E-Z-GO 2012 EXPRESS L6 Owner'S Manual Download Page 22

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GENERAL SPECIFICATIONS

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

2 - 4

MODEL: EXPRESS L6

TYPE: GAS POWERED PERSONNEL CARRIER

MODEL YEAR: 2012

Part No: 618868

Engine:

13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki

Overhead valve

Drive Train:

Automatic, continuously variable transmission (CVT)

Electrical:

Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve)

Transaxle:

Differential with helical gears, ground speed governor, forward/reverse

Brakes:

Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release
with self-compensating system

Capacity:

Choice of 6 seats (Std) or 4 seats and optional Wood Stake Sides or Roto-molded Cargo box
Cargo Bed: Roto-molded cross-linked polyethelene. Removable hinged multi-position tailgate requires no latch mechanism

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

PRODUCT OVERVIEW

Some items shown may be optional equipment

Specifications are subject to change without notice

* Field installed accessories may require installation charges

Power Source

Vehicle Power

Fuel Capacity

5.3 Gallons (20.0 L) tank

Drive Train

Continuously variable transmission (CVT)

Transaxle

Differential with helical gears

Forward - Reverse
11.42:1 (Forward) 15.78:1 (Reverse)

4 Cycle 24.5 cu in (401.0 cc)

Valve Train

Horsepower (kW)
Electrical System
Batteries (Qty, Type)

Air Cleaner

Cooling System

Gear Selection
Rear Axle Ratio

Single Cylinder OHV

13 hp (9.7 kW) Exceeds SAE J1940 Std.
Starter/Generator. Solid State Regulator
One, 12 Volt Maintenance Free

Replaceable Dry Cartridge

Key or Pedal Start

Pedal

Lubrication

Pressurized Oil System

Oil Filter

Spin-On

Air Cooled

Performance

Vehicle load capacity

6 Person

970.0 lb (445.0 kg) (Without Batteries)

Seating (Rear Facing Seat)

4 Person

Seating (Bed/Stake sides)

Dry Weight

1200.0 lb (540.0 kg)

Curb Weight

1020.0 lb (465.0 kg

25.5 ft (7.8 m)

Outside Clearance Circle

6.5 ft (1.98 m)

Intersecting Aisle Clrnce

Speed (Level Ground)

Fwd - 16.0 mph ± 0.5 mph (25.7 kph ± 0.8 kph)

Rev - 12.0 mph ± 0.5 mph (19.3 kph ± 0.8 kph)

N/A

Towing Capacity

Body & Chassis

Welded steel with DuraShield™ powder coat

Injection molded TPO

Frame

Front Body & Finish

Injection molded TPO

Rear Body & Finish

Fiberglass & Gelcoat

Seat Pod & Finish

Black

Standard Color

Steering & Suspension

Service Brake

Self-compensating rack and pinion
Leaf springs with hydraulic shock absorbers

Steering

Front Suspension

Rear wheel mechanical self-adjusting drum

Rear Suspension

Leaf springs with hydraulic shock absorbers

Self-compensating, single point engagement
Terra Trac 23 x 10.5 - 12 on Alloy Wheel

Parking Brake

Front Tires

Terra Trac 23 x 10.5 - 12 on Alloy Wheel

Rear Tires

Dimensions

Overall Height (No Canopy)

Overall Height (With Canopy)
Wheel Base
Front Wheel Track
Rear Wheel Track

138.0 in (351.0 cm)

46.5 in (119.0 cm)

Overall Length
Overall Width

95.0 in (241.0 cm)

Gnd Clearance @ Differential

38.5 in (98.0 cm)
7.0 in (18.0 cm)

37.5 in (95.0 cm)

76.0 in (193.0 cm)

52.5 in (133.5 cm) (Top of steering wheel)

Valve Train:

Pressurized oil system, spin-on oil filter

Lubrication:

Internal counter rotating balance shaft

Balancer:

Fixed float bowl with remote pulse fuel pump

Fuel System:

Electronic spark/magneto

Ignition:

Replaceable dry cartridge

Air Cleaner:

Noise & Vibration

Sound pressure; continued A-weighted equal to or less

than 76 db(A)

Highest RMS value of weighted acceleration is less

than 2.5 m/s

Highest RMS value of weighted acceleration is less

than 2.5 m/s

The uncertainty of measurement is 0.54 m/s

Noise

Vibration, WBV

Vibration, HAV

Measurement methods were applied per the ISO 2631 and ISO 5349 standards
under conditions of typical vehicle surfaces.

