavy load
or in high temperatures.
Note 3 - Clean more often under dusty conditions or when airborne
debris is present. Clean foam pre-cleaner first and replace paper cartridge if dirty. Replace either if showing signs of damage.

3-28

Tire condition should be inspected per the Periodic Service Schedule
(Ref Fig. 22 on page 3-26). Inflation pressures should be checked
when the tires are cool. Be sure to install the valve dust cap after checking or inflating.

SEAT PROP
The driver seat is equipped with a prop for use every time the seat is
raised. To use, lift seat up against steering wheel to allow the prop to
move over the center console flange (Ref Fig. 23 on page 3-29).

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
fuel tank first and plug. Remove filter from hose going to fuel pump and
discard.
Orient direction of new fuel filter according to the
FLOW arrow on the side of filter.

Install new fuel filter and reposition the clamps over the inlet and outlet.

CHECKING THE OIL LEVEL
Tool List

Qty. Required

Clean cloth ............................................................................ 2

Seat
Prop

Fig. 23 Seat Prop

REPLACING THE FUEL FILTER
To prevent a possible explosion, do
!
! not smoke near the 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 adequately ventilated.
Always wear safety glasses to prevent possible eye injury
from gasoline or gasoline vapor.
To replace fuel filter, use a pair of pliers to move clamps off ends of filter
and pull filter up higher than the fuel pump to reduce the amount of gas
that will spill (Ref Fig. 24 on page 3-30). Remove hose coming from

Never overfill the engine with oil,
foaming may result and oil may
enter the breather system.
When adding oil between oil changes, do not mix
brands and viscosity grades of oil. 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
contaminated and/or oil being discharged into the engine compartment.

Check oil level daily before starting the engine. The vehicle must be on
a level surface with the parking brake engaged. Use a cloth to wipe
clean the oil dipstick handle and oil fill cap (Ref Fig. 24 on page 3-30).
This is necessary to prevent debris from falling into the engine.
Remove the dipstick and wipe off the entire area indicated with a clean
cloth (Ref Fig. 25 on page 3-30).
Insert the dipstick fully into the dipstick tube and remove. Examine the
level of oil on the dipstick. Oil should be at the FULL mark (Ref Fig. 26
on page 3-30).

3-29

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
If oil is required, remove oil fill cap and add oil slowly to bring level to the
FULL mark. Do not overfill.
Replace dipstick fully into dipstick tube and firmly replace the oil fill cap.

Oil Fill
Cap

Oil
Dipstick

When adding oil between oil changes, do not mix
brands and viscosity grades of oil. 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
contaminated and/or oil being discharged into the engine compartment.

Fuel
Pump

Maximum oil level
DO NOT OVERFILL
ADD

Fuel
Filter

Fuel Line
From Tank

Fig. 24 Oil Fill Cap, Dipstick and Fuel Filter

FULL

Fig. 26 Check Oil Level on Dipstick

CHANGING THE OIL
Tool List

Qty. Required

Pliers......................................................................................1
Oil drain pan ..........................................................................1
ADD

FULL

Fig. 25 Clean Entire Dipstick

3-30

Clean cloth.............................................................................2
For maximum performance and longevity, the engine oil should be
replaced after the first five (5) to eight (8) hours of operation. After the
initial oil change, it should be changed per the Periodic Service Schedule (Ref Fig. 22 on page 3-26).

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
The oil must be high quality detergent oil classified ‘For Service SF, SG,
SH, SJ’ or higher. Do not use special additives and do not mix oil with
gasoline. The selection of oil viscosity is dependent upon the climate in
which the vehicle will be used. Most vehicles require SAE 30 oil; however, vehicles used in cold climates will require a multi-viscosity oil (Ref
Fig. 27 on page 3-31).
Synthetic oil meeting ILSAC GF-2, API certification mark and API service symbol with ‘SJ/CF ENERGY CONSERVING’ or higher, is an
acceptable oil at all temperatures. Use of synthetic oil does not alter
required oil change intervals.
Do not use special additives in recommended oil.
Do not mix oil with gasoline.

