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Ezgo ST SPORT 2+2, Service Manual

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Ezgo ST SPORT 2+2 Service Manual Download Page 45

Page 29

GENERAL SPECIFICATIONS

Owner’s Manual and Service Guide

Fig. 33  Vehicle Dimensions and Incline Specifications 

6 in

(15 cm)

107 in (272 cm)

49 in

(124 cm)

65.5 in (166 cm)

Rear

38 in (96 cm)

Front

38.5" (97 cm)

81.5 in

(207 cm)

46.5 in

(118 cm)

ST SPORT 2+2

RECOMMENDED MAX RAMP GRADE 

25% or 14

o

 MAX

RECOMMENDED MAX SIDE TILT

25% or 14

o

 MAX

Summary of Contents for ST SPORT 2+2

Page 1: ...ST SPORT 2 2 OWNER S MANUAL SERVICE GUIDE ...

Page 2: ...peeds encountered on a flat surface To pre vent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum speed on level ground See GENERAL SPECIFICATIONS Limit speed by applying the service brake Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessiv...

Page 3: ...nual is subject to change without notice E Z GO Division of TEXTRON Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual TO CONTACT US NORTH AMERICA TECHNICAL ASSISTANCE WARRANTY PHONE 1 800 774 3946 FAX 1 800 448 8124 SERVICE PARTS PHONE 1 888 GET EZGO 1 888 438 3946 FAX 1 800 752 6175 INTERNATIONAL PHONE 01...

Page 4: ... batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batteries must be clean fully charged and disconnected from any source of electrical drain The battery charger and...

Page 5: ...6 Accelerator Brake and Horn 3 LOAD BED 4 MANUAL LIFT BED 4 Fig 7 Manual Bed Latch 4 Fig 8 Gas Strut 4 SEATING 5 VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER 5 STORAGE 5 VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER 5 CARGO PLATFORM 5 Fig 9 Cargo Platform and Rear Compartment 5 REAR STORAGE COMPARTMENT 5 GLOVE COMPARTMENTS 5 CARGO BASKET 5 OPERATING THE VEHICLE 6 TERRAIN 6 MODIFICATIONS TO VEHICLE 6 ST...

Page 6: ...Periodic Service Schedule 15 TIRE INSPECTION 16 BRAKES 16 PERIODIC BRAKE TEST FOR MECHANICAL BRAKES 17 Fig 21 Typical Brake Performance Test 17 REAR AXLE 17 CHECKING THE LUBRICANT LEVEL 17 LUBRICATION 17 Fig 22 Add Check and Drain Axle Lubricant 18 Fig 23 Lubrication Points 18 CAPACITIES AND REPLACEMENT PARTS 18 Fig 24 Capacities and Replacement Parts 18 HARDWARE 19 Fig 25 Torque Specifications 19...

Page 7: ...Fig 33 Vehicle Dimensions andVehicle Incline Specifications 29 Fig 34 Turning Clearance Diameter 30 VEHICLE WARRANTIES 31 DOMESTIC WARRANTY 32 INTERNATIONAL WARRANTY 2005 33 DECLARATION OF CONFORMITY EUROPE ONLY 35 LABELS AND PICTOGRAMS A 1 Fig 35 Label Locations Appendix A 3 Fig 36 Pictogram Definitions Appendix A 4 Fig 37 Pictogram Definitions Appendix A 5 Fig 38 Pictogram Definitions Appendix A...

Page 8: ...Page vi Owner s Manual and Service Guide TABLE OF CONTENTS Notes ...

Page 9: ...ehicles BE OPER ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION of the product On behalf of E Z GO I am directing that E Z GO Branch personnel Distributors and Dealers advise all customers to adhere to this SAFETY RESTRICTION in connection with the use of all products new and used the ...

Page 10: ... extend the stopping distance and may reduce the stability of the vehicle Do not make any such modifications or changes The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when use...

Page 11: ...ons are smoking Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated The manufacturer cannot anticipate all situations therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damag...

Page 12: ...Owner s Manual and Service Guide SAFETY INFORMATION Page x Notes ...

Page 13: ...on which affects capacity or safe operation or make any change not in accordance with the owner s manual without the manufacturer s prior written authori zation Where authorized modifications have been made the user shall ensure that capacity operation warning and maintenance instruction plates tags or decals are changed accordingly 4 3 3 As required under paras 4 3 1 or 4 3 2 the manufacturer sha...

Page 14: ...vious experience 5 2 3 The user should include in the operators train ing program the following a instructional material provided by the manufac turer b emphasis on safety of passengers material loads carrier operator and other employees c general safety rules contained within this Standard and the additional specific rules determined by the user in accordance with this Standard and why they were ...

