E Z Go St 480 Users Manual

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

: E-Z-Go E-Z-Go-St-480-Users-Manual-536969 e-z-go-st-480-users-manual-536969 e-z-go pdf

Open the PDF directly: View PDF .
Page Count: 66

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 dam-

aged 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.

ANOTE indicates a condition that should be

observed.

A CAUTION indicates a condition that

may result in damage to the vehicle.

A WARNING indicates a hazard-

ous condition which could result

in severe injury or death.

Please observe these notes, cautions, and warnings; be aware that servicing a

vehicle requires mechanical skill and a regard for conditions that could be haz-

ardous. Improper service or repair may damage the vehicle or render it unsafe.

Engine exhaust from this product

contains chemicals known, in cer-

tain quantities, to cause cancer,

birth defects, or other reproductive harm.

The exhaust emissions of this vehicles’ engine

complies with regulations set forth by the Environ-

mental Protection Agency (EPA) of the United States of America

(USA) at time of manufacture. Significant fines could result from

modifications or tampering with the engine, fuel, ignition or air

intake systems.

Battery posts, terminals and relat-

ed accessories contain lead and

lead compounds. Wash hands

after handling.

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 brouilleu

r

du Canada.

i

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

ii

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).

TABLE OF CONTENTS

1-1

TITLE PAGE 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

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

1-2

TABLE OF CONTENTS

TITLE PAGE 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

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

2-1

The Owner’s Manual and Service Guide has been designed to assist in main-

taining the vehicle in accordance with procedures developed by the manufac-

turer. 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 possi-

ble combination of circumstances that may occur.

Good common sense and prudent driving practices do more to prevent acci-

dents and injury than all of the warnings and instructions combined. The manu-

facturer 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 Depart-

ment.

•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 mate-

rial 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 vehi-

cle. 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.

SAFETY INFORMATION

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

2-2

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 ser-

vice 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 mainte-

nance. 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 bat-

tery 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.

• 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 experi-

ence to recognize and protect themselves from potential dangerous situa-

tions. These situations could result in severe personal injury or death and

damage to the vehicle. Use extreme caution and if unsure as to the poten-

tial for injury refer the repair or maintenance to a qualified mechanic.

• Test drive the vehicle after any repairs are made or maintenance proce-

dures 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 pedes-

trian 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 partic-

ular 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

3-1

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

\

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 Vehi-

cle’. 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 represen-

tative on servicing the vehicle in accordance with the Periodic Service

Schedule.

Service Parts Manuals, Technician’s Repair and Service Manuals and

engine Repair Manuals are available from a local Distributor, an autho-

rized 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.

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 utili-

ty vehicle. It is NOT an all terrain vehicle (ATV).

This vehicle is not a toy and using it while engaging in horse-

play is dangerous.

Plan carefully before using the vehicle to go significant dis-

tances 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-

! !

OPERATION AND SERVICE INFORMATION

3-2

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 batter-

ies 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 INI-

TIAL SERVICE CHART must be performed (Ref Fig. 1 on page 3-2).

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.

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 vehi-

cle 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 dam-

age to the vehicle.

Fig. 1 Initial Service Chart

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

! !

OPERATION AND SERVICE INFORMATION

3-3

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 cen-

ter 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. Chil-

dren 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 abil-

ity 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 recom-

mended 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.) exces-

sively 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, opera-

tion 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 nat-

ural part of the lead acid battery

charging process. A 4% concentra-

tion of hydrogen gas is explosive and could cause severe

! !

! !

OPERATION AND SERVICE INFORMATION

3-4

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 batter-

ies 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 perfor-

mance of the vehicle.

To prevent severe injury or death

while driving, be aware of the follow-

ing:

Environmental hazards such as steep slopes, overhanging

limbs, etc.

Danger of fire when vehicle is operated over dry combusti-

ble 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, under-

stand 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.

! !

Fig. 2 Winch Mounted to Vehicle

Front Axle

Clevis Pin

Spring Pin

Winch shown mounted at front of vehicle

OPERATION AND SERVICE INFORMATION

3-5

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).

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 pre-

mature 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

operate winch while sitting in passenger seat. Read the following sec-

tion (Winch Applications) before attempting to operate winch.

WINCH APPLICATIONS

The winch may be used for a number of purposes, including pulling the

vehicle if it loses traction on unsuitable terrain.

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.

