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Page A-1

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

SERIAL AND MANUFACTURING NUMBER
LABEL LOCATIONS

Supplemental Information Label Location

The supplemental Information label is located on the
driver side of the horizontal frame tube below truck bed
(Ref Fig. 1 on page A-1).

Serial and Manufacturing No. Label Location

The serial and manufacturing number label is located on
the passenger side of the horizontal frame tube below
the truck bed (Ref Fig. 1 on page A-1).

Serial and Manufacturing No. (Stamped)

The serial number and manufacturing number are
stamped on the frame below the truck bed (Ref Fig. 1 on
page A-1).

Serial No. Sticker Location

The serial number is located on the seat support panel
below the choke (Ref Fig. 1 on page A-1).

SERVICING THE VEHICLE

To prevent severe per-
sonal injury or death,
resulting from improper

servicing techniques, observe the following Warn-
ings:

Any servicing requiring adjustments to be made
to the powertrain while the motor is running must
be made with all wheels raised.

Fig. 1 Serial and Manufacturing Number Label Locations

Serial No.

Label

Supplemental Information label

Serial No. & Mfg No.
(Stamped)

Serial No. & Mfg No.
(Label)

GENERAL INFORMATION & ROUTINE MAINTENANCE

Содержание ST 4X4

Страница 1: ...ST 4X4 GASOLINE POWERED 4 WHEEL DRIVE UTILITY VEHICLE STARTING MODEL YEAR 2004 TECHNICIAN S REPAIR AND SERVICE MANUAL 600392 Ref Fcv 19...

Страница 2: ...rouilleur du Canada Read and understand all labels located on the vehicle For any questions on any of the information contact a represen tative for clarification Always replace any damaged or missing...

Страница 3: ...the informa tion contained in this manual 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 re...

Страница 4: ...adjusting the 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 origina...

Страница 5: ...Routine Maintenance A Safety B Body and Truckbed C Brakes D Continuously Variable Transmission CVT E Direction and Drive Selector F Electrical G Engine and Transmission H Front Suspension and Steering...

Страница 6: ...Page iv Repair and Service Manual TABLE OF CONTENTS Notes...

Страница 7: ...f 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 do n...

Страница 8: ...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 wheel...

Страница 9: ...om 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 vehicle i...

Страница 10: ...Repair and Service Manual SAFETY INFORMATION Page viii Notes...

Страница 11: ...POSITION A 3 BRAKES A 4 TIRES A 4 CARE AND CLEANING OF THE VEHICLE A 4 VEHICLE CARE PRODUCTS A 4 TOP AND WINDSHIELD IF EQUIPPED A 5 TRAILERING A 5 PROLONGED STORAGE A 5 HARDWARE A 6 TORQUE SPECIFICAT...

Страница 12: ...GENERAL INFORMATION ROUTINE MAINTENANCE Page A ii Repair and Service Manual Notes...

Страница 13: ...bed Ref Fig 1 on page A 1 Serial and Manufacturing No Stamped The serial number and manufacturing number are stamped on the frame below the truck bed Ref Fig 1 on page A 1 Serial No Sticker Location T...

Страница 14: ...heavy spring loaded highly cor rosive explosive may produce amperage or reach high temperatures Gasoline carbon monoxide battery acid and hydrogen gas could result in serious bodily injury to the tech...

Страница 15: ...a dropped wrench shorting out a battery which could result in an explosion To prevent accidental starting remove and ground spark plug wires and disconnect battery at negative terminal before servicin...

Страница 16: ...g mate rials be used Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil ta...

Страница 17: ...ts are adequately secured before trailering the vehicle The rated capacity of the trailer must exceed the weight of the vehicle see GENERAL SPECIFICATIONS for vehicle weight and load Engage the parkin...

Страница 18: ...over a few seconds to distribute oil Clean body chassis and engine of debris mud chaff or grass See ENGINE section HARDWARE Periodically the vehicle should be inspected for loose fasteners Fasteners...

Страница 19: ...wet and require approximately 80 of the torque required for dry fasteners 4 5 8 11 15 20 24 33 35 47 55 75 75 102 130 176 125 169 190 258 Grade 5 Grade 8 6 8 13 18 23 31 35 47 55 75 80 108 110 149 200...

Страница 20: ...pect X Rotors Drums Clean X Park Brake Clean X X Reverse Warning Buzzer if equipped Check X Tires Check X X Overall Vehicle Condition Check X Wheels Check X Fuel Gauge Check X Alternator Belt Check X...

Страница 21: ...EVERY 300 HOURS EVERY 500 HOURS Tie Rods Linkages Check X Rear Axle Lubricant Check X X Replace X X Front Axle Lubricant Check X X Replace X X Transmission Transfer Case Lubricant Check X X Replace X...

Страница 22: ...L INFORMATION ROUTINE MAINTENANCE Page A 10 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...

