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MAINTENANCE

Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers.

CAPACITIES AND REPLACEMENT PARTS

HARDWARE

Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the
Torque Specifications table.

Use care when tightening fasteners and refer to the Technician’s Repair and Service Manual for specific torque values.

Generally, three grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on
the hexagonal head and grade 8 hardware is identified by 6 marks on the head. Unmarked hardware is Grade 2.

Fuel Tank / Fuel

Engine Oil

Oil Filter

Air Filter

Spark Plug

Starter/Generator Belt

Clutch Belt

Rear Axle Oil

Fuse

LED Bulb

Headlight Bulb

Turn Signal Bulb

6.0 gal (22.5 liters) / 87 Octane Min.

1.4 US qt (1.3 liters)

51 oz (1.5 liters) / SAE 30

2 oz (60 mL) (P/N 625753)

15 amp (P/N 18392-G1)

(P/N 619101)

(P/N 619100)

(P/N 619102)

P/N 26591-G01

P/N 28463-G01

NGK BPR2ES (P/N 25523-G3)

.020 - .030" (.71 - .75 mm) Gap

P/N 606138

P/N 606136

#1157 (P/N 21759-G1)

Tail Light Bulb

Friction Modifier (Rear Axle)

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"

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 approximately 80% of the torque required for 'dry' fasteners.

(5)

(11)

(20)

(33)

(47)

(75)

(102)

130

(176)

125

(169)

190

(258)

Grade 5

Grade 8

(8)

(18)

(31)

(47)

(75)

(108)

110

(149)

200

(271)

320

(434)

480

(651)

(8)

(24)

(47)

(75)

(108)

110

(149)

170

(230)

280

(380)

460

(624)

680

(922)

BOLT SIZE

Class 5.8
(Grade 2)

M10

M12

M14

(2)

(3)

(6)

(14)

(27)

(47)

(76.4)

Class 8.8
(Grade 5)

(3)

(6)

(10)

(24)

(47)

(83)

(131)

Class 10.9
(Grade 8)

(4)

(8)

(14)

(34)

(66)

(117)

136

(184)

5.8

8.8

10.9

Содержание 2012 EXPRESS L4

Страница 1: ...622022 Owner s Guide ISSUED JULY 2011 REVISED AUGUST 2012...

Страница 2: ...es in controls will be illustrated Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in a...

Страница 3: ...eserves the right to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously The information contained in this manual...

Страница 4: ...onents must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED ST...

Страница 5: ...thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers SECTION PAGE NO SAFETY 1 1 GENERAL SPECIFICATIONS 2 1 INTRODUCTION 3 1 OPERATING PROCEDURES...

Страница 6: ...Page iv TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

Страница 7: ...amiliar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 1 TITLE PAGE NO SAFETY 1 3 NOTICES CAUTIONS WARNINGS AND DANGERS 1 3 GENERAL 1 5 GENERAL OPERATION 1 5 M...

Страница 8: ...1 2 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1...

Страница 9: ...ated under the pas senger seat in the Tow position If the vehicle is to be used in a commercial environment signs similar to the ones illustrated should be used to warn of situations that could result...

Страница 10: ...RAL LAW the modified product will be a Low Speed Vehicle LSV subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571 500 In these instances pursuant to Federal law the...

Страница 11: ...eral Motor Vehicle Safety Standards of the United States of America USA and are not equipped for operation on public streets Some communities may permit these vehicles to be operated on their streets...

Страница 12: ...le using wheel chocks and jack stands NEVER get under a vehicle that is supported by a jack lift the vehicle in accordance with the manufacturer s instructions maintain the vehicle in an area away fro...

Страница 13: ...PERSONAL GOVERNOR GOVERNOR TAMPERING CAN RESULT IN SERIOUS PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY INJURY AND WILL VOID THE VEHICLE WARRANTY P P MAX 500 lbs 228 kg MAX 5 in 12 cm MAX 14o 25...

Страница 14: ...F GRAVITY COULD RESULT IN TIP OVER LOAD CENTER OF 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 B...