Fig. 3 Winch Remote Control

Receptacle

Remote Control

Fig. 4 Winch Clutch Knob

Pull out

ENGAGED

Clutch Knob

LOCKED OUT

Turn 900

! !

! !

OPERATION AND SERVICE INFORMATION

3-6

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.

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 oper-

ation.

The rolling load capacity of the winch decreases with the

steepness of the slope.

The winch is designed for intermittent duty only. The elec-

tric 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.

Replace frayed wire cable with a direct factory replace-

ment only.

Never operate the winch with less than five (5) full turns of

cable around the drum (Ref Fig. 5 on page 3-6).

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.

! !

! !

Fig. 5 Never Operate Winch with Less Than

Five Turns Around Drum

OPERATION AND SERVICE INFORMATION

3-7

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).

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 con-

nections. 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 suspen-

sion 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

Fig. 6 Do Not Hook Cable to Itself

Ref Wca 2 Fig. 7 Use a Nylon Sling and Install a Damper when Winching

Nylon

Sling

Damper

Ref Wcd 2

OPERATION AND SERVICE INFORMATION

3-8

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

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.

CONTROLS AND INDICATORS

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

Located on the dash panel, this switch enables the basic electrical sys-

tem 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 cus-

tom accessories, some accessories remain opera-

tional with the key switch in the ‘OFF’ position.

DIRECTION SELECTOR

To reduce the possibility of

Fig. 8 Do Not Pull at Angle

Correct

Incorrect

Ref Wps 2

OPERATION AND SERVICE INFORMATION

3-9

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

component damage, the vehicle must be completely

stopped before moving the direction selector.

Located on the console between the seats, this lever permits the selec-

tion 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-

29). If oil level is between ADD and FULL mark on dipstick, a mechani-

cal 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.

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

ON

OFF

FUEL

F

E

Low Oil Pressure

Indicator Light

Key/Light Switch Fuel

Gauge

Fig. 10 Console Controls

Parking

Brake

75694G01

Choke

Direction

Selector Differential

Locked

Differential

Unlocked

Differential

Lock Lever

(Stop Vehicle

Before Moving

Lever)

OPERATION AND SERVICE INFORMATION

3-10

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 vehi-

cle.

ACCELERATOR PEDAL

Unintentional movement of the

accelerator pedal may cause the

vehicle to move which could result

in severe injury or death.

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.

SERVICE BRAKE PEDAL

Depressing the foot operated service brake pedal activates the

wheel brakes, slowing or stopping the vehicle (Ref Fig. 11 on page

3-10).

PARK BRAKE

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

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

The rear drive axle is equipped with a manually operated locking differ-

ential. 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

Fig. 11 Accelerator, Brake and Horn

! !

Service

Brake

Accelerator

H

O

R

N

Horn

OPERATION AND SERVICE INFORMATION

3-11

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 for-

ward towards the red ‘locked’ symbol (Ref Fig. 10 on page 3-9).

To disengage the differential lock, stop the vehicle and push the differ-

ential 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 remain-

ing 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 posi-

tioned 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 misjudg-

ment of distance or an unstable surface could result in the vehicle fall-

ing backwards.

Before operating load bed, check to ensure no one is behind the vehi-

cle.

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).

! !

! !

! !

OPERATION AND SERVICE INFORMATION

3-12

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

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 condi-

tions and the environmental factors which effect the ter-

rain 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

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 back-

ward into the drop off.

To reduce the possibility of severe

injury or death resulting from

improper vehicle operation, the fol-

lowing 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 dan-

gerous.

The vehicle should not be operated on public highways. It

Fig. 12 Electric Lift Switch

Raise

Lower

! !

! !

OPERATION AND SERVICE INFORMATION

3-13

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 recom-

mended 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).

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.

Fig. 13 Check Oil Level on Dipstick

Maximum oil level

DO NOT OVERFILL

ADD FULL

OPERATION AND SERVICE INFORMATION

3-14

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 MAINTE-

NANCE 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

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 de-

energized and the engine stops. To stop the vehicle more quickly,

depress the service brake pedal.

When the direction selector is in the reverse posi-

tion, 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

3-15

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 nor-

mal speeds encountered on a flat surface. To reduce the possible loss

of vehicle control and severe drivetrain damage, speeds should be lim-

ited 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 gaso-

line. 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.

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, auto-

motive grade gasoline (Ref Fig. 38 on page 3-40). High altitude or

heavy use/load applications may benefit from higher octane gasoline.