Страница 23: ...LIST OF ILLUSTRATIONS GENERAL B 1 NOTES CAUTIONS AND WARNINGS B 5 IMPORTANT SAFETY WARNING B 5 MODIFICATIONS TO VEHICLE B 5 GENERAL MAINTENANCE B 5 BEFORE SERVICING THE VEHICLE B 6 BATTERY REMOVAL AND...

Страница 24: ...SAFETY Page B ii Repair and Service Manual Notes...

Страница 25: ...trians 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 stated in vehicle...

Страница 26: ...ocks 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 Rules and P...

Страница 27: ...void 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 specified...

Страница 28: ...esigned 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 condi...

Страница 29: ...f the component should move unex pectedly Some components are heavy spring loaded highly cor rosive explosive or may produce high amperage or reach high temperatures Gasoline carbon monoxide battery a...

Страница 30: ...operate the starter with the spark plugs removed unless the ignition system has been dis abled and the engine exhaust are cold Fuel expelled from the cylinders could be ignited by the ignition system...

Страница 31: ...on A Tool List Qty Required Ratchet 3 8 drive 1 Torque wrench 3 8 drive ft lbs 1 Extension 12 3 8 drive 1 Socket 1 2 3 8 drive 1 Insulated wrench 1 2 1 Battery carrier 1 Turn vehicle key OFF and remov...

Страница 32: ...4 Some servicing operations may require the front rear or the entire vehicle to be raised To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 2 on page B 8 Center...

Страница 33: ...Panel Replacement C 12 Front Fender Well Replacement C 12 LIST OF ILLUSTRATIONS Fig 1 Seat Bottom Replacement C 1 Fig 2 Seat Back Replacement C 1 Fig 3 Gas Spring Replacement C 2 Fig 4 Light Guard Si...

Страница 34: ...BODY AND TRUCKBED Page C ii Repair and Service Manual Notes...

Страница 35: ...Release the truck bed handle and raise the bed Ref Fig 2 on page C 1 Remove the screws item 1 and the washers item 2 securing the seat back to the cover plate item 3 using Phillips screwdriver Remove...

Страница 36: ...1 Park vehicle on a level surface Engage park brake Hold the bolts item 1 using a 9 16 socket and remove the nuts item 2 using a 9 16 wrench Ref Fig 4 on page C 3 Remove the washers item 3 Use an ass...

Страница 37: ...help to remove the front brush guard item 4 carefully from the vehicle Installation of front brush guard is the reverse of disas sembly using new lock nuts Tighten the hardware per torque specificatio...

Страница 38: ...socket and remove the nuts item 2 using 3 4 wrench Ref Fig 7 on page C 4 Remove washers item 3 Remove the bolts item 1 and the backing plates item 4 Lower the receiver item 5 and move through the driv...

Страница 39: ...is the reverse of disassembly Cowl Replacement 6Q RTGXGPV UGXGTG RGT UQPCN KPLWT QT FGCVJ TGUWNVKPI HTQO GZRNQUKQP ECWUGF D CP GNGEVTKECN CTE DG UWTG VJCV VJG MG UYKVEJ KU QHH CPF CNN GNGEVTKECN CEEGU...

Страница 40: ...Refer Battery Removal and Installation in SAFETY Separate the head light plugs and receptacles Refer ELECTRICAL for head light replacement Remove all the wiring connected to instru ment panel and note...

Страница 41: ...YTGPEJGU YKVJ XKP N VCRG VQ RTGXGPV VJG RQUUKDKNKV QH C FTQRRGF YTGPEJ HTQO UJQTVKPI QWV VJG DCVVGT YJKEJ EQWNF TGUWNV KP CP GZRNQUKQP CPF UGXGTG RGT UQPCN KPLWT QT FGCVJ 6JG DCVVGT PGICVKXG ECDNG OW...

Страница 42: ...16 1 Phillips head screwdriver 1 Park vehicle on a level surface Engage park brake Hold the bolts item 1 using Phillips head screwdriver and remove the nuts item 2 using 7 16 wrench Ref Fig 12 on page...

Страница 43: ...the bed Remove the screws item 2 using Phillips head screwdriver Ref Fig 14 on page C 9 Remove the fuel cap item 1 Remove the seat panel passenger side item 3 from fuel tank neck Replace the fuel cap...

Страница 44: ...rk vehicle on a level surface Engage park brake Remove rocker panel Ref Rocker Panel Replacement Section on page C 8 Remove the floorpan Ref Floor pan Replacement Section on page C 8 Remove the riv et...

Страница 45: ...se truck bed handle and lift the bed Remove the ratchet fasteners item 1 from the top of rear fender Ref Fig 18 on page C 11 Hold the screws item 2 using 3 8 wrench and remove the nut item 3 using 7 1...