Страница 15: ...GROUND BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE DO NO...

Страница 16: ...CTION 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...

Страница 17: ...LOCK DIFFERENTIAL PUSH BOTTOM OF SWITCH 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...

Страница 18: ...1 12 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1...

Страница 19: ...rnings and Dangers 2 TITLE PAGE NO TERRAIN 500 Vehicle Specifications 2 3 TERRAIN 1000 Vehcile Specifications 2 4 EXPRESS S4 Vehicle Specifications 2 5 EXPRESS L4 Vehicle Specifications 2 6 TERRAIN 50...

Страница 20: ...2 2 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2...

Страница 21: ...elded steel with DuraShield powder coat Injection molded TPO Frame Front Body Finish Injection molded TPO Rear Body Finish Forest Green Standard Color Dimensions Overall Height No Canopy Overall Heigh...

Страница 22: ...DuraShield powder coat Injection molded TPO Frame Front Body Finish Steel Base coat clear coat Rear Body Finish Forest Green Standard Color Dimensions Overall Height No Canopy Overall Height With Can...

Страница 23: ...ac 22 x 11 10 Polished Spoke Whls Parking Brake Front Tires Rear Tires Terra Trac 22 x 11 10 Polished Spoke Whls Body Chassis Welded steel with DuraShield powder coat Injection molded TPO Frame Front...

Страница 24: ...l Wolf 20 x 11 10 Uni directional Parking Brake Front Tires Rear Tires Trail Wolf 20 x 11 10 Uni directional Body Chassis Welded steel with DuraShield powder coat Injection molded TPO Frame Front Body...

Страница 25: ...n 166 0 cm Front 38 0 in 96 0 cm Rear 38 5 in 97 0 cm 28 75 in 73 0 cm 30 5 in 77 0 cm 49 0 in 124 0 cm 49 0 in 124 0 cm 79 5 in 186 0 cm 10 0 in 25 0 cm 15 0 in 38 0 cm 5 3 in 15 0 cm TERRAIN 1000 11...

Страница 26: ...Cautions Warnings and Dangers 2 8 2 Front 38 5 in 97 cm Rear 38 0 in 96 cm 78 0 in 198 0 cm 49 0 in 125 0 cm 107 0 in 272 0 cm 65 5 in 166 cm 6 0 in 15 0 cm EXPRESS S4 46 5 in 118 0 cm Front 38 5 in 9...

Страница 27: ...vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TURNING CLEARANCE DIAMETER TERRAIN 500 20 5 ft 6 3 m TERRAIN 1000 23 5 ft 7 2 m EXPRESS S4 20 5 ft 6 3 m EXPRESS L4 20 5...

Страница 28: ...2 10 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2...

Страница 29: ...e Indicator Light 3 4 Fuel Gauge 3 4 Direction Selector 3 4 Accelerator Pedal 3 4 Brake and Park Brake 3 4 Horn 3 4 Rear View Mirror 3 5 Front Seats 3 5 Hip Restraint Front 3 5 Front Lights 3 5 Brake...

Страница 30: ...3 2 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3...

Страница 31: ...accessories some accessories remain operational with the key switch in the OFF position 1 Key Switch Headlight Switch Located on the dash panel this switch enables the basic electrical system of the v...

Страница 32: ...vehicle to move which could result in severe injury or death With the key switch ON depressing the accelerator pedal starts the engine When the pedal is released the engine will stop To stop the vehic...

Страница 33: ...bench front seat is designed for one occupant on each side of the center console 10 Hip Restraint Front The front hip restraints are designed to help keep the occupants properly positioned in the eve...

Страница 34: ...of the instrument panel 15 Cup Holder A cup holder is provided for convenience of both the driver and passenger 16 Steering Wheel The steering wheel located in front of the driver seat is used to stee...

Страница 35: ...affect vehicle handling characteristics and cause the vehicle to tip over or cause structural damage to the vehicle 21 GUN HOLDER IF EQUIPPED Check that firearms are unloaded with the safety engaged b...