Do not use gasoline which contains Methanol.

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.

BATTERY

Excessive use of accessories may

drain the battery and leave

insufficient reserve to start the vehicle.

! !

Fig. 14 Fueling

1" Min.

(2.5 cm)

Fuel

OPERATION AND SERVICE INFORMATION

3-16

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.) exces-

sively 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 bat-

tery 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.

LABELS AND PICTOGRAMS

Vehicles may be labeled with pictograms as a method of conveying

information or warnings. Appendix A illustrates and explains picto-

grams that may appear on the vehicle. Not all pictograms shown in

Appendix A will be found on your vehicle.

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.

The sun top and windshield provide some protection from the ele-

ments; however, they will not keep the operator and passenger dry in a

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.

TOWING A TRAILER

The vehicle is equipped with a receiver that can be fitted with a stan-

dard 1 7/8" ball. The trailer and its load must not exceed 500 lbs (227

! !

Fig. 15 12 Volt Power Outlet

12V Power

Outlet

ON

OFF

FUEL

F

E

OPERATION AND SERVICE INFORMATION

3-17

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 elec-

trical 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. Thor-

oughly clean any areas where mud or other debris can collect. Sedi-

ment 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.

! !

OPERATION AND SERVICE INFORMATION

3-18

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, non-

tacky, dry coating that will not crack, peel or flake over a wide tem-

perature 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, envi-

ronmentally safe solvents. (P/N 75504-G01)

• Multi-purpose Hand Cleaner is an industrial strength cleaner con-

taining 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 termi-

nal corrosion and can be rinsed with water. (P/N 75506-G01)

• Biodegradable Cleaner that breaks down grease to be easily

wiped or rinsed away. (P/N 75507-G01)

• Multi-purpose Value Pack sampler includes 4 ounce (118 ml)

aerosol cans of Battery Protector, Penetrant/Lubricant, White Lith-

ium Grease, and Carburetor and Choke Cleaner. (P/N 75508-

G01)

•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

3-19

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 posi-

tion 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 vehi-

cle 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

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

Torque wrench, 1/2" drive......................................................1 Fig. 16 Lifting the Vehicle

View from Underside of Vehicle

OPERATION AND SERVICE INFORMATION

3-20

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 infla-

tion 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, overinfla-

tion can occur in seconds. Never exceed the tire manufac-

turer’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 bro-

ken 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 side-

wall. Standard and optional tires should be inflated to pressure desig-

nated 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 pres-

sure 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

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 auto-

motive 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 manu-

facturer’s specifications.

To reduce the possibility of severe

injury, be sure mounting/demount-

ing 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 man-

ufacturer’s recommendations must be followed in order to reduce pos-

sibility 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 seat-

ing of the wheel against the hub.

! !

! !

OPERATION AND SERVICE INFORMATION

3-21

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 indi-

cating 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) incre-

ments following the ‘cross sequence’ pattern.

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 previ-

ously 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 3-

22). 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.

Fig. 17 Wheel Installation

Tire style may vary

1

2

3

4

'Cross Sequence'

Front of

Vehicle

R

o

t

a

t

i

o

n

Fig. 18 Headlight and Turn Signal Bulb Replacement

Headlight

Bulb

Turn Signal Lens

Turn Signal

Housing

Inside

of Cowl

! !

OPERATION AND SERVICE INFORMATION

3-22

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

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.

TRANSPORTING VEHICLE

TOWING This vehicle is not designed to be

towed.

It is recommended that the vehicle be moved by placing the entire vehi-

cle 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:

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 neu-

tral 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.

Fig. 19 Tail and Brake Light Bulb Replacement

Rear

Fender

Tail/Brake

Light

Roll Rubber

Bezel Away

From Body

! !

! !

OPERATION AND SERVICE INFORMATION

3-23

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

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

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 vehi-

cle (see GENERAL SPECIFICATIONS for vehicle weight) and load.

Lock the park brake and secure the vehicle using ratchet tie downs.

SERVICE AND MAINTENANCE

To reduce the possibility of severe

injury or death from improper servic-

ing techniques:

Do not attempt any type of servicing operations before

reading and understanding all notes, cautions and warn-

ings 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 vehi-

cle. Use extra care when working around bat-

teries, 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 elec-

trical loads from the battery before removing battery

wires.