Air cooled engines run hotter than
automotive engines. The use of nonsynthetic multi-viscosity oils (5W-30, 10W-30, etc.) in
temperatures above 40° F (4° C) will result in higher
than normal oil consumption. When using a multiviscosity oil, check oil level more frequently.
SAE 30 oil, if used below 40° F (4° C) will result in hard
starting and possible engine bore damage due to
inadequate lubrication.

To reduce the possibility of severe
injury, wear rubber gloves to protect
skin from exposure to hot, used oil
and degreaser. These fluids contain chemicals known to
cause cancer.

!

!

SAE 30

5W-30, 10W-30
Synthetic 5W-20, 5W-30

F0

-20

C -30
0

0
-20

20

40

60

80

-10
0
20
10
(Air Temperature)

100
30

40

Fig. 27 Oil Viscosity Chart

drain pan under the engine. Wipe the oil fill cap clean with a cloth and
remove the cap (Ref Fig. 24 on page 3-30).
Clean the area around the oil drain valve (Ref Fig. 28 on page 3-32).
Open the valve and allow the oil to drain through the hole in the engine
mounting plate. Close valve once oil has drained.
Add 1 quart (1 liter) of oil. Start and drive vehicle at a slow speed for 30
seconds. Stop and turn off vehicle on a level surface and wait 30 seconds for the oil to settle to the bottom of the engine. Check for leaks.
Slowly add more oil to bring level to the FULL mark on dipstick. Do not
overfill.
Replace dipstick fully into the dipstick tube and firmly replace the oil fill
cap.

The oil should be changed with the engine warm. Park the vehicle on a
level surface, engage the parking brake and remove the key. Place a

3-31

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

LUBRICATION
Oil Filter
Oil Drain
Valve

Do not use more than three (3)
pumps of grease in each grease
fitting at any one time. Excess grease may cause
grease seals to fail or grease migration into areas that
could damage components.
Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure (Ref Fig. 29 on
page 3-32).
King Pin

Idler Arm

King Pin

Fig. 28 Oil Drain and Filter

CHANGING THE OIL FILTER
Tool List

Qty. Required

Oil filter wrench, to fit 3" (76 mm) oil filter.............................. 1
Oil drain pan .......................................................................... 1
Clean cloth ............................................................................ 2
Clean the area around the oil filter and oil drain. Drain engine oil per
‘Changing the Oil’ and remove oil filter (Ref Fig. 28 on page 3-32).
Make sure the seal came off with filter and is not stuck to the engine.
Wipe around the sealing surface of filter mount with a clean, lint free
cloth. Lightly oil the seal on the new filter with fresh, clean oil. Screw filter on by hand until the seal contacts the filter mount. Tighten 1/2 to 3/4
turn more. Refill engine with new oil per ‘Changing the Oil’.

3-32

Steering
Unit

Ball Joint
on Rack
and Rod

Fig. 29 Lubrication Points

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

AIR CLEANER INSPECTION AND REPLACEMENT
The air cleaner is a dual filter cleaner, equipped with a foam pre-cleaner
over a conventional paper cartridge. The filters must be serviced per
the Periodic Service Schedule (Ref Fig. 22 on page 3-26) for optimum
engine life and performance.
To prevent engine damage, be
careful not to let debris fall into the
carburetor when servicing the air cleaner.
To prevent water entering air cleaner and causing
starting or engine problems, replace air cleaner cover
making sure the entire flange around the bottom of
the cover fits over the top edge of the air cleaner base.
Secure with the spring clips.

Air Cleaner
Cover

Knob
Plate

Cartridge

Pre-cleaner

Access the filters by unsnapping the spring clip on each side of the air
cleaner and removing the air cleaner cover (Ref Fig. 30 on page 3-33).
If necessary, vacuum or wipe out any loose dirt or trash from the air
cleaner base.

Air Cleaner
Base

Pre-Cleaner Service
The foam pre-cleaner is to be used dry. Do not put
oil on the foam.

