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Textron EZGO Workhorse ST 350, Owner'S Manual And Service Manual

Get your hands on the Textron EZGO Workhorse ST 350 Owner's Manual and Service Manual for free download. This comprehensive manual provides all the information you need to properly maintain and operate your vehicle. Visit our website to download it now and keep your Workhorse running smoothly.

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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. 44  Capacities and Replacement Parts

Fuel Tank / Fuel

6.0 gal (22.5 liters) 87 Octane

1 1/2 qt (1.4 liters)

40 oz (1.2 liters)

15 amp (P/N 18392-G1) ST Sport

15 amp (P/N 35212-G01) ST 350

P/N 20209-G3

#1157 (P/N 21759-G1)

P/N 26591-G01

P/N 28463-G01 Canister Filter

NGK BPR5ES (P/N 25523-G4)

.020 - .030" (.71 - .76 mm) Gap

P/N 26414-G01

P/N 72328-G01

Engine Oil

Rear Axle Oil

Fuse

Headlight Bulb

Turn Signal Bulb

#1157 (P/N 21759-G1)

Tail Light Bulb

Oil Filter

Air Filter

Spark Plugs

Starter/Generator Belt

Clutch Belt

Summary of Contents for EZGO Workhorse ST 350

Page 1: ...OWNER S MANUAL SERVICE GUIDE Starting Model Year 2003 R...

Page 2: ...hat 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 t...

Page 3: ...manual is subject to change without notice Textron Golf Turf Specialty Products is not liable for errors in this manual or for incidental or consequential damage that result from the use of material...

Page 4: ...tory specifications will void the vehicle warranty When servicingengines all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States o...

Page 5: ...1 Choke 3 9 FUEL GAUGE 3 9 LOW OIL PRESSURE INDICATOR LIGHT 3 9 ACCELERATOR PEDAL 3 10 Fig 12 Accelerator and Brake Controls 3 10 COMBINATION BRAKE AND PARK BRAKE PEDAL 3 10 HORN 3 10 Fig 13 Horn Butt...

Page 6: ...Lubricant Level 3 33 Fig 35 Add Check and Drain Rear Axle Lubricant 3 33 STARTER GENERATOR BELT TENSION 3 33 Fig 36 Checking Belt Tension with Gauge 3 34 Fig 37 Checking Belt Tension Manually 3 34 Ad...

Page 7: ...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 St...

Page 8: ...er 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 pr...

Page 9: ...nch or the Ser vice Parts Department When ordering parts or requesting information for your vehicle provide vehicle model serial number and manufacture date code BEFORE INITIAL USE Read understand and...

Page 10: ...ompartment and cargo in the load bed Never carry passengers in the load bed The total payload of the ST 350 is 800 lbs 363 kg and the ST SPORT is 650 lbs 295 kg The weight of the driver and passenger...

Page 11: ...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...

Page 12: ...on ST SPORT Read understand and follow all of the following informa tion on the operation and use of winch before attempting to operate it OPERATION OF THE WINCH The winch can be mounted at the front...

Page 13: ...erator 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...

Page 14: ...alls 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...

Page 15: ...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...

Page 16: ...e fuel gauge low oil pressure indicator light accelerator pedal combination service and park brake pedal horn KEY LIGHT SWITCH Located on the dash panel this switch enables the basic electrical sys te...

Page 17: ...ns on using the choke properly FUEL GAUGE The fuel gauge if equipped will either be located on the dash panel electric Ref Fig 9 on page 3 8 or directly on the fuel tank mechani cal LOW OIL PRESSURE I...

Page 18: ...ause 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 vehicle is not driven wi...

Page 19: ...bed Do not drive the vehicle with the load bed raised or with the tailgate unsupported When using the electric lift on the ST 350 be sure to avoid backing up to the edge of a drop off such as a loadi...

Page 20: ...at 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...

Page 21: ...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...

Page 22: ...ng the service brake pedal until the park brake releases Slowly depress the accelerator pedal to start the engine Release service brake when engine starts When the accelerator pedal is released the ig...

Page 23: ...ondition The fuel tank is located under the seat on the passenger side of the vehicle Ref Fig 16 on page 3 15 Fill the tank with fresh clean auto motive grade gasoline Ref Fig 44 on page 3 40 High alt...

Page 24: ...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...

Page 25: ...ercial 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 w...

Page 26: ...rpose 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 p...

Page 27: ...otation when moving forward Tire condition should be inspected per the Periodic Service Schedule Ref Fig 24 on page 3 26 Inflation pressures should be checked when the tires are cool Be sure to instal...

Page 28: ...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 mo...

Page 29: ...hile removing two screws securing lens Ref Fig 20 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 an...

Page 30: ...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 on the direction selector...

Page 31: ...perate 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 usin...

Page 32: ...esigned 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...

Page 33: ...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 T...

Page 34: ...s missing or loose lug nuts FUEL GAUGE Check for proper operation at fueling and fuel cap vent is free of dirt ENGINE OIL Check and add if required DO NOT OVERFILL STARTER GENERATOR BELT Check for ten...

Page 35: ...acks 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 s...

Page 36: ...he tank off the filter first and plug Then twist and pull filter out of the hose from the fuel pump and discard Orient direction of new fuel filter according to the FLOW arrow on the side of filter In...

Page 37: ...ee cloth Ref Fig 25 on page 3 29 Insert the dipstick fully into the dipstick hole and remove Examine the level of oil on the dipstick The engine can be operated safely as long as oil is within the saf...