Fig. 20 Neutral Lock

Fr

o

nt

o

f

V

e

hi

c

l

e

N

eu

tr

al

Lock

Direction

Selector

Dir

ec

tion

S

elector

Br

ac

k

et

S

lo

t

Detent

L

oc

k

ed

P

os

iti

on

cke

d

t

i

on

u

t

a

n

d

rotate 90

˚

to lock

ou

t

a

n

d

rotate 90

˚

to unlock

C

onsol

e

2

! !

OPERATION AND SERVICE INFORMATION

3-24

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 electro-

lyte 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) dis-

solved 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. Preven-

tative 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 appro-

priate service intervals (Ref Fig. 22 on page 3-26). Refer to Lubrication

Points for appropriate lubrication locations (Ref Fig. 29 on page 3-32).

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, remov-

ing or replacing any components that are not operating properly, con-

sider the safety of yourself and those around you, should the

component move unexpectedly.

Some components are heavy, spring loaded, highly corrosive, explo-

sive, may produce amperage or reach high temperatures. Gasoline,

carbon monoxide, battery acid and hydrogen gas could result in seri-

ous 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 unfore-

seen 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

3-25

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 inhala-

tion:

• 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.

SERIAL NUMBER PLATE LOCATION

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).

Design changes take place on an ongoing basis. In order to obtain cor-

rect components for the vehicle, the manufacturing date code, serial

number and vehicle model must be provided when ordering service

parts.

To prolong vehicle life, some

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.

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.

Some service procedures may require the vehicle to be lifted. Refer to

LIFTING THE VEHICLE for proper lifting procedure and safety infor-

mation.

Fig. 21 Serial Number Plate Location

OFF

ON

FUEL

F

E

OPERATION AND SERVICE INFORMATION

3-26

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 ✓ Examine for cuts, excessive wear and pressure, see GENERAL SPECIFICATIONS

WHEELS ✓ Check for bent rims, missing or loose lug nuts

FUEL GAUGE ✓ Check for proper operation (at fueling), and fuel cap vent is free of dirt

STARTER/GENERATOR BELT ✓ Check for tension, wear, cracks (Refer to page 3-34)

25 HOURS (includes items listed in previous table & the following)

WIRING ✓ Check all wiring for loose connections and broken/missing insulation

ACCELERATOR ✓ Check for smooth movement - DO NOT LUBRICATE CABLE

BRAKE FLUID (HYDRAULIC BRAKES) ✓ Check level, add if required (DOT 3) and check for leakage (Refer to page 3-37)

PARK BRAKE ✓ Check brake performance and adjust if required

CHOKE CABLE ✓ Check for smooth movement and adjustment - DO NOT LUBRICATE CABLE

CARBURETOR LINKAGE ✓ Check attachment, adjust as required

DIRECTION SELECTOR ✓ Check for smooth movement and attachment, adjust as required

ENGINE ♦ 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

OPERATION AND SERVICE INFORMATION

3-27

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

STEERING ASSEMBLY ✓ Check for abnormal play, tightness of all hardware

TIE RODS/LINKAGES ✓ Check for excessive play, bent components or loose connections

REAR AXLE ✓ Check for leakage, add SAE 30 oil as required (Refer to page 3-34)

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

ENGINE ▲ Change oil, DO NOT OVERFILL (Refer to page 3-30), see Note 1 and Note 2 on Pg. 3-40

✓ Check spark plug wires for cracks/loose connections

EXHAUST ✓ Inspect/clean spark arrester

FRONT AXLE ✓ Check for damage to axle and loose or missing hardware

FRONT SHOCK ABSORBERS ✓ Check for oil leakage and loose fasteners

FRONT SPRINGS ✓ Check for loose hardware, cracks at attachments

FRONT WHEEL ALIGNMENT ✓ Check for unusual tire wear, align if required

PARKING (PARK) BRAKE

✓ Check for binding cables

✓ Check for damage or wear

♦ Lubricate as required, use light oil. DO NOT LUBRICATE CABLES

REAR SHOCK ABSORBERS ✓ Check for oil leakage, loose mounting hardware

ENGINE ELECTRICAL SYSTEM ✓ Check coil/spark plug wires for cracks/loose connections

FUEL SYSTEM ✓ Check for leaks at tank, cap, system lines, filters, pump, carburetor

