E-Z-GO ST SPORT Owner'S Manual & Service Manual Download

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OWNER'S MANUAL

SERVICE GUIDE

GASOLINE POWERED VEHICLES

606909-GB

ISSUED OCTOBER 2007 REVISED FEBRUARY 2010

Summary of Contents for ST SPORT

Page 1: ...OWNER S MANUAL SERVICE GUIDE GASOLINE POWERED VEHICLES 606909 GB ISSUED OCTOBER 2007 REVISED FEBRUARY 2010...

Page 2: ...tions that could be hazardous Improper service or repair may damage the vehicle or render it unsafe WASH HANDS AFTER HANDLING Battery posts terminals and related accessories contain lead and lead comp...

Page 3: ...E Z GO Division and therefore is subject to change without notice The E Z GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL and the E Z GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDEN...

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: ...g 9 Winch Mounted to Vehicle 4 WINCH APPLICATIONS 4 Fig 10 Never Operate Winch with Less Than Five Turns Around Drum 5 Fig 11 Use a Nylon Sling and Install a Damper when Winching 6 Fig 12 Do Not Hook...

Page 6: ...ement 18 Fig 28 Tail and Brake Light Bulb Replacement 18 Fig 29 Tail and Brake Light Bulb Replacement 18 FUSE REPLACEMENT 18 VEHICLE WITH A DISCHARGED BATTERY 18 TRANSPORTING VEHICLE 19 TOWING 19 NEUT...

Page 7: ...Cleaner 27 LUBRICATION 29 SPARK PLUG 29 Fig 49 Lubrication Points 30 Fig 50 Gapping the Spark Plug 30 PROLONGED STORAGE 30 CAPACITIES AND REPLACEMENT PARTS 31 Fig 51 Capacities and Replacement Parts 3...

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

Page 9: ...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 Distributor or Dealer has reason...

Page 10: ...e in safe operating condition Read and observe all warnings and operation instruction labels affixed to the vehicle Follow all safety rules established in the area where the vehicle is being operated...

Page 11: ...raffic Replace damaged or missing warning caution or information labels Keep complete records of the maintenance history of the vehicle The manufacturer cannot anticipate all situations therefore peop...

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

Page 13: ...terrain and conditions However improper operation faulty maintenance or poor housekeeping may contrib ute to a condition of instability and defeat the purpose of the standard Some of the conditions w...

Page 14: ...or trailer 6 5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers 6 5 1 The user shall require battery changing and charging facilities and procedures to be in accorda...

Page 15: ...1 Personnel and Burden Carrier Operator Qualifications Only persons whoa are trained in the proper operation of the carrier shall be authorized to operate the carrier Oper ators shall be qualified as...

Page 16: ...zed speed limits Under normal traffic conditions keep to the right Maintain a safe distance based on speed of travel from a carrier or vehicle ahead and keep the carrier under control at all times 7 3...

Page 17: ...d addressed via appropriate hazardous materials regulations 7 3 4 7 Do not operate a carrier with a leak in the fuel system or battery s Battery s shall be charged and serviced per manufacturer s inst...

Page 18: ...ectional controllers limit switches protective devices electrical conductors insulators and connections shall be inspected and maintained per carrier manufacturer s recommendation p Carriers shall be...

Page 19: ...Owner s Manual and Service Guide Page xvii SAFETY INFORMATION NOTES...

Page 20: ...Owner s Manual and Service Guide Page xviii SAFETY INFORMATION NOTES...

Page 21: ...vehicle is not a toy and using it while engaging in horseplay is dangerous Plan carefully before using the vehicle to go significant distances over questionable terrain Remember that a one hour drive...

Page 22: ...damage the vehi cle must be completely stopped before moving the direc tion selector Located on the seat support panel this lever permits the selection of either F forward or R reverse Ref Fig 3 on p...

Page 23: ...d method of releasing the park brake to assure the lon gest service life of brake components COMBINATION SERVICE AND PARK BRAKE PEDAL The brake pedal incorporates a park brake feature Ref Fig 5 on pag...

Page 24: ...t five turns of cable on drum Re engage drum by turning clutch knob 90 returning it to original position Ref Fig 9 on page 4 To wind cable use handsaver bar to keep tension on the cable while activati...

Page 25: ...pacity of the winch decreases with the steepness of the slope The winch is designed for intermittent duty only The electric motor should not be allowed to become excessively hot If the motor becomes u...

Page 26: ...all winching connections Check winch attachment hook attach ment nylon sling if required and load attachment Do not pull at an angle This will cause the wire cable to pile up on one end of the winch...