Carefully remove pre-cleaner from cartridge and wash it in liquid detergent and water. Rinse. Dry by squeezing pre-cleaner in a clean cloth.
Do not put oil on the pre-cleaner. Install pre-cleaner over cartridge.
Replace air cleaner cover making sure the entire flange around bottom
of cover fits over the top edge of the air cleaner base. Secure with the
spring clips.

Fig. 30 Air Cleaner

Cartridge Service
Do not use petroleum solvents,
pressurized water, or compressed
air to clean cartridge. Doing so will damage the
cartridge and will damage the engine.
The paper cartridge is a dry unit. Do not use oil on
the cartridge.

3-33

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Unscrew the knob securing the cartridge to the air cleaner base and
remove plate. Remove cartridge and inspect. Replace if too dirty to
clean or at the first sign of filter paper deterioration. Clean cartridge by
gently tapping on a flat surface.

from the check plug hole. Install the check plug and the fill plug. In the
event that the lubricant is to be replaced, a drain plug is provided at the
bottom of the differential housing. Capacity of axle is 48 oz. (1.4 liters).

To reduce the possibility of engine
damage from ingesting unfiltered
air, ensure plate is centered and correctly seated on
top of cartridge before securing with knob.
Place cartridge in air cleaner base. Install plate centered and fully
seated on top of cartridge. Secure with knob and install pre-cleaner
over cartridge.
Replace air cleaner cover making sure that the entire flange around the
bottom of the cover fits over the top edge of the air cleaner base.
Secure with the spring clips.

Check Plug
Drain Plug

Fig. 31 Add, Check and Drain Rear Axle Lubricant

REAR AXLE

STARTER/GENERATOR BELT TENSION

The rear axle is provided with a lubricant level check plug located on
the driver side at the rear of the housing (Ref Fig. 31 on page 3-34).
Unless leakage is evident, an annual lubricant check is sufficient.

Tool List

Checking the Lubricant Level
Tool List

Belt tension gauge.................................................................1
Wrench, 3/4" ..........................................................................1
Wrench, 1/2" ..........................................................................2

Qty. Required

Wrench, 13 mm ..................................................................... 1
Funnel ................................................................................... 1
Clean area around check and fill plugs. Remove the check plug. The
correct lubricant level is just below the bottom of the threaded hole. If
lubricant is to be added, remove the fill plug and add lubricant (SAE 30
oil) using a funnel. Add lubricant slowly until lubricant starts to seep

3-34

Qty. Required

Socket, 1/4" hex bit, 3/8" drive...............................................1
Ratchet, 3/8" drive .................................................................1
Socket, 3/4", 3/8" drive ..........................................................1
Socket, 1/2", 3/8" drive ..........................................................1
Pry bar ...................................................................................1
Torque wrench, 3/8" drive, ft. lbs. ..........................................1

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
The starter/generator belt tension should be checked after the first 1520 hours of operation and set to 75 - 80 lbs. (34 - 36 kg).
A loose belt can cause audible vibration and
squeal.

3/8" (1 cm) Max. Deflection for New Belt
1/2" (1.3 cm) Max. Deflection for Existing Belt

Tighten a new starter/generator belt to 90 - 110 lbs. (41 - 50 kg) tension
when a gauge is applied half way between the two pulleys (Ref Fig. 32
on page 3-35).
Fig. 33 Check Belt Tension with Finger

Loosen adjusting bolt. Use pry bar to force starter/generator towards
front of vehicle until proper belt tension is achieved. Hold starter/generator in place and tighten adjusting bolt.
Tighten pivot bolts to 25 ft. lbs. (35 Nm) torque.
Fig. 32 Check Belt Tension with Gauge

Adjusting Bolt

Although not as accurate, the belt may be depressed with a finger. A
maximum deflection of 3/8" (1 cm) is acceptable for a new belt (Ref
Fig. 33 on page 3-35).
Tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the
same technique and inspect for cracking or wear. A maximum deflection of 1/2" (13 mm) is acceptable.