Страница 36: ...jury could result if bed is released and traps fingers or other body parts To raise the manual lift bed pull back on the latch release handle immediately behind the driver seat Raise the bed using the...

Страница 37: ...3 9 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers INTRODUCTION 3...

Страница 38: ...3 10 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3...

Страница 39: ...TITLE PAGE NO SERIAL NUMBER LOCATION 4 3 BEFORE INITIAL USE 4 4 OPERATING THE VEHICLE 4 4 Run in 4 5 Cold Starting 4 6 STARTING AND DRIVING 4 6 Starting The Vehicle 4 6 Coasting 4 7 Fuel 4 7 Battery...

Страница 40: ...4 2 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 4...

Страница 41: ...t The other is located on the chassis between the seat back supports To access it raise the seat and lift up the flap on the access panel Design changes take place on an ongoing basis In order to obta...

Страница 42: ...oper maintenance may result in damage or decreased performance Read and understand the following warnings before attempting to operate the vehicle To reduce the possibility of severe injury or death r...

Страница 43: ...Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operating in reverse All occupants must be seated Keep entire body inside vehicle and hold on while vehi...

Страница 44: ...brake and deter mine the cause of the problem If the vehicle had been running and the engine does not start within 10 seconds use the choke STARTING AND DRIVING To reduce the possibility of roll back...

Страница 45: ...TIONS Limit speed by applying service brake FUEL To reduce the possibility of severe injury or death from improper fuel handling Do not smoke near the fuel tank Do not refuel near open flame or electr...

Страница 46: ...ut is a starting battery Multiple deep cycling will result in the premature failure of the battery If the vehicle battery has become discharged it must be charged using a 12 volt charger that is rated...

Страница 47: ...l change the weight distribution of the vehicle Changes to the weight distribution or the center of gravity may make it unstable or prone to roll over which could result in severe injury or death to t...

Страница 48: ...bed pull back on the latch release handle immediately behind the driver seat Raise the bed using the handle on the side of the bed Manual Bed Latch On the ST 400 the gas strut will assist in raising t...

Страница 49: ...ngers 4 Gas Strut with Tether Cable 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...

Страница 50: ...4 12 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 4...

Страница 51: ...NT 5 10 FUSE REPLACEMENT 5 10 VEHICLE DISCHARGED BATTERY 5 10 TRANSPORTING VEHICLE 5 11 Towing 5 11 Neutral Lock 5 11 Hauling 5 11 SERVICE AND MAINTENANCE 5 12 ROUTINE MAINTENANCE 5 13 Tire Inspection...

Страница 52: ...familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 5 2 5 TITLE PAGE NO LUBRICATION 5 22 SPARK PLUGS 5 22 PROLONGED STORAGE 5 23 PERIODIC SERVICE SCHEDULE...

Страница 53: ...5 3 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers MAINTENANCE 5...

Страница 54: ...5 4 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 5...

Страница 55: ...mercial 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...

Страница 56: ...d terrain When driving at full speed on a dirt road loose surfaces or wet grass vehicle stopping distance will increase If the vehicle is fully loaded it will take longer to stop than with no load Whe...

Страница 57: ...and jack stands at the areas indicated only Lifting The Vehicle Tool List Qty Tool List Qty Floor jack 1 Jack stands 4 Wheel Chocks 4 Remove payload from vehicle before lifting No person s should be i...

Страница 58: ...wrench 3 4 1 Impact socket 3 4 1 2 drive 1 Impact wrench 1 2 drive 1 Torque wrench 1 2 drive 1 Use caution when inflating tires Due to the low volume of the small tires overinflation can occur in seco...

Страница 59: ...ecommendations must be fol lowed in order to reduce possibility of severe injury Wheel Installation To reduce the possibility of component damage do not tighten lug nuts to more than 85 ft lbs 115 Nm...

Страница 60: ...ce the tail and brake light bulb roll the rubber bezel from around the edge of the taillight and remove lens Install replacement bulb and replace lens To replace the tail and brake light bulb remove h...