Страница 46: ...NG 6Q RTGXGPV UGTKQWU RGTUQPCN KPLWT QT FGCVJ TGUWNVKPI HTQO GZRNQUKQP ECWUGF D CP GNGEVTKECN CTE DG UWTG VJCV VJG MG UYKVEJ KU QHH CPF CNN GNGEVTKECN CEEGUUQTKGU CTG VWTPGF QHH DGHQTG UVCTVKPI YQTM Q...

Страница 47: ...Hold the bolt item 2 connecting upper mount frame to the main frame using 9 16 wrench and remove the nut item 3 using 9 16 socket Ref Fig 21 on page C 14 Remove the bolt item 4 using 13mm wrench and w...

Страница 48: ...GRCKT CPF 5GTXKEG CPWCN 4GCF CNN QH 5GEVKQP CPF VJKU UGEVKQP DGHQTG CVVGORVKPI CP RTQEGFWTG 2C RCTVKEWNCT CVVGPVKQP VQ CNN 0QVGU CWVKQPU CPF 9CTPKPIU Fig 21 Front Fender Well Replacement 6 8 10 12 11...

Страница 49: ...rake Rotor Replacement D 11 BLEEDING AND FLUSHING D 11 Bleeding D 11 Bleeding Sequence D 12 Flushing D 12 BRAKE PEDAL REPLACEMENT D 13 PARKING BRAKE D 13 Lubrication D 13 Adjustment D 13 Cable Replace...

Страница 50: ...BRAKES Page D ii Repair and Service Manual Notes...

Страница 51: ...l Notes Cautions and Warnings Fig 1 Hydraulic Brake System Components Brake Pedal Extension Spring Clevis Yoke Rotor Rear Brake Line Mounts To Frame Mounts To Frame Mounts To Frame Front Brake Line Br...

Страница 52: ...The wheel cylinders are a double piston design providing even distribution of force to each shoe There are no links Shoes rest directly on the piston ends Wheel cylinders incorporate external boots B...

Страница 53: ...in braking effect from the friction material being worn away a loss of braking at one wheel or a sudden and complete failure with no brakes working except the park ing brake Should the brakes at one w...

Страница 54: ...Flushing section During this process it is likely that brake fluid will leak from the master cyl inder Avoid allowing brake fluid to contact the painted body components of the vehicle Wipe off immedia...

Страница 55: ...m 1 Remove the master cylinder item 1 from the vehicle Installation of a new master cylinder is the reverse of dis assembly using new lock nuts Reconnect and tighten the brake lines items 2 3 per torq...

Страница 56: ...ll the brake drum slide the brake drum into place WHEEL BRAKE SERVICE AND REPLACEMENT To prevent dust inhala tion or eye injury always wear a dust mask and eye protection whenever working on wheel bra...

Страница 57: ...bolts item 6 from the rear axle item 7 flange using a 1 2 wrench and remove it using 1 2 socket and extension Pull the brake assembly item 8 and rear axle shaft item 9 out from the axle tube item 7 a...

Страница 58: ...djusters are frozen badly worn or loose replace the adjuster assembly Replace the wheel cylinder item 14 if there is any sign of leakage Insure that the parking lever and strut assem bly moves freely...

Страница 59: ...and reverse stops by applying firm pressure to the brake pedal on each stop to bring shoes to proper adjust ment FRONT DISC BRAKE REPLACEMENT To prevent dust inhala tion or eye injury always wear a du...

Страница 60: ...Torque wrench 1 2 drive 165 ft lbs capacity 1 Impact socket 3 4 1 2 drive 1 Allen wrench 9 mm 3 8 drive 1 Needle nose pliers 1 Park the vehicle on a level surface engage park brake Loosen the four nut...

Страница 61: ...of the disc brake rotor is the reverse of disas sembly Tighten the wheel lug nuts to 50 85 ft lbs 70 115 Nm torque in 20 ft lbs 30 Nm increments BLEEDING AND FLUSHING Tool List Qty Required Torque wr...

Страница 62: ...linder reservoir and wheel cylinder bleeder valves Clean each fitting before opening to prevent contaminating the system Fill master cylinder reservoir to the maximum level with new brake fluid before...

Страница 63: ...item 4 back so that clevis yoke item 5 will come out of master cylinder item 6 Inspect the shoulder bolt item 2 for corrosion that could cause binding This bolt and both bushings item 7 must be repla...

Страница 64: ...k the tension see that the cable is straight Correct tension is when at the sixth click of the hand operated parking brake lever the vehicle will not move while under a load on a typical area slope Re...

Страница 65: ...tie securing the rubber boot to the parking brake item 1 Remove the boot Remove the nut item 6 and spherical nut item 7 Remove cotter pin and clevis pin item 2 and pull cable item 4 free Check to see...

Страница 66: ...BRAKES Page D 16 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 Notes...

Страница 67: ...S E 1 Drive Clutch E 1 Driven Clutch E 1 Increased Load E 2 Equilibrium E 2 Drive Clutch Replacement E 2 Driven Clutch Replacement E 3 DRIVE BELT E 4 Removing the Drive Belt E 4 Drive Belt Service E 4...