Adjusting the Belt
Loosen front and back pivot bolts of starter/generator (Ref Fig. 34 on
page 3-35).
Pivot Bolt

Fig. 34 Adjust Belt Tension

3-35

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

BATTERY CLEANING
To reduce the possibility of damage
to vehicle or floor, neutralize acid
before rinsing battery.
To reduce the possibility of damage to electrical
components while cleaning, do not use a pressure
washer.
Cleaning should take place per the Periodic Service Schedule (Ref Fig.
22 on page 3-26).

components adjacent to the battery which should also be sprayed with
the sodium bicarbonate (baking soda) solution.
1 quart
(1 liter)
Clear Water

2 Teaspoons (10 ml)
Sodium Bicarbonate
(Baking Soda)

When cleaning the outside of the 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.
Plastic
Spray
Bottle

Use of a water hose without first neutralizing any acid, will move acid
from the top of the battery to another area of the vehicle or storage facility where it will attack the metal structure or the concrete/asphalt floor.
Additionally, a residue will be left on the battery which is conductive and
will contribute to the discharge of the battery.

Fig. 35 Preparing Acid Neutralizing Solution

To reduce the 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 the battery.

Allow the solution to sit for at least three minutes; use a soft bristle
brush or cloth to wipe the tops of the battery to remove any residue that
could contribute to the self discharge of the battery. Rinse the entire
area with low pressure clear water. Do not use a pressure washer.

The correct cleaning technique is to spray the top and sides of the battery with a solution of sodium bicarbonate (baking soda) and water.
This solution is best applied with a plastic spray bottle. The solution
should consist of 2 teaspoons (10 ml) of sodium bicarbonate (baking
soda) mixed with 1 quart (1 liters) of clear water (Ref Fig. 35 on page 336). In addition to the battery, special attention should be paid to metal

3-36

AIR INTAKE AND COOLING FINS
To prevent possible burns, engine
!
! parts should be kept clean to reduce
risk of overheating and ignition of
accumulated debris.

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
After every off road use, allow to cool and then check for a build up of
dirt and debris in the air intake and cooling fins. Dirt and debris may
clog the engine’s air cooling system. Clean areas shown to prevent
engine damage (Ref Fig. 36 on page 3-37). Keep linkages, springs and
controls clean. Keep area around muffler free of any combustible material.
Cooling
Fins

Air
Intake

Fig. 36 Cleaning Air Intake and Cooling Fins

Remove and inspect the spark plugs at intervals per the Periodic Service Schedule (Ref Fig. 22 on page 3-26). All new spark plugs should
be properly gapped before installation (Ref Fig. 38 on page 3-40).
Apply a light coat of anti-seize compound and tighten to 15 ft. lbs. (20
Nm) torque.
Fouled spark plugs are indicated by a wet, black appearance. This
could be caused by a dirty air filter element or other restrictions in the air
intake system. Incorrectly adjusted valves, spark plug wires which are
in poor condition or poor quality fuel could also contribute to the problem.
Do not sand blast spark plugs. They should be
cleaned by scraping or wire brushing by hand and
washing in a commercial solvent.

BRAKES
The master cylinder is located under the driver side seat.

Ratchet, 1/2" drive .................................................................1

It is important to maintain proper fluid levels in the brake master cylinder. The fill cap for the cylinder is located under the seat. When checking the fluid, wipe off any dirt from the fill cap before removing it to
prevent contamination. Fluid level should be maintained at 1/4" (6 mm)
below the top of the housing. Use DOT 3 automotive brake fluid.

Plug gauge, wire type ............................................................1

Daily Brake Test

SPARK PLUGS
Tool List

Qty. Required

Spark plug socket, 5/8", 1/2" drive.........................................1

Anti-seize compound ..........................................................AR
Torque wrench, 1/2" drive, ft. lbs. ..........................................1
Use care not to over-tighten the
plug. Over-tightening can cause
damage to the aluminum cylinder head threads.