Page 27: ...brake unit If wet the brakes will lose much of their effect Slow down when in unfamiliar terrain Slow down when cresting a hill in an area that you are unfamiliar with Some hills are too steep to cli...

Page 28: ...a manual dump feature A load bed warning label is affixed to the front of the bed See Appendix A For safe operation of the vehicle this label must be understood See the load bed warn ing label for ma...

Page 29: ...ot trapped by the bed TAIL GATE OPERATION To open the tail gate lift tail gate straight up with a sharp upward pull to lift out of the closed position and pivot out for open position To remove the tai...

Page 30: ...r sudden maneuver To prevent damage to rear seat be sure to move any obstructing accessories mounted to rear handrail when folding seat up or down The cargo platform is accessed by folding the rear se...

Page 31: ...y engaged and are properly secured with muzzle pointing in a safe direction before operating vehicle The gun holder is mounted to the floor of the vehicle near the accelerator pedal Ref Fig 20 on page...

Page 32: ...e park brake move direction selector to forward position turn key to OFF position and remove key Make sure that the direction selector is in correct position before attempting to start the vehicle Alw...

Page 33: ...rvice 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 igni tion c...

Page 34: ...any undesirable operating symptoms occur use gasoline with a lower percentage of alcohol or ether Use fresh regular grade unleaded fuel Ethanol blend fuel up to 10 is permissible BATTERY Excessive us...

Page 35: ...injury to operator or bystander damage to seals plastics seat material body finish or electrical system Do not use pressure in excess of 700 psi 4800 kpa to wash exterior of vehicle Clean windshield...

Page 36: ...behind each front wheel Ref Fig 24 on page 16 Cen ter the jack under the rear frame crossmember Raise the vehicle enough to place a jack stand under the outer ends of the rear axle Lower the jack and...

Page 37: ...o install the valve dust cap after checking or inflating The vehicle is fitted with low pressure tubeless tires mounted on one piece rims therefore the most cost effective way to repair a puncture in...

Page 38: ...stall replacement bulb Ref Fig 29 on page 18 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...

Page 39: ...ate motion 2 the neutral lock pin han dle so that the pointed portion of the handle is over the side of the direction selector cam Ref Fig 30 on page 19 Move direction selector lever towards the area...

Page 40: ...t 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...

Page 41: ...hardware 3 Check overall vehicle condition WEEKLY includes items listed in previous table the following TIRES 3Examine for cuts excessive wear pressure See GENERAL SPECIFICATIONS WHEELS 3 Check for b...

Page 42: ...ition and all connections DIRECTION SELECTOR 3 Check for wear and smooth movement lubricate shaft with light oil if required KING PINS 3 Check for excessive play and tightness of retaining nuts STEERI...

Page 43: ...d remove Examine the level of the oil on the dipstick Fig 34 Check Oil Level on Dipstick The engine can be operated safely as long as oil is within the safe operating range as indicated on the dip sti...

Page 44: ...ef Fig 36 on page 24 Remove the oil fill cap Fig 36 Cleaning Top of Engine Clean the area around filter Using a filter wrench strap wrench or other suitable wrench A remove the filter B from the engin...

Page 45: ...oil to enter the air filter enclosure Fig 40 Add Engine Oil Both the oil dipstick and fill cap must be in place before operat ing the engine Failure to install the dipstick and fill cap will result in...

Page 46: ...o another area of the vehicle or storage facility where it will attack the metal structure or the concrete asphalt floor Addition ally a residue will be left on the battery which is conduc tive and wi...

Page 47: ...Performance Test should be per formed regularly as an evaluation of braking system per formance It is useful as a method of identifying subtle loss of performance over time Fig 44 Preparing Acid Neut...

Page 48: ...le should stop within the normal range of stopping distances If the vehicle stops more than 4 ft 1 2 m beyond the acceptable stopping distance or pulls to one side the vehicle has failed the test and...

Page 49: ...page 29 Clean inside of cover canister and dust collector Install the element and cover the same way they were removed Be sure the positioning arrow on cover is pointing upward and all clips are faste...

Page 50: ...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 prevent possible...

Page 51: ...the Torque Specifications table Ref Fig 52 on page 32 Use care when tightening fasteners and refer to the Technician s Repair and Service Manual for specific torque values Generally three grades of h...

Page 52: ...hart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque required for dry fasteners 4 5 8 11 15 20...