Страница 61: ...ring service operations a neutral lock is located on the direction selector To operate Turn key switch to OFF and lift seat Pull out and rotate the neutral lock pin handle so that the pointed portion...

Страница 62: ...cting battery at negative terminal before servicing Wear eye protection when working on the vehicle Use extra care when work ing around batteries or using solvents or compressed air To reduce the poss...

Страница 63: ...t five years is the periodic inspection of the rear axle for lubricant leakage Unless leakage is evident the lubricant need only be replaced after five years Refer to the Service and Repair Man ual fo...

Страница 64: ...t gets hot Do not overfill Check that the oil cap is firmly in place When adding oil between oil changes do not mix brands and viscosity grades of oil The oil dipstick fill cap must be in place before...

Страница 65: ...isture that has accumulated during storage Be aware that engine fluids may be hot and contact to the skin may cause severe burns Wear rubber gloves to protect skin from exposure to the old oil and deg...

Страница 66: ...n lbs 7 0 Nm torque Apply engine oil to the oil filter seal and install oil filter onto the engine until the seal contacts mounting surface of the engine Then turn the filter 2 3 to 3 4 rotations by H...

Страница 67: ...et 3 4 3 8 drive 1 The starter generator belt tension should be checked after the first 15 20 hours and set to 75 80 lbs 34 36 kg A loose belt can cause audible vibration and squeal Tighten a new star...

Страница 68: ...ductive and will contribute to the discharge of the battery To reduce the possibility of battery explosion that could result in severe injury or death do not use metallic spray wand to clean battery a...

Страница 69: ...tual vehicle weight 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 pressur...

Страница 70: ...and debris may clog the engine s air cooling system Clean areas shown to prevent engine damage Keep linkages springs and con trols clean Keep area around muffler free of any combustible material At le...

Страница 71: ...to clean the air filter doing so will damage the filter which may result in damage to the engine The air cleaner element is accessible by unsnapping the clips on the air canister and removing the cove...

Страница 72: ...of grease in a grease fitting could damage grease seals and cause premature bearing failure SPARK PLUGS Tool List Qty Spark plug socket 13 16 1 2 drive 1 Ratchet 1 2 drive 1 Plug gauge wire type 1 An...

Страница 73: ...ling to prevent possible eye injury from gasoline or gasoline vapor Keep hands clothing and jewelry away from moving parts Use care not to contact hot objects Raise the rear of the vehicle and support...

Страница 74: ...angers 5 24 5 Remove spark plug and pour about 1 2 oz 15 ml of SAE 10 30 weight oil or Fogging oil into the cylinder Rotate the crankshaft by hand several times then install the spark plug Do not enga...

Страница 75: ...n previous table the following WIRING Check all wiring for loose connections and broken missing insulation ACCELERATOR Check for smooth movement DO NOT LUBRICATE CABLE SERVICE BRAKE MECHANICAL BRAKES...

Страница 76: ...rdware AIR FILTER ELEMENT Check filter element clean replace as required OIL FILTER Replace at oil change ENGINE OIL Replace with SAE 10W 30 or 10W 40 that meets or exceeds SF SG CC oil DO NOT OVERFIL...

Страница 77: ...4 US qt 1 3 liters 51 oz 1 5 liters SAE 30 2 oz 60 mL P N 625753 15 amp P N 18392 G1 P N 619101 P N 619100 P N 619102 P N 26591 G01 P N 28463 G01 NGK BPR2ES P N 25523 G3 020 030 71 75 mm Gap P N 6061...

Страница 78: ...5 28 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 5...

Страница 79: ...ad all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers TABLE OF CONTENTS FOR APPENDIX A TITLE PAGE NO DECLARATION O...

Страница 80: ...A 2 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

Страница 81: ...A 3 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers DECLARATION OF CONFORMITY...

Страница 82: ...APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers A 4 DECLARATION OF CONFORMITY CONTINUED...

Страница 83: ...A 5 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers APPENDIX A...

Страница 84: ...A 6 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

Страница 85: ......

Страница 86: ...of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Service Parts Manuals as well as Repair and Service Manuals ar...

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