Summary of Contents for 2012 EXPRESS L6

Page 1: ...622009 Owner s Guide ISSUED JULY 2011 REVISED AUGUST 2012 ...

Page 2: ...ces in controls will be illustrated Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in accordance with the Periodic Service Schedule Repair or replacement parts are available through your E Z GO retailer or E Z GO Genuine Service Parts The following information is needed when contacting...

Page 3: ...right to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may be revised periodically by E Z GO Division of Textron Inc and therefore is subject to change without notice E Z GO Division of Textron Inc DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCL...

Page 4: ...ponents must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not fr...

Page 5: ...e thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers SECTION PAGE NO SAFETY 1 1 GENERAL SPECIFICATIONS 2 1 INTRODUCTION 3 1 OPERATING PROCEDURES 4 1 MAINTENANCE 5 1 DELCARATION OF CONFORMITY APPENDIX A 1 ...

Page 6: ...Page iv TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 7: ...familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 1 TITLE PAGE NO SAFETY 1 3 NOTICES CAUTIONS WARNINGS AND DANGERS 1 3 GENERAL 1 4 GENERAL OPERATION 1 5 MAINTENANCE 1 5 VENTILATION 1 6 LABELS AND PICTOGRAMS 1 7 ...

Page 8: ...1 2 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1 ...

Page 9: ...cated under the pas senger seat in the Tow position If the vehicle is to be used in a commercial environment signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition Observe these NOTICES CAUTIONS WARNINGS and DANGERS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous Improper se...

Page 10: ...ERAL LAW the modified product will be a Low Speed Vehicle LSV subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571 500 In these instances pursuant to Federal law the Distributor or Dealer MUST equip the product with headlights rear lights turn signals seat belts top horn and all other modifications for LSV s mandated in FMVSS 571 500 and affix a Vehicle Identific...

Page 11: ...deral 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 With electric powered vehicles be sure that all electrical accessories are grounded directly to the battery post Never use the chassis or bo...

Page 12: ...cle 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 maintain the vehicle in an area away from exposed flame or persons who are smoking be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated test drive the vehicle after any repairs or mainte...

Page 13: ...g MAX 5 in 12 cm P P MAX 100 lbs 45 kg 74821G0 cm MIN 150 R F ON OFF I O ON OFF I O F R F ON OFF I O ON OFF I O R F ON OFF I O ON OFF I O R F 14 25 14 25 614121 614121 www ezgo com 608822 AUTHORIZED REPRESENTATIVE IN EC IS RANSOMES JACOBSEN LTD WEST ROAD IPSWICH SUFFOLK IP3 9TT UK 28203G01 28203 G01 601783 35493G01 3 3 01 601781 610631 MAX 4 in 10 cm MAX 14o 25 MAX 250 lbs 110 kg 610631 614068 608...

Page 14: ... OF GRAVITY COULD RESULT IN TIP OVER LOAD CENTER OF GRAVITY MAXIMUM HEIGHT 14û25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAPACITY DO NOT RIDE IN LOAD BED DANGER OF EXPLOSION DO NOT FILL GAS CAN IN LOAD BED x in xx cm MAX LOAD XXX LBS XXX KG WARNING MAXIMUM LOAD CENTER OF GRAVITY KEEP LOAD AS FAR FORWARD AS POSSIBLE...