Page 15: ...g brakes It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit 5 5 13 Avoid running over loose objects potholes and bumps 5 5 14 To negotiate turns reduce speed to improve stability then turn hand steering wheel or tiller in a smooth sweeping motion 5 6 Loading 5 6 1 Handle only stable and safely arranged loads When handling off center loads which...

Page 16: ...luids for cleaning parts j Properly ventilate the work area k Handle LP gas cylinders with care Physical dam age such as dents scrapes or gouges may danger ously weaken the tank and make it unsafe for use l Brakes steering mechanisms speed and direc tional control mechanisms warning devices lights gov ernors guards and safety devices shall be inspected regularly and maintained in a safe operating ...

Page 17: ...vehicle is not a toy and using it while engaging in horseplay is dangerous Plan carefully before using the vehicle to go signifi cant distances over questionable terrain Remember that a one hour drive may take many hours to walk out should you run out of battery power or be strand ed by becoming stuck on unsuitable terrain Hydrogen gas is generated as a natural part of the lead acid battery chargi...

Page 18: ...over or catching the cord on the vehicle when driving away To prevent a physical hazard that could result in an electrical shock or electrocution be sure that the charger plug is not damaged and is inserted into a grounded receptacle The power AC cord is equipped with a grounded plug do not attempt to pull out cut or bend the ground post The charging DC cord is equipped with a polarized connector ...

Page 19: ...s the service brake If key switch is ON and park brake is set depressing the accelerator inadvertently will release the park brake and will cause the vehicle to move which 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 vehi cle is not driven with the park brake engaged Depress ing the accelerator peda...

Page 20: ...o the edge of a drop off such as a loading dock or ravine A misjudgment of distance or an unstable surface could result in the vehicle falling backwards Never fill a gas can in the bed of a vehicle Static discharge could ignite gasoline vapor and cause an explosion Always place a gas can on the ground before filling Never fill a gas can in the bed of the vehicle Static elec tricity is built up dur...

Page 21: ...a maxi mum load of 250 lbs 115 kg The load must be posi tioned on the platform as far forward as possible its center of gravity must not be higher than 4 10 cm above the platform and securely fastened down Failure to follow these instructions could cause personal injury damage to the vehicle and or cause the vehicle to tip over Be aware that increased loads may effect driving characteristics REAR ...

Page 22: ...d To prevent inadvertent movement when the vehi cle is to be left unattended engage the park brake move direction selector to neutral position electric powered vehicles 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 Do not t...

Page 23: ...of control is costly is considered abuse and will not be covered under warranty LABELS AND PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings Appendix A illus trates and explains pictograms that may appear on the vehicle Not all pictograms shown in Appendix A will be found on your vehicle VEHICLE CAPACITY Due to the variety of ways the vehicle may b...

Page 24: ...Facing Seat Cargo Deck 2 Persons or Cargo not to exceed 200 Lbs 90 kg Maximum Vehicle Capacity 800 lbs 360 kg Ref Lbc 2 S FIXED ROTOMOLDED BED Maximum Bed Capacity 250 lbs 115 kg Maximum Vehicle Capacity 650 lbs 290 kg ROTOMOLDED BED with Manual Dump or Optional Electric Dump Maximum Bed Capacity 500 lbs 225 kg Maximum Vehicle Capacity 800 lbs 360 kg Fig 11 Cargo Basket Ref Bsk1S Fig 12 Gun Holder...

Page 25: ...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 prod ucts designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on t...

Page 26: ... the vehicle safely Always review side effects of any medication with a doctor or pharmacist before operating vehicle Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when operating vehicle in rough or densely wooded terrain When driving at full speed on a dirt road loose surfaces or wet grass vehicle stopping distance will increase If the vehicle i...

Page 27: ...stability of the vehicle on the two jack stands Place the jack at the center of the front axle Raise the vehicle enough to place jack stands under the frame crossmember as indicated Lower the jack and test the stability of the vehicle on all four jack stands If only the front or rear of the vehicle is to be raised place the chocks in front and behind each wheel not being raised to stabilize the ve...

Page 28: ...r a puncture in the tread is to use a commercial tire plug Tire plug tools and plugs are available at most automotive parts outlets and have the advan tage of not requiring the tire be removed from the wheel If the tire is flat remove the wheel and inflate the tire to the maximum recommended pressure for the tire Immerse the tire in water to locate the leak and mark with chalk Insert tire plug in ...

Page 29: ...all replacement bulb and replace lens To replace the tail and brake light bulb remove hardware securing lens and remove lens Install replacement bulb See Tail and Brake Light Bulb Replacement on page 13 FUSE REPLACEMENT To replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new auto motive type fuse Headlight and taillight bulbs and fuses are availab...

Page 30: ...rminal before servicing The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physician immediately Any electrolyte spills should be neutralized with a solution of 2 teaspoons 10 ml sodium bicarbon ate baking soda dissolved in 1 quart 1 liters of water an...

