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E-Z-GO Express L6 - Gas, Owner'S Manual

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E-Z-GO Express L6 - Gas Owner'S Manual Download Page 7

                                                    

1 -  1

SAFETY

Read all of this manual to become thoroughly 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

Summary of Contents for Express L6 - Gas

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

Page 2: ...es 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 a...

Page 3: ...ight 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 revis...

Page 4: ...onents 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 ST...

Page 5: ...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...

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: ...amiliar 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 M...

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: ...ated 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...

Page 10: ...RAL 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...

Page 11: ...eral 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...

Page 12: ...le 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 fro...

Page 13: ...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 REP...

Page 14: ...F GRAVITY COULD RESULT IN TIP OVER LOAD CENTER OF GRAVITY MAXIMUM HEIGHT 14 25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD B...

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 NO...

Page 16: ...CTION 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...

Page 17: ...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...

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: ...ith 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...

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: ...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...

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 10...

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...

Page 24: ...r 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 CLEARA...

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...

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: ...rical 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 L...

Page 30: ...ich 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 D...

Page 31: ...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 standar...

Page 32: ...ns 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...

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: ...ion 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 Start...

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: ...t 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 obta...

Page 38: ...oper 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 r...

Page 39: ...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 vehi...

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...

Page 41: ...TIONS 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 electr...

Page 42: ...ome 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...

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: ...NT 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...

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...

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: ...mercial 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...

Page 50: ...d 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 Whe...

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 i...

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...

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...

Page 54: ...h 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 r...

Page 55: ...ion 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 han...

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 dropp...

Page 57: ...t 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 fo...

Page 58: ...s 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 bef...

Page 59: ...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...

Page 60: ...1 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 b...

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...

Page 62: ...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...

Page 63: ...hicle 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 adj...

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 conditio...

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 cove...

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 int...

Page 67: ...nt 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 a...

Page 68: ...n 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...

Page 69: ...rdware 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 OVERFIL...

Page 70: ...n 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...

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: ...ad 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 O...

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 ar...

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