Page 15: ... 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 DO NOT DISPOSE OF BATTERIES IN LANDFILL DO NOT DRIVE ON HIGHWAY LOW OIL PRESSURE WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS BATTERIES ARE HEAVY USE CARE LIFTING USE INSULATED TOOLS WEAR EYE...

Page 16: ...ECTION 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 ON OFF KEEP CLEAR HAND OR FINGERS CAN BE TRAPPED ON POSITIO...

Page 17: ...O LOCK DIFFERENTIAL PUSH BOTTOM OF SWITCH TO UNLOCK DIFFERENTIAL 58 REAR DIFFERENTIAL LOCK SWITCH 59 PUSH TOP PART OF SWITCH TO RAISE LOAD BED PUSH BOTTOM PART OF SWITCH TO LOWER LOAD BED 61 54 WARNING READ OWNER S MANUAL BEFORE OPERATING VEHICLE IN FORWARD OR REVERSE WARNING READ OWNER S MANUAL BEFORE ENGAGING TWO OR FOUR WHEEL DRIVE 57 55 WARNING READ OWNER S MANUAL BEFORE PARKING VEHICLE AND LE...

Page 18: ...1 12 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1 ...

Page 19: ...with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TITLE PAGE NO EXPRESS S6 Vehicle Specifications 2 3 EXPRESS L6 Vehicle Specifications 2 4 EXPRESS S6 L6 Vehicle Dimensions 2 5 EXPRESS S6 L6 Vehicle Incline Information and Turning Diameter 2 6 ...

Page 20: ...2 2 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2 ...

Page 21: ...8 0 cm 5 0 in 13 0 cm 4 Cycle 24 5 cu in 401 0 cc Valve Train Horsepower kW Electrical System Batteries Qty Type Air Cleaner Cooling System Gear Selection Rear Axle Ratio Single Cylinder OHV 13 hp 9 7 kW Exceeds SAE J1940 Std Starter Generator Solid State Regulator One 12 Volt Maintenance Free Replaceable Dry Cartridge Key or Pedal Start Pedal Lubrication Pressurized Oil System Oil Filter Spin On ...

Page 22: ... Spin On Air Cooled Performance Vehicle load capacity 6 Person 970 0 lb 445 0 kg Without Batteries Seating Rear Facing Seat 4 Person Seating Bed Stake sides Dry Weight 1200 0 lb 540 0 kg Curb Weight 1020 0 lb 465 0 kg 25 5 ft 7 8 m Outside Clearance Circle 6 5 ft 1 98 m Intersecting Aisle Clrnce Speed Level Ground Fwd 16 0 mph 0 5 mph 25 7 kph 0 8 kph Rev 12 0 mph 0 5 mph 19 3 kph 0 8 kph N A Towi...

Page 23: ... to all Notices Cautions Warnings and Dangers 2 141 8 in 360 0 cm 93 5 in 237 0 cm 49 0 in 124 0 cm Rear 38 5 in 98 0 cm Front 37 5 in 95 0 cm 73 0 in 185 0 cm EXPRESS S6 5 0 in 13 0 cm 138 0 in 351 0 cm 99 0 in 241 0 cm 46 5 in 119 0 cm Rear 38 5 in 98 0 cm Front 37 5 in 95 0 cm 52 5 in 133 5 cm 76 0 in 193 0 cm EXPRESS L6 ...

Page 24: ...ar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 6 2 RECOMMENDED MAX SIDE TILT 25 or 14 MAX RECOMMENDED MAX RAMP GRADE 25 or 14 MAX EXPRESS S6 TURNING CLEARANCE DIAMETER 35 ft 6inches 10 8 m EXPRESS S6 25 ft 6inches 7 8 m EXPRESS L6 ...

Page 25: ...2 7 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers GENERAL SPECIFICATIONS 2 ...

Page 26: ...2 8 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2 ...