Страница 68: ...CONTINUOUSLY VARIABLE TRANSMISSION CVT Page E ii Repair and Service Manual Notes...

Страница 69: ...er of the drive clutch sheaves which increases the speed of the belt As the drive clutch sheaves close the driven clutch sheaves are forced open by the belt as it rises in the drive clutch The ratio i...

Страница 70: ...inadvert ant movement of the vehicle Disable the electrical system before attempting to remove the drive belt to prevent the engine from inadvertently starting Do not allow fingers to become trapped...

Страница 71: ...e the bolt item 1 and remove the CVT cover item 2 Remove the drive belt item 3 Ref Removing the Drive Belt section on page E 4 Remove the driven clutch bolt item 8 using 1 2 socket lock washer item 9...

Страница 72: ...en be rolled off the driven clutch Drive Belt Service The drive belt will require no service unless the vehicle has been operated in an extremely dusty or muddy loca tion in which case it should be wa...

Страница 73: ...ector Replacement F 3 DRIVE SELECTOR F 3 Drive Selector Replacement F 3 Proximity Sensor Switch Replacement F 4 LIST OF ILLUSTRATIONS Fig 1 Direction Drive Selector Components F 1 Fig 2 Direction Driv...

Страница 74: ...DIRECTION AND DRIVE SELECTOR Page F ii Repair and Service Manual Notes...

Страница 75: ...ention to all Notes Cautions and Warnings Fig 1 Direction Drive Selector Components Levers On Transmission Transfer Case Shifter Housing Direction Selector Cable Drive Selector Cable Proximity Sensor...

Страница 76: ...nd Drive Selector Cables Adjust ment Failure of the transmission to engage correctly indicates that cable adjustment is required Tool List Qty Required Open end wrench 15 16 Direction selector 2 Open...

Страница 77: ...selector bracket item 5 to the shifter housing item 6 from back side of dash Remove direction selector cable item 7 Ref Direction And Drive Selector Cables Adjustment Section on page F 2 Remove the d...

Страница 78: ...arate the wire harness at the sensor Move the drive control to the 4 wheel drive position Ref Fig 6 on page F 4 Select the audible continuity setting on the DVOM Insert the two DVOM test probes into t...

Страница 79: ...TING G 6 POWER SUPPLY G 6 ACCESSORY WIRING G 7 INSTRUMENT CLUSTER G 7 DIFFERENTIAL LOCK SOLENOIDS G 7 FUEL CUT SOLENOID G 8 NEUTRAL SWITCH G 8 HEADLIGHTS G 8 TAILLIGHT ACCESSORY G 8 BRAKE SWITCH G 8 P...

Страница 80: ...ELECTRICAL Page G ii Repair and Service Manual Notes...

Страница 81: ...GHT HEADLT TAIL LIGHT BRAKE LIGHT PWR OUTLET PARK BRAKE SWITCH KEY SWITCH 25 AMP IN LINE FUSE OIL LIGHT SWITCH FUEL SENDING SWITCH LIGHT SWITCH BRAKE LIGHT SWITCH ENGINE STOP DIODE REGULATOR RECTIFIER...

Страница 82: ...s closed and will operate the starter if the neutral switch is in the closed position 2 The fuel shut off solenoid opens and permits fuel to flow to the carburetor main jet 3 The magneto ground is ope...

Страница 83: ...usly There is no distributor required since the valve timing controls the power stroke of each cylinder The engine can be stopped by turning the key switch to OFF position which shorts the mag neto in...

Страница 84: ...wiring harness Check for continuity of the key switch Remove key switch plate from instrument panel Ref Instrument Panel Replacement section in BODY AND TRUCKBED Detach electrical plug from key switc...

Страница 85: ...oose or corroded terminal posts and con nections Check electrolyte level b Check charging circuit component termi nals for proper clean tight connections Check for charging voltage as follows 1 Raise...

Страница 86: ...If power is not present but the other headlight functions a wiring problem is indicated between the two headlights In some cases where battery voltage is expected the easiest way to test the circuit...

Страница 87: ...e instrument cluster connector If voltage is present but the indicator is not working replace the instrument cluster If voltage is not present verify that the switch is correctly oriented in relation...

Страница 88: ...ey switch to ON and remove the wiring harness from the neutral switch Check for voltage between the two terminals at the har ness Turn key switch to OFF If voltage is present insert a jumper wire betw...

Страница 89: ...tion before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Fig 4 Fuse Block Instrument Cluster And Head Light FUSE BLOCK 25Amp Fuse RED WHT BLU 10 GA WHT ORN RED...

Страница 90: ...rticular attention to all Notes Cautions and Warnings Fig 5 Head Light Switch Key Switch And 12V Outlet 12V OUTLET RED WHT BLK YEL To I On Key Switch RED WHT To M2 On Key Switch BLK WHT To S On Key Sw...