✓ Check system lines for cracks/deterioration

THROTTLE/GOVERNOR LINKAGE ✓ Check operation and governed speed

HARDWARE AND FASTENERS ✓ Check for loose or missing hardware and components

♦ Tighten or replace missing hardware

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

BATTERY ♦ Clean battery & terminals

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

▲ Change air cleaner cartridge if damaged or dirty (Refer to page 3-33), see Note 3 on Pg. 3-40

DIRECTION SELECTOR ✓ Check for wear and smooth movement (lubricate shaft with light oil if required)

KING PINS ✓ Check for excessive play and tightness of retaining nuts

♦ Lubricate, use wheel bearing grease

STEERING ASSEMBLY ♦ Lubricate unit and idler arm, use wheel bearing grease

Fig. 22 Periodic Service Schedule

OPERATION AND SERVICE INFORMATION

3-28

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

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 car-

tridge if dirty. Replace either if showing signs of damage.

TIRE INSPECTION

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 check-

ing 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).

RACK END BALL JOINT ♦ Lubricate, use wheel bearing grease

REAR AXLE ✓ Check for unusual noise and loose or missing mounting hardware

DRIVE BELT ✓ Check for cracks, fraying and excessive wear

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

FRONT WHEEL BEARINGS ✓ Check and adjust as required, see Technician’s Repair and Service Manual

REAR AXLE ✓ Check lubricant, add lubricant (SAE 30 oil) as required (Refer to page 3-34)

SERVICE BRAKES ♦ Clean, see Technician’s Repair and Service Manual

✓ Check brake shoe linings, see Technician’s Repair and Service Manual

FUEL FILTER ♦ Replace (Refer to page 3-29)

SPARK PLUGS ♦ Replace, gap new plugs (Ref. Capacities and Replacement Parts on page 3-40)(Refer to page 3-37)

MUFFLER/EXHAUST ✓ Check mounting hardware; check for leaks at head and muffler gaskets

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

Overhead Valve Engines

500 HOURS

REAR AXLE ▲ Replace lubricant

CYLINDER HEAD AND PISTONS ♦ 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

OPERATION AND SERVICE INFORMATION

3-29

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

REPLACING THE FUEL FILTER

To prevent a possible explosion, do

not smoke near the fuel tank or in an

area where gasoline is being han-

dled. 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 ven-

tilated.

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

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

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 dip-

stick 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 com-

partment.

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).

Fig. 23 Seat Prop

Seat

Prop

! !

OPERATION AND SERVICE INFORMATION

3-30

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.

When adding oil between oil changes, do not mix

brands and viscosity grades of oil. Both the oil dip-

stick 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 com-

partment.

CHANGING THE OIL

Tool List Qty. Required

Pliers......................................................................................1

Oil drain pan ..........................................................................1

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 Sched-

ule (Ref Fig. 22 on page 3-26).

Fig. 24 Oil Fill Cap, Dipstick and Fuel Filter

Fig. 25 Clean Entire Dipstick

Fuel Line

From Tank

Fuel

Pump

Fuel

Filter

Oil

Dipstick

Oil Fill

Cap

ADD FULL

Fig. 26 Check Oil Level on Dipstick

Maximum oil level

DO NOT OVERFILL

ADD FULL

OPERATION AND SERVICE INFORMATION

3-31

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; how-

ever, 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 ser-

vice 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 non-

synthetic 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 multi-

viscosity 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.

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

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 sec-

onds 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.

! !

Fig. 27 Oil Viscosity Chart

-20 0 20 40 60 80 100

-30 -20 -10 0 10 20 30 40

C

F0

0

SAE 30

SAE 30

(Air Temperature)

5W-30, 10W-30

5W-30, 10W-30

Synthetic 5W-20, 5W-30

Synthetic 5W-20, 5W-30

OPERATION AND SERVICE INFORMATION

3-32

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

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 fil-

ter 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’.

LUBRICATION

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 dam-

age grease seals and cause premature bearing failure (Ref Fig. 29 on

page 3-32).

Fig. 28 Oil Drain and Filter

Oil Drain

Valve

Oil Filter

Fig. 29 Lubrication Points

Steering

Unit

Ball Joint

on Rack

and Rod

King Pin

King Pin Idler Arm

OPERATION AND SERVICE INFORMATION

3-33

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.

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.

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 deter-

gent 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.

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.

Fig. 30 Air Cleaner

Plate

Air Cleaner

Cover

Air Cleaner

Base

Knob

Cartridge

Pre-cleaner

OPERATION AND SERVICE INFORMATION

3-34

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.