Page 31: ...ut not described in this manual contact a local Service Representa tive 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 service brake general operation Check park brake function Check warning device function in reverse Check tire condition Check overall vehicle...

Page 32: ... for loose hardware cracks at attachments FRONT WHEEL ALIGNMENT Check for unusual tire wear align if required PARK BRAKE Check for bent binding linkage rod Check for damage or wear to latch arm or catch bracket Lubricate as required use light oil DO NOT LUBRICATE CABLES OR BRAKE LATCH REAR SHOCK ABSORBERS Check for oil leakage loose mounting hardware HARDWARE AND FASTENERS Check for loose or missi...

Page 33: ...lock Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched The vehicle should stop within the normal range of stopping distances If the vehicle stops more than 4 ft 1 2 m beyond the accept able stopping distance or pulls to one side the vehicle has failed the test and should be tested again If the vehicle fails the second tes...

Page 34: ...CEMENT PARTS Fig 22 Add Check and Drain Axle Lubricant Fig 23 Lubrication Points Check Fill Plug Ref Raf 1 Steering Unit Ball Joint on Rack and Rod King Pin King Pin Idler Arm View From Underside Of Vehicle Ref Lub 4S Fig 24 Capacities and Replacement Parts Rear Axle Oil Fuse Headlight Sealed Beam Turn Signal Light Tail Light Bulb 40 oz 1 2 liters 15 amp P N 18392 G1 P N 20209 G2 P N 19180 G2 1157...

Page 35: ...Unmarked hardware is Grade 2 Ref Fig 25 on page 19 Fig 25 Torque Specifications 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 approximat...

Page 36: ...with extreme care Insulate metal con tainer to prevent can from contacting battery termi nals which could result in an explosion Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from shorting out a battery which could result in an explosion and severe personal injury or death BATTERY A battery is defined as two dissimilar metals immersed in an acid If the acid is absent...

Page 37: ...c acid droplets will be carried out of the battery vents by the hydrogen gas however this loss is minimal If the battery electrolyte level is too high the electrolyte will block the vent tube and the gas will force it out of the vent tube and battery cap The water will evaporate but the sulfuric acid will remain where it can damage vehicle components and the storage facility floor Sulfuric acid lo...

Page 38: ... from the battery The correct cleaning technique is to spray the top and sides of the batteries with a solution of sodium bicarbon ate baking soda and water This solution is best applied with a garden type sprayer equipped with a non metallic spray wand or plastic spray bottle The solution should consist of the ingredients shown in the illustration Ref Fig 29 on page 22 In addition special attenti...

Page 39: ... protected from damage and is located in an area to prevent injury that may result from personnel running over or tripping over the cord set The charger is automatically turned off during the connect disconnect cycle and therefore no electri cal arc is generated at the DC plug receptacle contacts AC VOLTAGE Battery charger output is directly related to the input volt age If multiple vehicles are r...

Page 40: ...icle has been operated USING A HYDROMETER 1 Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and note the reading Examine the color of the electrolyte A brown or gray coloration indicates a problem with the battery and is a sign that the bat tery is nearing the end of its life 2 Draw the minimum quantity of electrolyte into the h...

Page 41: ...specific gravity and there fore the state of charge of a battery In winter conditions the battery must be fully charged to prevent the possibility of freezing Ref Fig 33 on page 25 A fully charged battery will not freeze in tempera tures above 75 F 60 C Although the chemical reac tion is slowed in cold temperatures the battery must be stored fully charged and disconnected from any circuit that cou...

Page 42: ...OPERATION AND SERVICE INFORMATION Page 26 Owner s Manual and Service Guide Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings ...

Page 43: ...Page 27 GENERAL SPECIFICATIONS Owner s Manual and Service Guide GENERAL SPECIFICATIONS ...

Page 44: ...Shock Absorbers STEERING Single Reduction Rack Pinion STEERING WHEEL Dual Handgrips Pencil Holder Clipboard SEATING Cushion Foam Vinyl Cover Hip Restraint Hand Hold SEATING CAPACITY Operator 3 Passengers TOTAL LOAD CAPACITY 800 lbs 360 kg Including Operator Passenger Accessories Cargo SPEED 12 14 mph 19 23 kph STANDARD COLORS Hunter Green DASH PANEL Scuff Resistant Glass Fiber Reinforced Plastic T...

Page 45: ... Fig 33 Vehicle Dimensions and Incline Specifications 6 in 15 cm 107 in 272 cm 49 in 124 cm 65 5 in 166 cm Rear 38 in 96 cm Front 38 5 97 cm 81 5 in 207 cm 46 5 in 118 cm ST SPORT 2 2 RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX ...

