E-Z-GO 602080 Owner'S Manual And Service Manual Download

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602080

REVISED DATE:

JAN

. 200

Summary of Contents for 602080

Page 1: ...TM 602080 REVISED DATE JAN 2007...

Page 2: ...w Consider the terrain and traffic conditions Consider environmental factors which effect the terrain and the ability to control the vehicle Avoid driving fast down hill Sudden stops or change of dire...

Page 3: ...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...

Page 4: ...e governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle sp...

Page 5: ...4WD SELECTOR 5 Fig 7 2WD 4WD Selector 5 DIFFERENTIAL LOCK 5 Fig 8 Differential Lock 5 ACCELERATOR 6 Fig 9 Accelerator Pedal 6 FUEL 6 FUEL GAUGE 6 Fig 10 Fuel Tank and Gauge 7 LOW OIL PRESSURE INDICATO...

Page 6: ...and Level Check 18 OIL CHANGE 18 Fig 26 Oil Change 18 OIL FILTER CHANGE 18 Fig 27 Oil Filter Change 19 SPARK PLUGS 19 ALTERNATOR BELT 19 ADJUSTING BELT 19 Fig 28 Adjusting Alternator Belt 20 AIR CLEAN...

Page 7: ...HYDRAULIC BRAKES 27 CAPACITIES 27 Fig 40 Capacities 27 HARDWARE 28 Fig 41 Torque Specifications and Bolt Grades 28 GENERAL SPECIFICATIONS 29 Fig 42 Vehicle Dimensions 31 Fig 43 Vehicle Incline Specifi...

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

Page 9: ...se of the material in this manual This vehicle conforms to the current applicable standard s for safety and performance requirements These vehicles are designed and manufactured for off road use They...

Page 10: ...rmine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle Support the vehicle using...

Page 11: ...from accumulating Never fuel a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane water heaters and furnaces Never work around or operate a vehicl...

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

Page 13: ...warning pedestrians and vehicle operators of traffic conditions and to use cau tion B 1 1 1 4 The controlling party shall train vehicle operators to adhere strictly to the operating instructions state...

Page 14: ...Interlocks B 1 1 8 1 The controlling party shall make periodic inspections of the vehicle to be certain that the safety interlock system if so equipped is operating properly B 2 Operating Safety Rule...

Page 15: ...vement Avoid loads which cannot be centered B 2 4 3 Transport only loads within the gross vehicle weight capacity B 2 4 4 Avoid material loads exceeding the physical dimensions of the vehicle or as sp...

Page 16: ...vices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved oper ating features n Fuel systems shall be checked for leaks and...

Page 17: ...death do not use vehicle improperly such as engaging in horseplay or attempt ing to perform tasks for which it is not designed This vehicle is a utility vehicle It is NOT a toy or an all terrain vehi...

Page 18: ...rresponsibly If vehicle is operated improperly and or irresponsibly severe injury or death to operator passenger or bystand ers can occur All operators should possess a valid driver s license Children...

Page 19: ...ghtly and push in release button at end of handle then fully lower park brake handle CHOKE Starting a cold engine may require use of choke To use pull choke knob out and hold while starting engine Ref...

Page 20: ...ion the differential lock sole noid s will be activated Ref Fig 6 on page 4 and Ref Fig 8 on page 5 Over time the solenoids will drain the battery to a point where the vehicle will be unable to be sta...

Page 21: ...ring wheel to center causing loss of grip on wheel Front and rear differentials are equipped with electrically actuated locks Ref Fig 8 on page 5 With a differential unlocked if one tire looses tracti...

Page 22: ...o not smoke near the fuel tank Do not refuel near open flame or electrical items including cellular phones which could produce a spark Never fill a gas can in the bed of a vehicle Static discharge cou...

Page 23: ...do not operate engine until oil pressure is corrected Do not overfill engine Too much oil may cause smoking or allow oil to enter air filter enclosure If oil level is below ADD mark on dipstick add oi...

Page 24: ...vehicle on a hill Release park brake while depressing accelerator with right foot and release the service brake by lifting left foot COASTING To reduce possibility of severe injury or death from coas...

Page 25: ...ull handle up with one hand to release and lift bed with other hand Ref Fig 14 on page 9 A gas strut located underneath will assist in raising bed when empty and will keep it raised when empty Over ti...

Page 26: ...d take precautions to protect yourself your passenger and any bystanders When pulling vehicle with winch pull straight only Do not permit cable to contact side of drum WINCH MOUNTING Winch can be moun...

Page 27: ...um or cable under tension Unplug winch remote control before working on winch drum in order to prevent inadvertent opera tion Take up slack in cable slowly Stop winch before cable becomes tight and in...

Page 28: ...de of vehicle while it is moving TRANSPORTING VEHICLE TOWING This vehicle is not designed to be towed It is recommended that vehicle be moved by placing entire vehicle on a trailer flatbed truck or ot...

Page 29: ...wed on a trailer is 1500 lbs 680 kg OPENING THE COWL HOOD To lift cowl Ref Fig 20 on page 13 Pull down and out on both latches to clear receiv ers mounted to frame Lift cowl up fully to allow catch to...

Page 30: ...itself off when supported by only two jack stands It is in the best interest of both vehicle owner and service technician to carefully follow procedures recommended in this manual Preventative mainte...

Page 31: ...X Rotors Drums Clean X Park Brake Clean X X Tires Check X X Overall Vehicle Condition Check X Wheels Check X Fuel Gauge Check X Alternator Belt Check X Engine Fan and Cooling Fins Clean X CVT Enclosu...