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.

REAR AXLE

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.

Checking the Lubricant Level

Tool List 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

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).

STARTER/GENERATOR BELT TENSION

Tool List Qty. Required

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

Wrench, 3/4"..........................................................................1

Wrench, 1/2"..........................................................................2

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

Fig. 31 Add, Check and Drain Rear Axle Lubricant

Check Plug

Drain Plug

OPERATION AND SERVICE INFORMATION

3-35

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 15-

20 hours of operation and set to 75 - 80 lbs. (34 - 36 kg).

A loose belt can cause audible vibration and

squeal.

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).

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 deflec-

tion 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).

Loosen adjusting bolt. Use pry bar to force starter/generator towards

front of vehicle until proper belt tension is achieved. Hold starter/gener-

ator in place and tighten adjusting bolt.

Tighten pivot bolts to 25 ft. lbs. (35 Nm) torque.

Fig. 32 Check Belt Tension with Gauge

Fig. 33 Check Belt Tension with Finger

Fig. 34 Adjust Belt Tension

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

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

Pivot Bolt

Adjusting Bolt

OPERATION AND SERVICE INFORMATION

3-36

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).

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.

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 facil-

ity 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.

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.

The correct cleaning technique is to spray the top and sides of the bat-

tery 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 3-

36). In addition to the battery, special attention should be paid to metal

components adjacent to the battery which should also be sprayed with

the sodium bicarbonate (baking soda) solution.

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.

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.

! !

Fig. 35 Preparing Acid Neutralizing Solution

1 quart

(1 liter)

Clear Water

2 Teaspoons (10 ml)

Sodium Bicarbonate

(Baking Soda)

Plastic

Spray

Bottle

! !

OPERATION AND SERVICE INFORMATION

3-37

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 mate-

rial.

SPARK PLUGS

Tool List Qty. Required

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

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

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

Remove and inspect the spark plugs at intervals per the Periodic Ser-

vice 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 prob-

lem.

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.

It is important to maintain proper fluid levels in the brake master cylin-

der. The fill cap for the cylinder is located under the seat. When check-

ing 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.

Daily Brake Test To prevent severe injury or death

resulting from operating a vehicle

with improperly operating brake sys-

tem, 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.

Fig. 36 Cleaning Air Intake and Cooling Fins

Air

Intake

Cooling

Fins

! !

OPERATION AND SERVICE INFORMATION

3-38

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 venti-

lated. 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 pos-

sible 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.

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 informa-

tion.

• 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 manu-

facturer’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. Fas-

teners should be tightened in accordance with the Torque Specifica-

tions 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

3-39

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).

Fig. 37 Torque Specifications and Bolt Grades

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

BOLT SIZE

Grade 2

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

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

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

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

4

(5) 8

(11) 15

(20) 24

(33) 35

(47) 55

(75) 75

(102) 130

(176) 125

(169) 190

(258)

Grade 5

Grade 8

6

(8) 13

(18) 23

(31) 35

(47) 55

(75) 80

(108) 110

(149) 200

(271) 320

(434) 480

(651)

6

(8) 18

(24) 35

(47) 55

(75) 80

(108) 110

(149) 170

(230) 280

(380) 460

(624) 680

(922)

BOLT SIZE

Class 5.8

(Grade 2)

M4 M5 M6 M8 M10 M12 M14

1

(2) 2

(3) 4

(6) 10

(14) 20

(27) 35

(47) 55

(76.4)

Class 8.8

(Grade 5) 2

(3) 4

(6) 7

(10) 18

(24) 35

(47) 61

(83) 97

(131)

Class 10.9

(Grade 8) 3

(4) 6

(8) 10

(14) 25

(34) 49

(66) 86

(117) 136

(184)

5.8

8.8

10.9

OPERATION AND SERVICE INFORMATION

3-40

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

CAPACITIES AND REPLACEMENT PARTS

Fig. 38 Capacities and Replacement Parts

Fuel Tank / Fuel

Engine Oil

Oil Filter

Air Cleaner Filter

Pre-Cleaner Filter

Spark Plugs

Starter/Generator Belt

Clutch Belt

Rear Axle Oil

Fuse

Headlight Bulb

Turn Signal Bulb

Tail Light Bulb

6.0 gal (22.5 liters) 87 Octane

1 1/2 qt (1.4 liters)

40 oz (1.2 liters)

15 amp (P/N 35212-G01)

7.5 amp (P/N 35212-G05)

P/N 20209-G3

#1157 (P/N 21759-G1)

#1157 (P/N 21759-G1)

P/N 492932

P/N 394018

P/N 272490

CHAMPION RC12YC (P/N 491055)

.030" (.76 mm) Gap

P/N 75690-G01

P/N 75691-G01

4-1

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.