Страница 91: ...Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Fig 6 Neutral Switch And Fuel Sending Unit A YEL BLK A 2 Pin C...

Страница 92: ...oids Fig 8 Voltage Regulator Fuel Cut Solenoid And Starter 3 Pin Connector To Rear Differential 3 Pin Connector To Front Differential DRIVER SIDE FRONT OF VEHICLE Connector To Voltage Regulator YEL To...

Страница 93: ...1 EXHAUST MANIFOLD REPLACEMENT H 12 TRANSMISSION REPLACEMENT H 13 Checking Transmission Transfer Case Lubrication Level H 14 SPARK ARRESTER CLEANING H 15 ENGINE SUB FRAME REPLACEMENT H 15 ISOLATION MO...

Страница 94: ...NTS FOR SECTION H CONT SECTION TITLE PAGE NO Fig 20 Transmission Replacement H 14 Fig 21 Transmission Lubricant Level H 14 Fig 22 Spark Arrester Removal H 15 Fig 23 Spark Arrester Cleaning H 15 Fig 24...

Страница 95: ...all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Fig 1 Engine Starter Air Cleaner Air Plenum Exhaust Manifold Air Hose Oil...

Страница 96: ...tic multi viscosity oils 5W 30 10W 30 etc in temperatures above 40 F 4 C will result in higher than normal oil consump tion When using a multi viscosity oil check oil level more fre quently SAE 30 oil...

Страница 97: ...Pliers 1 Oil drain pan 1 Clean cloth 2 For maximum performance and longevity the engine oil should be replaced after the first twenty 20 hours of operation After the initial oil change it should be c...

Страница 98: ...ith new oil Ref Changing the Oil section on page H 3 Air Cleaner Maintenance The filters must be serviced per the Periodic Service Schedule in Section A for optimum engine life and perfor mance Access...

Страница 99: ...elt may be depressed with a finger A maximum deflection of 3 8 1 cm is acceptable for a new belt Ref Fig 11 on page H 5 Re tighten an existing belt to 75 80 lbs 34 36 kg ten sion using the same techni...

Страница 100: ...lve Number of cylinders 2 V block Displacement 614 cc Rated horsepower 18hp 13 4 kw Spark plug type NGK ZGR5A or DENSO J16CR U Spark plug gap 030 76 mm Cooling Fan Oil Filter Replaceable Spin off Engi...

Страница 101: ...Allen wrench and remove the lock washers item 2 Ref Fig 14 on page H 7 Remove the bolts item 3 using a 7 16 socket from the driven clutch side and remove the wash ers item 4 Remove cover back plate it...

Страница 102: ...ion Remove seat bottom Ref Seat bottom Replacement in BODY AND TRUCK BED Remove seat cross member Drain oil from engine CVT Back Cover Removal Remove the CVT back cover Ref CVT BACK COVER REPLACEMENT...

Страница 103: ...d all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Fig 15 Air Intake System Removal Fig 16 Accelerator and Governor Cable R...

Страница 104: ...Fig 17 on page H 10 Remove the nuts item 2 and remove the washers item 3 Wear a personal back support brace and use proper lift ing technique before attempting to lift engine With a per son on each si...

Страница 105: ...ve clutch bolt to torque specified in CONTINU OUSLY VARIABLE TRANSMISSION section Install drive belt and CVT cover Tighten starter terminal nuts to specified torque If choke cable adjustment is requir...

Страница 106: ...tom Replacement Section in BODY AND TRUCK BED Remove the seat back Ref Seat Back Replacement Section in BODY AND TRUCK BED Remove seat crossmember Remove CVT cover Ref Drive Clutch Replacement sec tio...

Страница 107: ...t Qty Required Ratchet 3 8 drive 1 Torque wrench 3 8 drive ft lbs 1 Deep well socket 9 16 3 8 drive 1 Insulated wrench 1 2 1 Wrench 1 4 1 Wrench 9 16 2 Needle nose pliers 1 Pliers 1 Straight blade scr...

Страница 108: ...nut item 7 secur ing the accelerator governor bracket item 8 to transmis sion Remove the washer item 9 Remove the transmission item 10 Installation of the transmission is the reverse of disas sembly u...

Страница 109: ...T The following step involves lifting substan tial weight Two people are recommended Use of a personal back support brace and proper lifting technique is required to pre vent personal injury To preven...

Страница 110: ...s item 2 using 9 16 wrench Ref Fig 24 on page H 16 Remove the washer item 3 and remove the engine subframe item 4 Installation of the engine sub frame is the reverse of dis assembly using new lock nut...

Страница 111: ...VAL INSTAL LATION section on page H 7 Remove the transmission Ref TRANSMISSION REPLACEMENT section on page H 13 Remove the engine sub frame Ref ENGINE SUB FRAME REPLACEMENT section on page H 15 Hold t...