Page 32: ...EXTRON Inc 1451 Marvin Griffin Road Augusta Georgia USA 30906 3852 ITEM BEFORE EACH USE WEEKLY EVERY 20 HOURS EVERY 50 HOURS EVERY 100 HOURS EVERY 200 HOURS EVERY 300 HOURS EVERY 500 HOURS Tie Rods Li...

Page 33: ...tial cases Do not operate engine with 4 wheel drive or either differential locks engaged Never operate engine with CVT drive belt removed Some servicing operations may require entire vehicle to be rai...

Page 34: ...y set park brake and wait a minute for oil to settle Lift seat wipe oil fill cap clean with a cloth and remove fill cap Ref Fig 25 on page 18 Place drain pan under engine Remove drain plug from base o...

Page 35: ...ntribute If reusing spark plugs clean with wire brush Check gap Gap should measure 028 031 70 80 mm If necessary adjust gap being careful not to dam age plug If replacing spark plugs use only recommen...

Page 36: ...ce possibility of an explosion do not smoke near fuel tank or in an area where gasoline is being handled Do not perform procedures involving fuel system near open fire or electrical items which could...

Page 37: ...Unless equipped with optional high output alternator the vehicle uses a charge coil to charge battery Battery is charged while engine is running Do not operate acces sory items such as accessory ligh...

Page 38: ...ery which should also be sprayed with solution Allow solution to sit for at least three min utes Use a soft bristle brush or cloth to wipe battery removing any residue that could contribute to self di...

Page 39: ...ervice Parts Department Touch up paint specially formulated to match vehi cle colors for use on both metal and molded plas tic bodies P N 28140 G and 28432 G for solid colors 75831 G for camouflage co...

Page 40: ...e Under no condition should inflation pressure be higher than maximum pressure listed on sidewall of tire All four tires should have the same pressure for opti mum handling characteristics Use caution...

Page 41: ...sits from arrester screen without damaging screen Screen must be intact Replace spark arrester if screen is breached Install arrester on muffler and secure with screw PROLONGED STORAGE To reduce possi...

Page 42: ...threaded hole If lubricant is to be added use a funnel and add correct type lubricant slowly until it starts to seep from hole See Checking Axle Lubricant on page 26 Install plug and tighten to 18 ft...

Page 43: ...Ref BRAKES on page 27 Master cylinder is located under cowl When checking fluid wipe off any dirt from fill cap before removing it to reduce possibility of contamination Fluid level should be maintai...

Page 44: ...s Grade 2 Fig 41 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 text tighten all hardwar...

Page 45: ...Page 29 GENERAL SPECIFICATIONS Owner s Manual and Service Guide GENERAL SPECIFICATIONS...

Page 46: ...mm Disc Brakes BRAKES REAR Dual Rear Wheel Hydraulic 6 3 160 mm Drum Brakes PARK BRAKE Hand Operated Lever with Indicator Light FRONT SUSPENSION Independent with Hydraulic Struts REAR SUSPENSION Leaf...

Page 47: ...8 3 8 21 3 cm Clearance At Lowest Point Of Vehicle On Rear Axle 31 5 80 cm 54 137 cm 50 127 cm 11 28 cm Inside 11 1 2 29 cm 12 3 4 32 cm 18 1 4 46 cm 9 1 2 24 cm Clearance At Lowest Point On Frame Ref...

Page 48: ...Page 32 Owner s Manual and Service Guide GENERAL SPECIFICATIONS Fig 44 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance TURNING CLEARANCE DIAMETER Approx 25 6 7 8 m Ref Dim 3 3...

Page 49: ...Page 33 Owner s Manual and Service Guide VEHICLE WARRANTIES VEHICLE WARRANTIES...

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

Page 51: ...nd Obligations Refer to the HONDA Emission Control System Warranty sheet provided with vehicle for information ENGINE OWNER WARRANTY POLICY Refer to the Warranty sheet provided with vehicle for Engine...

Page 52: ...Page 36 Owner s Manual and Service Guide VEHICLE WARRANTIES Notes...

Page 53: ...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 Ransome...

Page 54: ...Page 38 Owner s Manual and Service Guide DECLARATION OF CONFORMITY 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: ...See Following Pages For Explanation Of These Pictograms 61 45 62 63 See Following Pages For Explanation Of These Pictograms 43 44 51 73767G01 73771G01 See Following Pages For Explanation Of These Pic...

Page 58: ...NING USE CAUTION IN INCLEMENT WEATHER MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED WARNING MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED LOAD WITH HIGH CENTER OF GRAVITY COULD RESULT IN TIP OVER LOAD CENTE...

Page 59: ...GINE GROUND FUEL PUMP LOW OIL PRESSURE NEGATIVE GROUND BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION NO TAMPERING KEEP HANDS OUT WARNING COR...

Page 60: ...ION 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 SE...

Page 61: ...NEUTRAL REVERSE WARNING READ OWNER S MANUAL BEFORE ENGAGING TWO OR FOUR WHEEL DRIVE PUSH TOP OF SWITCH TO LOCK DIFFERENTIAL PUSH BOTTOM OF SWITCH TO UNLOCK DIFFERENTIAL FRONT DIFFERENTIAL LOCK SWITCH...

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

Page 63: ...reated with the utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools list...

Page 64: ...ent StartingModel Year 2005 P N 602080 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 Warrant...

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