4-2

GENERAL SPECIFICATIONS

Fig. 1 Vehicle Dimensions

42.5 in (108 cm)

50 in

(127 cc)

34 in

(86 cm)

6 in

(15 cm)

Ground Clearance

110.5 in (281 cm)

15 in

(38 cm)

49 in

(125 cm)

77 in (196 cm)

Rear

38 in (96 cm)

Front

38.5 in (97 cm)

78 in

(198 cm)

or

75 in

(191 cm)

with Brush

Guard

Cage

11.5 in

(29 cm)

18 in

(46 cm)

4-3

GENERAL SPECIFICATIONS

Fig. 2 Vehicle Incline Specifications

Maximum Recommended Side Tilt

25% or 14˚ Max.

Maximum Recommended Ramp Grade

25% or 14˚ Max.

4-4

GENERAL SPECIFICATIONS

Fig. 3 Vehicle Turning Clearance Diameter

TURNING CLEARANCE DIAMETER

Approx. 23.5 ft (7.2 m)

5-1

LIMITED WARRANTY

EMISSION CONTROL SYSTEM WARRANTY

STATEMENT

(Owner’s Defect Warranty Rights and Obligations)

Refer to the Briggs & Stratton®Operating & Maintenance Instructions, provided

with vehicle, for Emission Control System Warranty information.

ENGINE OWNER WARRANTY POLICY

Refer to the Briggs & Stratton®Operating & Maintenance Instructions, provided

with vehicle, for Engine Warranty information.

5-2

LIMITED WARRANTY

Notes:

6-1

DECLARATION OF CONFORMITY

NOT AVAILABLE AT TIME OF PUBLICATION

6-2

DECLARATION OF CONFORMITY

Notes:

Appendix A-1

LABELS AND PICTOGRAMS

Fig. 1 Label Locations

35962G01

!

!

R

F

<

14

˚

25

%

P

F

!

<

14

˚

25

%

35962-G01

See Following

Pages For

Explanation

Of These

Pictograms:

(2,3,4,6,9,36,37,

38,39,40,29)

See Following Pages

For Explanation Of

These Pictograms:

(19,43,44,45)

75808G01

OFF

ON

75808-G01

H O

2

123

P

P

P

P

P

P

74093-G01

74093G01

See Following Pages

For Explanation Of These

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

22,17,15)

See Following Pages

For Explanation Of

These Pictograms:

(1,2,46,47,48)

75696G01

75696G01

75851G01

75851G01

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.

WARNING

24880G01

See Following Pages

For Explanation Of

These Pictograms:

(1,35)

Appendix A-2

LABELS AND PICTOGRAMS

Fig. 2 Label Locations (Continued)

WARNING

Keep entire body

inside car.

27653G01

See Following Pages For

Explanation Of Pictogram: (49)

P

P

MA

X

250 l

b

s.

114 k

g

MA

X

4 i

n

.

10 c

m

MA

X

14

o

/ 25

%

!

35980G01

35980G02 See Following

Pages For

Explanation

Of These

Pictograms:

(1,2,12,10,8,

7,5,11)

WARNING

Windshields do not

provide protection

from golf balls or

other flying objects.

EGWHL14

See Following Pages For

Explanation Of Pictogram: (30)

35493G01

See Following Pages

For Explanation Of

This Pictogram:

(28)

P

b

35493-G01

71489G01

See Following Pages

For Explanation Of

These Pictograms:

(1,2)

Appendix A-3

LABELS AND PICTOGRAMS

Fig. 3 Pictogram Definitions

WARNING

READ MANUAL

!

WARNING

USE CAUTION IN

INCLEMENT WEATHER

WARNING

DO NOT OPERATE

IF USING ALCOHOL

OR DRUGS

M

A

X

14

˚

/ 25

%

MAXIMUM

CROSS HILL/RAMP

ANGLE AS SPECIFIED

!