Страница 112: ...ENGINE AND TRANSMISSION Page H 18 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 Notes...

Страница 113: ...J 9 Steering Wheel Replacement J 10 Steering Column Replacement J 11 MAINTENANCE J 12 Wheel Alignment J 12 LIST OF ILLUSTRATIONS Fig 1 Suspension Components J 1 Fig 2 Brake Removal J 2 Fig 3 Tie Rod E...

Страница 114: ...FRONT SUSPENSION AND STEERING Page J ii Repair and Service Manual Notes...

Страница 115: ...re Pay particular attention to all Notes Cautions and Warnings Fig 1 Suspension Components Front Differential Hog Ring Control Arm Frame Half Shaft Strut Knuckle Steering Assembly Rotor Control Arm Bu...

Страница 116: ...osen the four nuts on the front wheels half turn Lift and support front of the vehicle per SAFETY section Remove the four front wheel nuts and remove the wheel Remove the bolt item 1 using Allen wrenc...

Страница 117: ...4 1 2 drive 1 Socket 1 1 8 1 2 drive 1 Impact socket 3 4 1 2 drive 1 Allen wrench 5 16 1 2 drive 1 Wrench 9 16 1 Wrench 11 16 1 Wrench 3 4 1 Plastic faced hammer 1 Straight blade screwdriver 1 Needle...

Страница 118: ...ver and plastic faced hammer Ref Fig 5 on page J 4 Remove the lock nut item 2 using a 1 1 8 socket Remove the outer brake washer item 3 Remove the tie rod end Ref Tie Rod End Removal Section on page J...

Страница 119: ...earing Replacement Worn bearing can be identified by checking for excessive play Jack up the vehicle and check the wheel by attempting to rock it back and forth to check for excessive play Use a comme...

Страница 120: ...pliers 1 Floor jack 1 1 2 ton 1 Jack stands 2 Wheel chocks 4 Loosen the four nuts on the front wheel half turn Lift and support front of the vehicle per SAFETY section Remove the wheels Ref Wheels an...

Страница 121: ...or jack 1 Jack stands 2 Wheel chocks 4 Loosen the four nuts on the front wheel half turn Lift and support front of the vehicle per SAFETY section Remove the wheels Ref Wheels and Brake Removal Section...

Страница 122: ...act wrench 1 2 drive 1 Impact socket 1 2 1 2 drive 1 Ball peen hammer 1 Park the vehicle on a flat surface Engage park brake Install chocks in front and behind each front wheel Remove bolts item 1 usi...

Страница 123: ...ring Assembly Replacement Tool List Qty Required Torque wrench 1 2 drive 165 ft lbs capacity 1 Impact wrench 1 2 drive 1 Impact socket 11 16 1 2 drive 1 Impact socket 3 4 1 2 drive 1 Wrench 13mm 1 Wre...

Страница 124: ...a small indent in the steering shaft to locate steering wheel puller When installing steering wheel apply commer cially available Anti Seize compound on all splines Tool List Qty Required Ratchet 1 2...

Страница 125: ...w Steering Column Replacement Tool List Qty Required Ratchet 3 8 drive 1 Ratchet 1 2 drive 1 Torque wrench 1 2 drive 165 ft lbs capacity 1 Socket 7 16 3 8 drive 1 Socket 9 16 1 2 drive 1 Allen wrench...

Страница 126: ...the tires to take their normal running position Measure the distance between the chalk lines at both the front and rear of the tires The measurement taken at the front of the tire should be between 0...

Страница 127: ...E AND REPLACEMENT K 2 Fuel Lines and Filter K 2 Fuel Pump K 3 Fuel Tank K 3 Choke System K 4 Choke Operation K 4 Choke Cable Replacement K 4 Carburetor Cleaning K 5 PROLONGED STORAGE K 5 LIST OF ILLUS...

Страница 128: ...FUEL SYSTEM Page K ii Repair and Service Manual Notes...

Страница 129: ...any procedure Pay particular attention to all Notes Cautions and Warnings APPROVED Fig 1 Fuel System Components Fuel Hose Fuel Line To Fuel Filter Fuel Cap Fuel Line From Tank Fuel Pump To Carburetor...

Страница 130: ...alcohol or ether Do not use gasoline which contains more than 5 Methanol Do not mix oil with gasoline The fuel tank cap is located near the passenger seat Fill the tank with fresh clean automotive gra...

Страница 131: ...of fuel remaining in old tank correctly Gasoline vapor left in fuel tank is extremely flammable Fill tank with water to help eliminate gaso line vapor Clean up any fuel leakage from hose Tool List Qt...

Страница 132: ...en the knob is released The motion should be smooth throughout the entire operating range If there is any binding or sharp bends the choke cable assembly and linkage must be inspected and parts replac...