Page 27: ... Information 3 3 Key Switch Headlight Switch 3 3 Low Oil Pressure Indicator Light 3 3 Fuel Gauge 3 4 Direction Selector 3 4 Accelerator Pedal 3 4 Brake and Park Brake 3 4 Horn 3 4 Rear View Mirror 3 4 Front Seats 3 4 Hip Restraint Front 3 4 Front Lights 3 5 Brake Light Turn Signal 3 5 Grab Handles 3 5 Glove Box 3 5 Cup Holder 3 5 Steering Wheel 3 6 Choke 3 6 Rear Seat 3 6 Hip Restraint Rear 3 6 ...

Page 28: ...3 2 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3 ...

Page 29: ...trical system of the vehicle to be turned on and off by turning the key To prevent inadvertent operation of the vehicle when left unattended the key should be turned to the OFF position and removed 2 LOW OIL PRESSURE INDICATOR LIGHT A low oil pressure indicator light is located on the dash panel The light illuminates when the oil pressure is low Check oil level If oil level is between ADD and FULL...

Page 30: ...hich could cause severe injury or death Depressing the accelerator pedal will release the park brake if it is engaged This is a feature to assure the vehicle is not driven with the park brake engaged Depressing the accelerator pedal is not the preferred method of releasing the park brake Depressing the lower section of the brake pedal is the preferred method of releasing the park brake to assure t...

Page 31: ...l The combination brake light turn signal assemblies are located on the rear fenders 13 Grab Handles The vehicle is equipped with grab handles 14 Glove Box A passenger side locking glove box is standard driver side is offered as an option A separate key is used for the locking glove boxes 15 Cup Holder A cup holder is provided for convenience of both the driver and passenger 16 17 15 18 19 14 H O ...

Page 32: ...ons 18 Rear Seat The rear seats is designed for two occupant on each side of the seat To prevent severe injury or death rear seat passengers should hold on to both the hip restraints and the rear hand hold when the vehicle is in motion Always be sure that all passengers are seated and holding on before operating vehicle 19 Hip Restraint Rear The rear hip restraints are designed to help keep the oc...

Page 33: ...3 7 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers INTRODUCTION 3 ...

Page 34: ...3 8 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3 ...

Page 35: ...tion to all Notices Cautions Warnings and Dangers 4 TITLE PAGE NO SERIAL NUMBER LOCATION 4 3 BEFORE INITIAL USE 4 4 OPERATING THE VEHICLE 4 4 Run in 4 5 Cold Starting 4 6 STARTING AND DRIVING 4 6 Starting The Vehicle 4 6 Coasting 4 7 Fuel 4 7 Battery 4 8 Sun Top And Windshield If Equipped 4 8 Labels And Pictograms 4 8 ...

Page 36: ...4 2 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 4 ...

Page 37: ...at The other is located on the chassis between the seat back supports To access it raise the seat and lift up the flap on the access panel Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the manufac ture date code serial number and vehicle model mustacture date code serial number and vehicle model must be provided when ordering service parts Seri...

Page 38: ...roper 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 fol lowing warnings must be observed When driving vehicle consider the terrain traffic conditions and the environmental factors which effect the terrain and ...

Page 39: ...e 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 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 te...

Page 40: ... brake and deter mine 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 service brake until engine has started To operate vehicle Apply the service brake place the key in the key switch and turn it to t...

Page 41: ...ATIONS 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...

Page 42: ...come 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 SUN TOP AND WINDSHIELD If Equipped The sun top does not provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects To prevent damage to the vehicle do no...

Page 43: ...4 9 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers OPERATING PROCEDURES 4 ...

Page 44: ...4 10 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 4 ...

Page 45: ...ENT 5 10 FUSE REPLACEMENT 5 10 VEHICLE DISCHARGED BATTERY 5 10 TRANSPORTING VEHICLE 5 11 Towing 5 11 Neutral Lock 5 11 Hauling 5 11 SERVICE AND MAINTENANCE 5 12 ROUTINE MAINTENANCE 5 13 Tire Inspection 5 13 Rear Axle 5 13 Four Cycle Engine 5 13 Checking the Oil Level 5 13 Changing Oil 5 14 STARTER GENERATOR BELT TENSION 5 17 Adjusting The Belt 5 17 BATTERY CLEANING 5 18 BRAKES 5 19 PERIODIC BRAKE ...