To prevent severe injury or death
resulting from operating a vehicle
with improperly operating brake system, the braking system must be properly maintained. All
driving brake tests must be done in a safe location with
regard for the safety of all personnel.

!

!

3-37

OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
After the vehicle has been put into service, it is recommended that the
brakes be checked daily by performing the following test:
Depress the brake pedal. The 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 is indicating that a brake inspection is
required. A brake pedal that falls after it is applied indicates a leak in the
master or wheel cylinders. Check for adequate brake fluid level. Adjust
brakes if required and inspect system for fluid leaks.

PROLONGED STORAGE
To prevent serious injury or death
!
! resulting from a possible explosion:
Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the 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 the 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. Raise the rear of the
vehicle and support on jack stands before attempting to
run the engine.

3-38

Preparing the engine 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
the carburetor and corrosion in the engine.
• Raise the rear of the vehicle and support on jack stands. Refer to
‘Lifting the Vehicle’ for proper lifting procedure and safety information.
• Disconnect the fuel hose at the fuel tank and plug hose.
• With proper ventilation, depress the accelerator pedal and allow
engine to run until it stops due to lack of fuel.
• Remove spark plugs (Refer to page 3-37) 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.
• Add a gasoline additive to the tank in accordance with the manufacturer’s recommendations.
• Reattach fuel line to tank and drive the vehicle for several minutes
to circulate the additive through the carburetor.
• While engine is still warm, change oil (Refer to page 3-30).
• Clean body, chassis and engine of debris, mud, chaff or grass
(Refer to page 3-36).

HARDWARE
Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref Fig. 37 on page 3-39).
Use care when tightening fasteners and refer to the Technician’s
Repair and Service Manual for specific torque values.

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

and grade 8 hardware is identified by 6 marks on the head. Unmarked
hardware is Grade 2 (Ref Fig. 37 on page 3-39).

ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)
Unless otherwise noted in text, tighten all hardware in accordance with this chart.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
BOLT SIZE

1/4"

5/16"

3/8"

7/16"

1/2"

9/16"

5/8"

3/4"

7/8"

1"

Grade 2

4
(5)

8
(11)

15
(20)

24
(33)

35
(47)

55
(75)

75
(102)

130
(176)

125
(169)

190
(258)

Grade 5

6
(8)

13
(18)

23
(31)

35
(47)

55
(75)

80
(108)

110
(149)

200
(271)

320
(434)

480
(651)

Grade 8

6
(8)

18
(24)

35
(47)

55
(75)

80
(108)

110
(149)

170
(230)

280
(380)

460
(624)

680
(922)

BOLT SIZE

M4

M5

M6

M8

M10

M12

M14

Class 5.8
(Grade 2)

5.8

1
(2)

2
(3)

4
(6)

10
(14)

20
(27)

35
(47)

55
(76.4)

Class 8.8
(Grade 5)

8.8

2
(3)

4
(6)

7
(10)

18
(24)

35
(47)

61
(83)

97
(131)

Class 10.9
(Grade 8) 10.9

3
(4)

6
(8)

10
(14)

25
(34)

49
(66)

86
(117)

136
(184)

Fig. 37 Torque Specifications and Bolt Grades

3-39

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

CAPACITIES AND REPLACEMENT PARTS
Fuel Tank / Fuel

6.0 gal (22.5 liters) 87 Octane

Engine Oil

1 1/2 qt (1.4 liters)

Oil Filter

P/N 492932

Air Cleaner Filter

P/N 394018

Pre-Cleaner Filter

P/N 272490

Spark Plugs

CHAMPION RC12YC (P/N 491055)
.030" (.76 mm) Gap

Starter/Generator Belt P/N 75690-G01
Clutch Belt

P/N 75691-G01

Rear Axle Oil

40 oz (1.2 liters)

Fuse

15 amp (P/N 35212-G01)
7.5 amp (P/N 35212-G05)

Headlight Bulb

P/N 20209-G3

Turn Signal Bulb

#1157 (P/N 21759-G1)

Tail Light Bulb

#1157 (P/N 21759-G1)