Page 46: ...Page 30 Owner s Manual and Service Guide GENERAL SPECIFICATIONS Fig 34 Turning Clearance Diameter TURNING CLEARANCE DIAMETER ST SPORT 2 2 20 5 ft 6 3 m ...

Page 47: ...Page 31 Owner s Manual and Service Guide VEHICLE WARRANTIES VEHICLE WARRANTIES ...

Page 48: ...CLE WARRANTIES DOMESTIC WARRANTY U S AND CANADA 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 manufacturer date code ...

Page 49: ...ILITY OR FITNESS FOR A PARTICULAR PURPOSE E Z GO WILL FURTHER DISCLAIM ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES TO INCLUDE BUT NOT BE LIMITED TO PERSONAL INJURY OR PROPERTY DAMAGE ARISING FROM ANY DEFECT IN THE VEHI CLE BATTERY CHARGER No agent employee or representative of E Z GO or any person has any authority to bind E Z GO to any other agree ment representation or warranty concern...

Page 50: ...Page 34 Owner s Manual and Service Guide VEHICLE WARRANTIES Notes ...

Page 51: ...e Guide DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY EUROPE ONLY Declaration of Conformity is packaged with vehicle For additional information contact Ransomes Jacobsen Limited West Road Ransomes Europark Ipswich England IP3 9TT ...

Page 52: ...Page 36 Owner s Manual and Service Guide DECLARATION OF CONFORMITY Notes ...

Page 53: ...Appendix A 1 LABELS AND PICTOGRAMS Owner s Manual and Service Guide LABELS AND PICTOGRAMS ...

Page 54: ...Appendix A 2 Owner s Manual and Service Guide LABELS AND PICTOGRAMS Notes ...

Page 55: ...Appendix A 1 LABELS AND PICTOGRAMS Owner s Manual and Service Guide LABELS AND PICTOGRAMS ...

Page 56: ...Appendix A 2 Owner s Manual and Service Guide LABELS AND PICTOGRAMS Notes ...

Page 57: ...ve the bed floor The load must be as far forward as possible and secure Top heavy loads may cause vehicle instability or tip over Drive slowly straight up and down slopes and in turns Do not permit anyone to ride on the platform when used as a load bed FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY 71093G01 71093G01 Maximum weight in basket is 25 lbs 11 kg Excess weight ...

Page 58: ... 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 13 KEEP HANDS FINGERS AWAY FROM DUMP BED DO NOT STAND BEHIND DUMP BED 14 14 25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL 9 DO NOT RIDE IN LOAD BED 11 LOAD WITH HIGH CENTER OF GRAVITY COULD RESULT IN TIP OVER 7 MAX xxxlbs xxxk...

Page 59: ...L FUEL ON A HOT ENGINE 23 NO TAMPERING KEEP HANDS OUT 21 DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND 22 SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION 24 WARNING CORROSIVE 25 WARNING EXPLOSIVE 19 LOW OIL PRESSURE 20 NEGATIVE GROUND BATTERY DO NOT DISPOSE OF BATTERIES IN LANDFILL 28 DO NOT DRIVE ON HIGHWAY 29 WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS 30 BATTERIES ARE HEAVY US...

Page 60: ...UDIBLE DEVICE WILL SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY 39 P F TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD 40 P N TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO NEUTRAL 41 ON ON POSITION 43 OFF OFF POSITION 44 HEADLIGHTS 45 UNLOCKED 46 LOCKED 47 DIF...

Page 61: ...WITCH TO UNLOCK DIFFERENTIAL 58 REAR DIFFERENTIAL LOCK SWITCH 59 FRONT DIFFERENTIAL LOCK SWITCH WARNING READ OWNER S MANUAL BEFORE ENGAGING FRONT DIFFERENTIAL LOCK DO NOT ENGAGE LOCK WHILE FRONT WHEELS ARE TURNED AND VEHICLE IS AT SPEED 60 PUSH TOP PART OF SWITCH TO RAISE LOAD BED PUSH BOTTOM PART OF SWITCH TO LOWER LOAD BED 61 55 WARNING READ OWNER S MANUAL BEFORE PARKING VEHICLE AND LEAVING IT U...

Page 62: ...Appendix A 8 Owner s Manual and Service Guide LABELS AND PICTOGRAMS Notes ...

Page 63: ...components will eventually fail to perform properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and there fore should be considered potentially hazardous Use extreme care w...

Page 64: ...tions Department P N 602560 ISSUED APRIL 2005 E Z GO Division Of Textron Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 TO CONTACT US North America Technical Assistance Warranty Phone 1 800 774 3946 FAX 1 800 448 8124 Service Parts Phone 1 888 GET EZGO 1 888 438 3946 FAX 1 800 752 6175 International Phone 010 1 706 798 4311 FAX 010 1 706 771 4609 ...

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