Page 46: ... familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 5 2 5 TITLE PAGE NO LUBRICATION 5 22 SPARK PLUGS 5 22 PROLONGED STORAGE 5 23 PERIODIC SERVICE SCHEDULE 5 24 CAPACITIES AND REPLACEMENT PARTS 5 26 HARDWARE 5 26 ...

Page 47: ...5 3 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers MAINTENANCE 5 ...

Page 48: ...5 4 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 5 ...

Page 49: ...mmercial 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 veh...

Page 50: ...ed terrain 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 the...

Page 51: ... and jack stands at the areas indicated only Lifting The Vehicle Tool List Qty Tool List Qty Floor jack 1 Jack stands 4 Wheel Chocks 4 Remove payload from vehicle before lifting No person s should be in or on the vehicle while lifting To raise the entire vehicle install chocks in front and behind each front wheel Center the jack under the rear frame crossmember Raise the vehicle enough to place a ...

Page 52: ... severe injury Tire Repair Tool List Qty Tool List Qty Lug wrench 11 16 1 Impact socket 11 16 1 2 drive 1 Impact wrench 1 2 drive 1 Torque wrench 1 2 drive 1 Use caution when inflating tires Due to the low volume of the small tires overinflation can occur in seconds Overin flation could cause the tire to separate from the wheel or cause the tire to explode Tire inflation should be determined by th...

Page 53: ... to floor Wear OSHA approved safety equipment when mounting demounting tires If the tire is to be removed or mounted the tire changing machine manufacturer s recommendations must be fol lowed in order to reduce possibility of severe injury 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 cros...

Page 54: ...th a new automo tive 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 The vehicle is equipped with a starter generator and does not idle When starting the eng...

Page 55: ...tion selector mounting bracket preventing any movement When in this position the direction selector remains locked in the neutral position To unlock the direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole in the direction selector cam HAULING To reduce the possibility of severe injury or death while transporting the vehicle ...

Page 56: ... electrical arc which could result in a battery explosion turn off all electrical loads from the battery before removing battery wires Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench shorting out a battery which could result in an explosion The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes Treat all electrolyte spills to ...

Page 57: ...st five years is the periodic inspection of the rear axle for lubricant leakage Unless leakage is evident the lubricant need only be replaced after five years Refer to the Service and Repair Man ual for the fluid replacement procedure FOUR CYCLE ENGINE Engine Specifications Engine model FJ400D Type Four cycle OHV Number of cylinders 1 Displacement 401 cc Rated horsepower 13 hp Spark plug type NGK ...

Page 58: ...as it gets hot Do not overfill Check that the oil cap is firmly in place When adding oil between oil changes do not mix brands and viscosity grades of oil The oil dipstick fill cap must be in place before operating the engine Failure to install the dipstick fill cap will result in oil becoming contaminated and or oil being discharged into the engine compartment Changing the Oil Tool List Qty Socke...

Page 59: ...y moisture that has accumulated during storage Be aware that engine fluids may be hot and contact to the skin may cause severe burns Wear rubber gloves to protect skin from exposure to the old oil and degreaser The oil should be changed with engine warm Park vehicle on a level surface engage parking brake and remove key Place a drain pan under engine Wipe top of the engine clean with a cloth Remov...

Page 60: ...61 in lbs 7 0 Nm torque Apply engine oil to the oil filter seal and install oil filter onto the engine until the seal contacts mounting surface of the engine Then turn the filter 2 3 to 3 4 rotations by HAND S Pour in the specified type and amount of oil See Capacity and Replacement Parts chart on page 55 Oil capacity is 1 1 3 quarts 1 3 liters Add slightly less than 1 1 3 quarts 1 3 liters to all...