Fig. 38 Capacities and Replacement Parts

3-40

GENERAL SPECIFICATIONS
ST 480
STANDARD EQUIPMENT:
BATTERY........................................One 12 Volt Maintenance Free (515 CCA, 82 Minute Reserve)
ENGINE...........................................16 H.P. (11.9 kW) 29.2 ci (480 cc) Twin Cylinder, Overhead Valve
Pressurized Lubrication with Spin Off Filter
Magnetron™ Ignition with Transistor Module
Replaceable Dry Cartridge Air Filter with Pre-Filter & Remote Intake
Fixed Jet Bowl Carburetor, Pulse Fuel Pump
TRANSAXLE...................................13.32:1 Helical geared with Differential Lock and Ground Speed
Governor
TRANSMISSION............................Automatic Continuously Variable Transmission (CVT)
FUEL TANK.....................................6 Gallon (23 Liters) Tank. 36 lbs. (16 kg) Fuel Weight
BRAKES..........................................Dual Rear Wheel, Self-Adjusting Hydraulic Drum Brakes
PARKING BRAKE...........................Hand Operated Mechanical Parking Brake
FRONT SUSPENSION...................Leaf Springs with Hydraulic Shock Absorbers
REAR SUSPENSION......................Leaf Springs with Hydraulic Shock Absorbers
STEERING......................................Single Reduction Rack & Pinion
STEERING WHEEL........................Dual Handgrips
SEATING.........................................Cushion Foam/Vinyl Cover Bucket Seats, Hip Restraint/Hand Hold
SEATING CAPACITY......................Operator & 1 Passenger
TOTAL LOAD CAPACITY...............800 lbs. (365 kg) Including Operator, Passenger, Accessories & Cargo
500 lbs. (230 kg) Maximum Bed Load
SPEED.............................................16.5 mph (26.5 kph) Max
CHASSIS ........................................Powder Coated (DuraShield™), Welded Tubular Steel
VEHICLE PROTECTION.................Tubular Steel Front Bumper with Brush Guards
BODY..............................................Flexible Impact Resistant DuraShield™ Injection Molded TPO
(Thermoplastic Olefin) with Base Coat/Clear Coat Front Cowl.
DuraShield™ Powder Coated Steel Rear Body
STANDARD COLOR(S) .................ST Series: Hunter Green; ST ADVANTAGE Series: RealTree®
Advantage Camo Body and Load Bed

DASH PANEL .................................Scuff Resistant Glass Fiber Reinforced Plastic (Thermoplastic Olefin)
with 4 Drink Holders
LOAD BED......................................Rotomolded cross link polyethelene & Electric Dump
LOAD BED FEATURES...................Hinged Removable Tailgate, Removable Bed Sides
LIGHTING/HORN (Standard)........Dual Halogen Headlights, Horn
TIRES (Standard)...........................22 x 9 - 10 Stryker I® (Uni-directional)
TIRE PRESSURE............................12 - 16 psi (85 - 110 kPa)
WEIGHT (Without Fuel).................1100 lbs (480 kg)
OPERATING CONTROLS
& INSTRUMENTATION .................Removable Key, ‘Deadman’ Accelerator Control, Direction Selector,
Audible Reverse Warning, Analog Fuel Gauge, Low Oil Pressure
Indicator and 12 Volt Power Outlet

Specifications subject to change without notice.

4-1

GENERAL SPECIFICATIONS
110.5 in (281 cm)

18 in
(46 cm)
49 in
(125 cm)
78 in
(198 cm)
or
75 in
(191 cm)
with Brush
Guard
Cage

11.5 in
(29 cm)
34 in
(86 cm)

15 in
(38 cm)
77 in (196 cm)

6 in
(15 cm)
Ground Clearance

Rear
38 in (96 cm)
Front
38.5 in (97 cm)

50 in
(127 cc)

42.5 in (108 cm)
Fig. 1 Vehicle Dimensions

4-2

GENERAL SPECIFICATIONS

Maximum Recommended Ramp Grade
25% or 14˚ Max.