Страница 133: ...ervice a Disconnect fuel hose at fuel filter and plug ends to prevent contamination Empty carburetor by run ning engine until it stops from lack of fuel b Disconnect negative cable from battery to pre...

Страница 134: ...FUEL SYSTEM Page K 6 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 Notes...

Страница 135: ...OR SECTION L SECTION TITLE PAGE NO Page L i Repair and Service Manual L PAINT PAINTING EXCEPT FRONT COWL L 1 Minor Scratches L 1 Larger Scratches L 1 Complete Panel Repair L 1 PAINTING FRONT COWL ONLY...

Страница 136: ...PAINT Page L ii Repair and Service Manual Notes...

Страница 137: ...is adequate prior to repair and use aerosol type touch up paint III Apply spray touch up paint in light even overlapping strokes Multiple coats may be applied to provide adequate coverage and finish...

Страница 138: ...rand product KPG0064 2 component polyurethane paint to manu facturer s specifications b Paint reactor c Paint ratio 1 5 1 paint reactor d Apply two medium wet coats of Valspar brand product KPG0064 in...

Страница 139: ...t apply one medium wet coat of Dupont brand 7601 Chromaclear Blender if necessary d Overlap repair paint and In mold coating e Overlap is 1 2 inches on wet repair and 6 8 inches on the dry In mold coa...

Страница 140: ...PAINT Page L 4 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 Notes...

Страница 141: ...ial Guard Replacement M 3 Rear Axle Replacement M 4 REAR SUSPENSION M 6 General M 6 Shock Absorber Removal M 6 Rear Spring Removal M 6 LIST OF ILLUSTRATIONS Fig 1 Rear Axle And Suspension Components M...

Страница 142: ...REAR AXLE AND SUSPENSION Page M ii Repair and Service Manual Notes...

Страница 143: ...re Pay particular attention to all Notes Cautions and Warnings Fig 1 Rear Axle And Suspension Components Rear Drive Shaft Rear Axle Rear Differential Solenoid Rear Leaf Spring Shock Mounting Shock Abs...

Страница 144: ...500 525 milliliters Solenoid Replacement Check solenoid for free actuation after assem bly Drain hole in the protective boot solenoid should be located towards bottom of the vehicle after assembly Too...

Страница 145: ...nd each rear wheel Release truck bed handle and lift the bed The rear drive shaft item 3 can be accessed from the top Remove bolts item 1 and washers item 2 using 1 2 impact socket Ref Fig 4 on page M...

Страница 146: ...en hammer 1 Straight blade screw driver 1 Pliers 1 Needle nose pliers 1 Drain Pan 1 Thread locking sealant AR Anti seize compound AR Loosen the four nuts on the rear wheels half turn Lift and support...

Страница 147: ...rvice Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Fig 6 Rear Axle Components 7 13 14 16 17 18 15 10 11 12...

Страница 148: ...ont and behind each rear wheel Release truck bed handle and lift the bed The shock absorber item 3 can be accessed from the top Hold the bolt item 1 using 9 16 wrench and remove lock nut item 2 using...

Страница 149: ...l to locate the jack on the axle tube flanges lift it and place the two jack stands just inboard of the spring pads and slightly below the rear axle tubes The jack stands are to prevent the rear axle...

Страница 150: ...REAR AXLE AND SUSPENSION Page M 8 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 Notes...

Страница 151: ...le Adjustment Procedure N 2 Governor Compression Spring Adjustment N 3 Accelerator governor Cable Adjustment N 3 Accelerator Pedal Replacement N 4 ROAD TEST N 5 TROUBLESHOOTING N 5 LIST OF ILLUSTRATIO...

Страница 152: ...SPEED CONTROL Page N ii Repair and Service Manual Notes...

Страница 153: ...particular attention to all Notes Cautions and Warnings Fig 1 Accelerator and Governor System Carburetor Throttle Lever Accelerator Pedal Accelerator Pedal Return Spring Accelerator Cable Governor Ca...

Страница 154: ...onal inju ry or death resulting from a loss of control by the vehicle operating above the factory specified speed never tamper with the governor Tampering with the governor may void the warranty If th...

Страница 155: ...overnor after calibration Hold the governor compression spring adjuster rod when turn ing the governor adjuster Failure to hold the rod will cause the accelerator cable to twist which may cause premat...

Страница 156: ...a bat tery which could result in an explosion and severe personal injury or death The negative battery cable must be removed using insulated wrench before removing the accelerator pedal from the vehic...

Страница 157: ...e time it takes to travel a known set distance with vehicle at maximum speed Enter time and distance into this formula to calcu late speed Rate in MPH Distance in feet 5280 Time in seconds 3600 or Rat...

Страница 158: ...SPEED CONTROL Page N 6 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 Notes...