Page 53: ...ATION AND SERVICE INFORMATION Page 33 Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B B N...

Page 54: ...OPERATION AND SERVICE INFORMATION Page 34 Repair and Service Manual NOTES...

Page 55: ...Page 35 GENERAL SPECIFICATIONS Owner s Manual and Service Guide GENERAL SPECIFICATIONS...

Page 56: ...p Restraint Hand Hold SEATING CAPACITY Operator 1 Passenger TOTAL LOAD CAPACITY 650 lbs 290 kg Including Operator Passenger Accessories Cargo SPEED 16 0 5 mph 25 26 5 kph STANDARD COLORS Hunter Green...

Page 57: ...ion 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 16 0 5 mph 25 26 5 kph STAND...

Page 58: ...Hand Hold SEATING CAPACITY Operator 1 Passenger TOTAL LOAD CAPACITY 800 lbs 360 kg Including Operator Passenger Accessories Cargo SPEED 16 0 5 mph 25 26 5 kph STANDARD COLORS Hunter Green DASH PANEL...

Page 59: ...ion 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 O...

Page 60: ...5 in 166 cm 35 in 89 cm Rear 38 in 96 cm Front 38 5 in 97 cm 72 in 183 cm 49 75 in 126 cm 28 75 in 73 cm ST SPORT ST 400 110 in 280 cm 77 in 196 cm Rear 38 in 96 cm Front 38 5 in 97 cm 11 5 in 29 cm...

Page 61: ...ge 41 GENERAL SPECIFICATIONS Owner s Manual and Service Guide 107 in 272 cm 65 5 in 166 cm Rear 38 in 96 cm Front 38 5 97 cm 46 5 in 118 cm ST SPORT 2 2 ST CUSTOM 76 in 193 cm 50 in 127 cm 5 in 12 7 c...

Page 62: ...e Guide GENERAL SPECIFICATIONS RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX TURNING CLEARANCE DIAMETER ST SPORT 2 2 20 5 ft 6 3 m ST CUSOTM 20 5 ft 6 3 m ST SPORT 2...

Page 63: ...Page 43 GENERAL SPECIFICATIONS Owner s Manual and Service Guide NOTES...

Page 64: ...Page 44 Owner s Manual and Service Guide GENERAL SPECIFICATIONS NOTES...

Page 65: ...Appendix A 1 LABELS AND PICTOGRAMS Owner s Manual and Service Guide LABELS AND PICTOGRAMS...

Page 66: ...Appendix A 2 Owner s Manual and Service Guide LABELS AND PICTOGRAMS NOTES...

Page 67: ...exceed 4 inches 10 cm above 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...

Page 68: ...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 BED CAPACITY DO NOT RIDE IN LOAD BED DANGER OF EXP...

Page 69: ...MINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE DO NOT DISPOSE OF BATTERIES IN LANDFILL DO NOT DRIVE ON...

Page 70: ...OUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD P N TO LEAVE AN ELECTRIC POWER...

Page 71: ...CH 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 READ OWNER S MANUAL BEFORE OPERATING...

Page 72: ...Appendix A 8 Owner s Manual and Service Guide LABELS AND PICTOGRAMS NOTES...

Page 73: ...Appendix B 1 VEHICLE WARRANTIES Owner s Manual and Service Guide VEHICLE WARRANTIES...

Page 74: ...ICLE 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...

Page 75: ...t or improper maintenance or unapproved modifications You are responsible for presenting your vehicle to E Z GO Division of Textron Inc distribution center or service center as soon as the problem exi...

Page 76: ...warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge...

Page 77: ...parts and or pressure regulator or fuel injection system Air fuel ratio feedback and control system if applicable Cold start enrichment system if applicable Air Induction System Intake manifold if app...

Page 78: ...o each subsequent owner of the engine E Z GO reserves the right to deny warranty coverage if the engine has not been properly maintained Warranty claims will not be denied however solely because of th...

Page 79: ...Appendix C 1 DECLARATION OF CONFORMITY Owner s Manual and Service Guide DECLARATION OF CONFORMITY EUROPE ONLY...

Page 80: ...Appendix C 2 Owner s Manual and Service Guide DECLARATION OF CONFORMITY...

Page 81: ...Appendix C 3 DECLARATION OF CONFORMITY Owner s Manual and Service Guide...

Page 82: ...Appendix C 4 Owner s Manual and Service Guide DECLARATION OF CONFORMITY NOTES...

Page 83: ...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 84: ...of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA UK and Europe Ransomes Jacobsen Limited Wes...

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