Page 38: ...nd the filter Oil drainage is accomplished by removing the three bolts securing the oil filter to the engine Remove the filter by pulling it from the engine and allow the oil to drain The O rings may...

Page 39: ...he filter should slide easily onto the nipple and seat against the engine using light hand pressure only Align the holes in the filter mounting plate with the holes in the engine Install and hand tigh...

Page 40: ...f oil level is below the safe area indicated on the dipstick 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 fai...

Page 41: ...ck is sufficient Checking the Lubricant Level Tool List Qty Required Socket 13 mm 3 8 drive 1 Ratchet 3 8 drive 1 Funnel 1 Clean the area around the check and fill plugs Remove the check plug The corr...

Page 42: ...ng the same technique and inspect for cracking or wear A maximum deflec tion of 1 2 13 mm is acceptable Adjusting the Belt Loosen the starter generator pivot bolt While holding the lower adjusting nut...

Page 43: ...d 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...

Page 44: ...ve 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...

Page 45: ...eight accessories installed and vehicle 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 incl...

Page 46: ...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 pre...

Page 47: ...Grade 2 Ref Fig 43 on page 3 39 Fig 43 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 te...

Page 48: ...ank Fuel 6 0 gal 22 5 liters 87 Octane 1 1 2 qt 1 4 liters 40 oz 1 2 liters 15 amp P N 18392 G1 ST Sport 15 amp P N 35212 G01 ST 350 P N 20209 G3 1157 P N 21759 G1 P N 26591 G01 P N 28463 G01 Canister...

Page 49: ...ody 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 Ho...

Page 50: ...OTECTION 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...

Page 51: ...4 3 GENERAL SPECIFICATIONS Fig 1 Vehicle Dimensions for ST 350 12 31 cm 32 81 cm 6 15 cm 110 5 281 cm 49 125 cm 48 122 cm 77 196 cm 40 102 cm Front 38 96 cm Rear 38 5 97 cm 76 193 cm...

Page 52: ...4 4 GENERAL SPECIFICATIONS Fig 2 Vehicle Dimensions for ST Sport 10 25 cm 32 81 cm 6 15 cm 103 260 cm 49 124 cm 46 5 118 cm 65 5 166 cm 35 89 cm Front 38 96 cm Rear 38 5 97 cm 76 193 cm...

Page 53: ...4 5 GENERAL SPECIFICATIONS Fig 3 Vehicle Incline Specifications Maximum Recommended Side Tilt 25 or 14 Max o Maximum Recommended Ramp Grade 25 or 14 Max o...

Page 54: ...ning Clearance Diameter and Intersecting Aisle Clearance TURNING CLEARANCE DIAMETER ST 350 Approx 23 5 ft 7 2 m ST SPORT Approx 20 5 ft 6 25 m ST 350 83 211 cm ST SPORT 78 198 cm INTERSECTING AISLE CL...

Page 55: ...iii Ignitor Complete iv Pulser Coil 4 Exhaust Manifold 5 Miscellaneous Items Used in Above Systems i Fuel Hoses clamps and sealing gaskets OBTAINING WARRANTY SERVICE To obtain warranty service take yo...

Page 56: ...MISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OF INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DEALER OR SERVICE CENTER AUTHORIZED BY TGT SP THE USE OF...

Page 57: ...eglect improper maintenance or unapproved modifications You are responsible for presenting your engine to a dealer distributor or warranty station authorized by TEXTRON Golf Turf Specialty Products Au...

Page 58: ...or modified parts This warranty does not cover any part which malfunctions fails or is damaged due to alterations by changing adding to or removing parts from the engine 3 Expenses incurred by process...

Page 59: ...Ignition Coil iii Ignitor Complete iv Pulser Coil 4 Exhaust Manifold 5 Miscellaneous Items Used in Above Systems i Fuel hoses clamps and sealing gaskets I MAINTENANCE STATEMENTS It is your responsibi...

Page 60: ...5 6 LIMITED WARRANTY Notes...

Page 61: ...inschlie lich aller nderungen und Erg nzungen sowie den Vorschriften die diese in das nationale Recht umsetzen entspricht soddisfa quanto previsto dalle seguenti direttive ed emendamenti europei e dal...

Page 62: ...6 2 DECLARATION OF CONFORMITY Notes...

Page 63: ...elerator While Releasing Service Brake As Vehicle Starts 74443G01 See Following Pages For Explanation Of These Pictograms 19 43 44 45 OFF ON 71131 G01 71131G01 See Following Pages For Explanation Of T...

Page 64: ...ER 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 This Label Is Located On Governor Cover...

Page 65: ...INCLEMENT WEATHER WARNING DO NOT OPERATE IF USING ALCOHOL OR DRUGS MAX 14 25 MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED 14 25 WARNING MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED LOAD WITH HIGH CENTER...

Page 66: ...AR 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 x in xx cm xx cm MAX LOAD MAX LOAD XXX LBS XXX LBS XXX KG XXX KG W...

Page 67: ...D 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...

Page 68: ...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 S...

Page 69: ...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 SMO...

Page 70: ...ndix 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...

Page 71: ......

Page 72: ...ission of Textron Golf Turf Specialty Products Technical Communications Department Textron Golf Turf Specialty Products P O Box 388 Augusta Georgia 30903 0388 USA Inside USA Phone 1 800 241 5855 FAX 1...

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