Page 61: ... Socket 3 4 3 8 drive 1 The starter generator belt tension should be checked after the first 15 20 hours 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 115 125 lbs 52 57 kg tension when a gauge is applied half way between the two pulleys A new belt may be checked manually A maximum deflection of 3 8 10 mm is acceptable Tigh...

Page 62: ...a resi due 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 battery ...

Page 63: ...ehicle speed No specific braking distance can be reliably specified The test is conducted by latching the park brake to eliminate different pedal pressures and to include the affects of linkage mis adjustment Establish the acceptable stopping distance by testing a new or known to be good vehicle and recording the stopping location or stopping distance For fleets of vehicles several vehicles should...

Page 64: ... Clean areas shown to prevent engine damage Keep linkages springs and con trols clean Keep area around muffler free of any combustible material At least once a year or more often under adverse conditions the cooling system should be cleaned Cleaning will assure an adequate supply of air to the cooling fins Compressed air may be used for routine cooling system mainte nance REAR AXLE The rear axle i...

Page 65: ... to clean the air filter doing so will damage the filter which may result in damage to the engine The air cleaner element is accessible by unsnapping the clips on the air canister and removing the cover and air filter element Clean inside of cover canister and dust collector Install the element and cover the same way they were removed Be sure the positioning arrow on cover is pointing upward and a...

Page 66: ... 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 plug at intervals indicated in the Periodic Service Schedule Spark plug should be properly gapped Tighten to 16 ft lbs 22 Nm torque Remove and inspect the spark plug at intervals indicated in the Periodic Servi...

Page 67: ...ent a build up of varnish and gum in the carburetor and corrosion in the engine Turn the Key Switch to OFF position and leave the Forward Reverse switch in the NEUTRAL position during storage Perform all required routine maintenance per the Periodic Service Schedule Properly inflate the tires to recommended pressure psi stated on sidewall of tires Place the Forward Reverse handle in the NEUTRAL po...

Page 68: ...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 SERVICE BRAKE MECHANICAL BRAKES Conduct brake performance test PARK BRAKE Check brake performance and adjust if required CHOKE CABLE Check for smooth movement and adjustment DO NOT LUBRICATE CABLE CARBURETOR LINKAGE Check attachmen...

Page 69: ...ardware AIR FILTER ELEMENT Check filter element clean replace as required OIL FILTER Replace at oil change ENGINE OIL Replace with SAE 10W 30 or 10W 40 that meets or exceeds SF SG CC oil DO NOT OVERFILL DRIVE BELT Check for cracks fraying and excessive wear ANNUAL 250 300 HOURS includes items listed in previous tables the following FRONT WHEEL BEARINGS Check and adjust as required see Technician s...

Page 70: ...in 1 4 US qt 1 3 liters 51 oz 1 5 liters SAE 30 2 oz 60 mL P N 625753 15 amp P N 18392G1 P N 619101 P N 619100 P N 619102 P N 607454 P N 28463G01 NGK BPR2ES P N 607462 028 031 7 mm 8 mm Gap P N 26414G1 P N 618630 1157 P N 611242 Tail Light Bulb Friction Modifier Rear Axle 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 t...

Page 71: ...5 27 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers MAINTENANCE 5 ...

Page 72: ...5 28 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 5 ...

Page 73: ...ead all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers TABLE OF CONTENTS FOR APPENDIX A TITLE PAGE NO DECLARATION OF CONFORMITY A 3 ...

Page 74: ...A 2 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 75: ...A 3 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers DECLARATION OF CONFORMITY ...

Page 76: ...APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers A 4 DECLARATION OF CONFORMITY CONTINUED ...

Page 77: ...A 5 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers APPENDIX A ...

Page 78: ...A 6 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes ...

Page 79: ......

Page 80: ... of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Genuine E Z GO Parts Accessories Department or at www shopezgo com ...

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