<

14

˚

25

%

WARNING

MAXIMUM CROSS

HILL/RAMP

ANGLE AS

SPECIFIED

LOAD WITH

HIGH CENTER

OF GRAVITY

COULD RESULT

IN TIP OVER

M

A

X

xx i

n

xx c

m

LOAD

CENTER

OF GRAVITY,

MAXIMUM

HEIGHT

1.

2.

3.

4.

5.

6.

7.

8.

Appendix A-4

LABELS AND PICTOGRAMS

Fig. 4 Pictogram Definitions (Continued)

!

<

14

˚

25

%

WARNING

READ MANUAL

FOR MAXIMUM

LOAD BED

CAPACITY.

MAXIMUM

RAMP/HILL

M

A

X

xxx l

b

s

.

xxx k

g

SECURE LOAD

AS FAR FORWARD

AS POSSIBLE.

MAXIMUM LOAD

BED CAPACITY

DO NOT RIDE IN

LOAD BED

P

P

DANGER OF EXPLOSION

DO NOT FILL GAS CAN

IN LOAD BED

x in

xin

xx cm

xx cm

MAX LOAD

MAX LOAD

XXX LBS

XXX LBS

XXX KG

XXX KG

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

9.

10.

11.

12.

13.

14.

Appendix A-5

LABELS AND PICTOGRAMS

Fig. 5 Pictogram Definitions (Continued)

13

H O

2

P

P

CLEAN UP

GASOLINE

SPILLS WITH

WATER BEFORE

STARTING ENGINE

P

P

UNLEADED

GASOLINE

P

P

GROUND

FUEL PUMP

P

P

DO NOT

SPILL FUEL

ON A HOT

ENGINE

NO

TAMPERING.

KEEP HANDS

OUT

NEGATIVE

GROUND

BATTERY

DO NOT CONNECT

POSITIVE BATTERY

TERMINAL TO GROUND

SHORTING BATTERY

TERMINALS MAY

CAUSE EXPLOSION

DO NOT

EXPOSE

TO FLAME

WARNING

CORROSIVE

WARNING

LETHAL

VOLTAGE

WARNING

EXPLOSIVE

LOW OIL PRESSURE

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Appendix A-6

LABELS AND PICTOGRAMS

Fig. 6 Pictogram Definitions (Continued)

DO NOT

DISPOSE OF

BATTERIES

IN LANDFILL

DO NOT

DRIVE ON

HIGHWAY

WINDSHIELDS

DO NOT

PROVIDE

PROTECTION

FROM

FLYING OBJECTS

BATTERIES ARE

HEAVY.

USE CARE LIFTING

USE INSULATED

TOOLS

WEAR EYE

PROTECTION

NO SMOKING

HOT SURFACE

28.

29.

30.

31.

32.

33.

34.

35.

OPERATE

FROM

DRIVERS SIDE

ONLY

36.

Appendix A-7

LABELS AND PICTOGRAMS

Fig. 7 Pictogram Definitions (Continued)

KEEP ARMS

AND LEGS

WITHIN VEHICLE

F

TO OPERATE VEHICLE IN FORWARD:

✱ TURN KEY TO ON

✱ MOVE DIRECTION SELECTOR TO

FORWARD

✱ DEPRESS ACCELERATOR PEDAL

AND ACCELERATE SMOOTHLY

KEEP CLEAR

HAND OR

FINGERS CAN

BE TRAPPED

37.

38.

42.

P

F

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

TO LEAVE A GASOLINE POWERED

VEHICLE IN PARK:

✱ APPLY PARKING BRAKE

✱ TURN KEY TO OFF

✱ MOVE DIRECTION SELECTOR TO

FORWARD

P

N

TO LEAVE AN ELECTRIC POWERED

VEHICLE IN PARK:

✱ APPLY PARKING BRAKE

✱ TURN KEY TO OFF

✱ MOVE DIRECTION SELECTOR TO

NEUTRAL

39.

40.

41.

Appendix A-8

LABELS AND PICTOGRAMS

Fig. 8 Pictogram Definitions (Continued)

ON

OFF

ON

POSITION

OFF

POSITION

HEADLIGHTS

UNLOCKED

43.

44.

45.

46.

LOCKED

DIFFERENTIAL

LOCKED

47.

48.

49. WARNING

KEEP ENTIRE BODY

INSIDE CAR

Starting Model Year 2004

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

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

E-Z-GO Division of Textron Inc.

76211-G01

A Textron Company