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Repair and Service Manual
GENERAL INFORMATION AND ROUTINE MAINTENANCE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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TRANSPORTING VEHICLE
Towing
This vehicle is not designed to be
towed.
It is recommended that the vehicle be moved by placing
the entire vehicle on a trailer, flatbed truck or other
suitable transport.
Hauling
To reduce the possibility of severe
injury or death while transporting
vehicle:
Secure the vehicle and contents.
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 and the seat bottom secured
(See SUN TOP on page 121). When transporting vehicle
below highway speeds, check for tightness of hardware
and cracks in sun top at mounting points. Always remove
windshield when transporting (See SPILT WINDSHIELD
on page 123). Always check that the vehicle and contents
are adequately secured before transporting. The rated
capacity of the trailer or truck must exceed the weight of
the vehicle and load plus 1000 lbs. (454 kg) (See GEN-
ERAL SPECIFICATIONS on page 155). Lock the park
brake and secure the vehicle using ratchet tie downs.
SERVICING THE ELECTRIC VEHICLE
To prevent severe injury or death,
resulting from improper servicing
techniques, observe the following
Warnings:
Do not attempt any type of servicing
operations before reading and
understanding all notes, cautions and
warnings in this manual.
Any servicing requiring adjustments to be
made to the powertrain while the motor is
running must be made with both drive
wheels raised.
Wear eye protection
when working on the
vehicle. In particular,
use care when working
around batteries, or
using solvents or
compressed air.
To reduce the possibility of causing an
electrical arc, which could result in a battery
explosion, turn off all electrical loads from
the batteries before removing any heavy
gauge battery wires.
To prevent the possibility of motor
disintegration, never operate vehicle at full
throttle for more than 4 - 5 seconds while
vehicle is in a “no load” condition.
It is in the best interest of both vehicle owner and servic-
ing dealer to carefully follow the procedures recom-
mended in this manual. Adequate preventive
maintenance, applied at regular intervals, is the best
guarantee for keeping the vehicle both dependable and
economical.
Before a new vehicle is put into operation, it is recom-
mended that the items shown in the INITIAL SERVICE
CHART be performed (Ref Fig. 3).
Vehicle batteries must be fully charged before initial use.
Fig. 3 Initial Service Chart
ROUTINE MAINTENANCE
NOTICE: Some maintenance items must be serviced
more frequently on vehicles used under severe driv-
ing conditions.
This vehicle will give years of satisfactory service
provided it receives regular maintenance. Refer to the
Periodic Service Schedule for appropriate service inter-
vals (Ref Fig. 5). Refer to Lubrication Point for
appropriate lubrication location (Ref Fig. 4).
Fig. 4 Lubrication Points
Do not use more than three pumps
of grease for 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 fit-
ting could damage grease seals and cause premature
bearing failure.
ITEM
SERVICE OPERATION
Batteries Charge
batteries
Seats
Remove protective plastic covering
Brakes
Check operation and adjust if necessary
Establish acceptable stopping distance
Check hydraulic brake fluid level
Tires
Check air pressure (see SPECIFICATIONS)
Portable
Remove from vehicle and properly mount
Charger
Rack
Ball
Joint
PRELIMINARY