Maximum Recommended Side Tilt
25% or 14˚ Max.

Fig. 2 Vehicle Incline Specifications

4-3

GENERAL SPECIFICATIONS

TURNING CLEARANCE DIAMETER
Approx. 23.5 ft (7.2 m)

Fig. 3 Vehicle Turning Clearance Diameter

4-4

LIMITED WARRANTY
EMISSION CONTROL SYSTEM WARRANTY
STATEMENT
(Owner’s Defect Warranty Rights and Obligations)

ENGINE OWNER WARRANTY POLICY
Refer to the Briggs & Stratton® Operating & Maintenance Instructions, provided
with vehicle, for Engine Warranty information.

Refer to the Briggs & Stratton® Operating & Maintenance Instructions, provided
with vehicle, for Emission Control System Warranty information.

5-1

LIMITED WARRANTY
Notes:

5-2

DECLARATION OF CONFORMITY

NOT AVAILABLE AT TIME OF PUBLICATION

6-1

DECLARATION OF CONFORMITY
Notes:

6-2

LABELS AND PICTOGRAMS
See Following
Pages For
Explanation
Of These
Pictograms:
(2,3,4,6,9,36,37,
38,39,40,29)

!

!

P
F
!

R

< 14˚ 25%

< 14˚ 25%

F

35962-G01

35962G01
See Following Pages
For Explanation Of
These Pictograms:
(19,43,44,45)

OFF
ON

75808-G01

75808G01

See Following Pages
For Explanation Of
These Pictograms:
(1,2,46,47,48)

75851G01

75851G01

PP

PP

3

2

1

PP

See Following Pages
For Explanation Of These
Pictograms: (1,23,27,18,20,
22,17,15)

H2O
74093-G01

74093G01

See Following Pages
For Explanation Of
These Pictograms:
(1,35)

75696G01

75696G01

WARNING

DO NOT TAMPER WITH OR CHANGE THIS ADJUSTMENT OF THE
GOVERNOR. FAILURE TO COMPLY COULD RESULT IN SERIOUS
PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY.

24880G01

Fig. 1 Label Locations

Appendix A-1

LABELS AND PICTOGRAMS
WARNING
See Following Pages For
Explanation Of Pictogram: (30)

Windshields do not
provide protection
from golf balls or
other flying objects.

EGWHL14
See Following Pages For
Explanation Of Pictogram: (49)
WARNING
MAX
250 lbs.
114 kg

Keep entire body
inside car.

!

PP

MAX
4 in.
10 cm

MAX
14o / 25%
35980G01

27653G01

35980G02

See Following Pages
For Explanation Of
These Pictograms:
(1,2)
71489G01

See Following Pages
For Explanation Of
This Pictogram:
(28)

Pb

35493-G01

35493G01

Fig. 2 Label Locations (Continued)

Appendix A-2

See Following
Pages For
Explanation
Of These
Pictograms:
(1,2,12,10,8,
7,5,11)

LABELS AND PICTOGRAMS
1.

5.

WARNING

MAX
14˚ / 25%

MAXIMUM
CROSS HILL/RAMP
ANGLE AS SPECIFIED

!

2.

WARNING
MAXIMUM CROSS
HILL/RAMP
ANGLE AS
SPECIFIED

READ MANUAL

6.
< 14˚ 25%
WARNING
USE CAUTION IN
INCLEMENT WEATHER

3.

LOAD WITH
HIGH CENTER
OF GRAVITY
COULD RESULT
IN TIP OVER

7.

!

4.

WARNING
DO NOT OPERATE
IF USING ALCOHOL
OR DRUGS

8.

MAX
xx in
xx cm

LOAD
CENTER
OF GRAVITY,
MAXIMUM
HEIGHT

Fig. 3 Pictogram Definitions

Appendix A-3

LABELS AND PICTOGRAMS

!

9.

WARNING
READ MANUAL
FOR MAXIMUM
LOAD BED
CAPACITY.
MAXIMUM
RAMP/HILL

12.
P
P

< 14˚ 25%

10.