Страница 159: ...TABLE OF CONTENTS FOR SECTION P SECTION TITLE PAGE NO Page P i Repair and Service Manual P TROUBLESHOOTING ENGINE P 1 GASOLINE VEHICLE PERFORMANCE P 1 STARTER GENERATOR P 5 SUSPENSION AND STEERING P 6...

Страница 160: ...TROUBLESHOOTING Page P ii Repair and Service Manual Notes...

Страница 161: ...wire and or connections Solenoid faulty If no audible click is heard check power and ground Replace solenoid if power and ground is good Starter terminals are loose or corroded Tighten or clean Leads...

Страница 162: ...n or replace jet Throttle lever motion restricted Check all linkages and repair Dirt or water in fuel line or carburetor Clean lines and carburetor Replace filter Clogged fuel filter Check and replace...

Страница 163: ...ition system Check and repair if required Poor quality gasoline Use correct fuel check bulk storage tank for proper storage and handling Air leak allowing dirt to enter system Repair Choke sticking cl...

Страница 164: ...retor throttle valve spring weak or broken Replace Incorrect adjustment of accelerator governor and carburetor linkages Adjust Carburetor throttle lever shaft bent Replace or rebuild carburetor Govern...

Страница 165: ...ies operating at one time exceeds generator output Reduce load to meet generator output Armature bent Repair or replace if necessary Brushes are worn beyond limits Replace Commutator is excessively ro...

Страница 166: ...IFF STEERING Damaged steering assembly Replace PLAY IN STEERING Steering wheel loose Inspect splines replace steering wheel if required Tighten steering wheel nut Steering components worn Replace Loos...

Страница 167: ...FOR SECTION R SECTION TITLE PAGE NO Page R i Repair and Service Manual R WHEELS AND TIRES WHEEL AND TIRE SERVICE R 1 Tire Replacement Repair R 1 Wheel Installation R 2 LIST OF ILLUSTRATIONS Fig 1 Whe...

Страница 168: ...WHEELS AND TIRES Page R ii Repair and Service Manual Notes...

Страница 169: ...wer tools Tire inflation will depend on the type of tires fitted but under no condition should inflation pressure be higher than recommended on the tire sidewall Standard and optional tires should be...

Страница 170: ...oss sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Be sure to positi...

Страница 171: ...n B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings Fig 1 Wheels and Tires Tire style may vary 1 2 3 4 CROSS SEQUENCE Valve stem is always...

Страница 172: ...WHEELS AND TIRES Page R 4 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 Notes...

Страница 173: ...epair and Service Manual S GENERAL SPECIFICATIONS Gasoline Powered ST 4X4 Utility Vehicle S 1 LIST OF ILLUSTRATIONS Fig 1 Vehicle Dimensions S 2 Fig 2 Vehicle Incline Specifications S 3 Fig 3 Vehicle...

Страница 174: ...GENERAL SPECIFICATIONS Page S ii Repair and Service Manual Notes...

Страница 175: ...AR Dual Rear Wheel Hydraulic 6 3 16 cm Drum Brakes PARK BRAKE Hand Operated Lever with Indicator Light FRONT SUSPENSION Independent with Hydraulic Struts REAR SUSPENSION Leaf Springs with Hydraulic Sh...

Страница 176: ...imensions Front 43 3 8 110 cm Rear 43 3 4 111 cm 76 193 cm 107 272 cm 50 127 cm 16 40 6 cm 8 3 8 21 3 cm Clearance At Lowest Point Of Vehicle On Rear Axle 31 5 80 cm 50 127 cm 40 102 cm 11 5 in 29 cm...

Страница 177: ...Page S 3 Repair and Service Manual GENERAL SPECIFICATIONS Fig 2 Vehicle Incline Specifications Maximum Recommended Side Tilt 25 or 14 Max Maximum Recommended Ramp Grade 25 or 14 Max...

Страница 178: ...Page S 4 Repair and Service Manual GENERAL SPECIFICATIONS Fig 3 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance TURNING CLEARANCE DIAMETER Approx 25 ft 7 6 m...

Страница 179: ...TABLE OF CONTENTS FOR SECTION T SECTION TITLE PAGE NO Page T i Repair and Service Manual T LIMITED WARRANTY EMISSION CONTROL SYSTEM WARRANTY STATEMENT T 1 ENGINE OWNER WARRANTY POLICY T 1...

Страница 180: ...LIMITED WARRANTY Page T ii Repair and Service Manual Notes...

Страница 181: ...Rights and Oblications Refer to the HONDA Operating Maintenance Instructions provided with vehicle for Emission Control System War ranty information ENGINE OWNER WARRANTY POLICY Refer to the HONDA Op...

Страница 182: ...Page T 2 Repair and Service Manual LIMITED WARRANTY Notes...

Страница 183: ...considered potentially hazardous Use extreme care when working on any vehicle When diag nosing removing or replacing any components that are not operating correctly take time to consider the safety o...

Страница 184: ...express permission 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 Inside USA Phone 1 800 2...

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