11.

MAX
xxx lbs.
xxx kg

SECURE LOAD
AS FAR FORWARD
AS POSSIBLE.
MAXIMUM LOAD
BED CAPACITY

DO NOT RIDE IN
LOAD BED

13.

MAX LOAD
XXX LBS
in
XXX KG xxx cm

14.

Fig. 4 Pictogram Definitions (Continued)

Appendix A-4

DANGER OF EXPLOSION
DO NOT FILL GAS CAN
IN LOAD BED

WARNING
MAXIMUM
LOAD &
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

LABELS AND PICTOGRAMS
3

1

15.
16.
17.
18.

H2O

PP

PP

PP

PP

CLEAN UP
GASOLINE
SPILLS WITH
WATER BEFORE
STARTING ENGINE

22.

UNLEADED
GASOLINE

23.

DO NOT
SPILL FUEL
ON A HOT
ENGINE

24.

NO
TAMPERING.
KEEP HANDS
OUT

WARNING
CORROSIVE

GROUND
FUEL PUMP

25.
19.

SHORTING BATTERY
TERMINALS MAY
CAUSE EXPLOSION

WARNING
EXPLOSIVE

LOW OIL PRESSURE

20.

NEGATIVE
GROUND
BATTERY

26.

WARNING
LETHAL
VOLTAGE

21.

DO NOT CONNECT
POSITIVE BATTERY
TERMINAL TO GROUND

27.

DO NOT
EXPOSE
TO FLAME

Fig. 5 Pictogram Definitions (Continued)

Appendix A-5

LABELS AND PICTOGRAMS

28.

29.

30.

DO NOT
DISPOSE OF
BATTERIES
IN LANDFILL

33.

DO NOT
DRIVE ON
HIGHWAY

34.

WINDSHIELDS
DO NOT
PROVIDE
PROTECTION
FROM
FLYING OBJECTS

31.

BATTERIES ARE
HEAVY.
USE CARE LIFTING

32.

USE INSULATED
TOOLS

Fig. 6 Pictogram Definitions (Continued)

Appendix A-6

WEAR EYE
PROTECTION

NO SMOKING

35.

HOT SURFACE

36.

OPERATE
FROM
DRIVERS SIDE
ONLY

LABELS AND PICTOGRAMS

KEEP ARMS
AND LEGS
WITHIN VEHICLE

37.

P

40.

TO LEAVE A GASOLINE POWERED
VEHICLE IN PARK:
✱ APPLY PARKING BRAKE
✱ TURN KEY TO OFF
✱ MOVE DIRECTION SELECTOR TO
FORWARD

F

38.
F

TO OPERATE VEHICLE IN FORWARD:
✱ TURN KEY TO ON
✱ MOVE DIRECTION SELECTOR TO
FORWARD
✱ DEPRESS ACCELERATOR PEDAL
AND ACCELERATE SMOOTHLY

P

41.

TO LEAVE AN ELECTRIC POWERED
VEHICLE IN PARK:
✱ APPLY PARKING BRAKE
✱ TURN KEY TO OFF
✱ MOVE DIRECTION SELECTOR TO
NEUTRAL

N

39.
R

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

42.

KEEP CLEAR
HAND OR
FINGERS CAN
BE TRAPPED

Fig. 7 Pictogram Definitions (Continued)

Appendix A-7

LABELS AND PICTOGRAMS

43.
44.
45.

46.

47.

ON

ON
POSITION

OFF

OFF
POSITION

48.

DIFFERENTIAL
LOCKED

49.

WARNING
KEEP ENTIRE BODY
INSIDE CAR

HEADLIGHTS

UNLOCKED

LOCKED

Fig. 8 Pictogram Definitions (Continued)

Appendix A-8

Starting Model Year 2004

A Textron Company

E-Z-GO Division of Textron Inc.
P.O. Box 388 Augusta, Georgia 30903-0388 USA
Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124
Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609

76211-G01

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



---

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