E-Z-GO 602080 manual

TM 602080 REVISED DA TE: JAN . 200 7[...]

SAFETY (NOTES, CAUTIONS AND WARNI NGS CONTINUED ON IN SIDE OF BACK COVER) NOTES, CAUTIONS AND W ARNINGS Throughout t his guide NOTE, CAUTION and W ARNING will be used. A NOTE indicates a condition that should be observed. A CAUTION indicates a condition that may result in damage to the vehicle. A WARNING indicates a hazardous condition that could r[...]

Page i Owner’s Manual and Service Guide OWNER’S MANUAL AND SER VICE GUIDE GASOLINE POWERED UTILITY VEHICLE ST 4x4 ST ARTING MODEL YEAR 2005 E-Z-GO Di vision of TEX TRON, Inc. reserve s the right to make design changes without obligation to ma ke these change s on units previo usly sol d and the inf or- mation containe d in this man ual is subje[...]

Page ii GENERAL INFOR MA TION Owner’s Manual and Service Guide This vehicle has been designed and manufactured in the United S t ates of America (USA) as a ‘W orl d V ehicle’. The St andards and Specifications listed in the following t ext originate in the USA unless otherwise indicated. The use of non Original Equipment Manufacturer (OEM) ap[...]

Page iii T ABLE OF CONTENTS Owner’s Manual and Service Guide SAFETY ................ ................ ................ ................ ................ ................. ............... inside c overs GENERAL INFORMATION ............... ... ... .... ................ ... ................ ................ ... ................. ....... ii SAFETY IN[...]

Page iv Owner’s Manual and Service Guide TA B L E O F C O N T E N TS TOP AND WIND SHIELD ............... ................ ................ ................ ................. ................ .......... 12 TRANSPORTING V EHICLE ... ................ ................ ................ ................ ................ ................ . 12 TOWING ...[...]

Page v T ABLE OF CONTENTS Owner’s Manual and Service Guide LIGHT BULB REPLACEM ENT ...... ................... ................ ................ ................ .................... .. 2 5 Fig. 35 Headlight Replacement ......................... ...................................................................... 25 FUSE REPLACEMENT ............[...]

Page vi Owner’s Manual and Service Guide TA B L E O F C O N T E N TS N otes:[...]

Owner’s Manual and Service Guide SAFETY INFORMA TION Page vii This manual has been designe d to assist in maintainin g the vehicle in accordance with pr ocedures developed by the manufacturer . Adherence to these procedure s and troubleshoo t ing tip s will ensu re the best po ssible service fro m the product. T o reduce the chance of persona l i[...]

Owner’s Manual and Service Guide SAFETY INFORMA TION Page viii • Apply service brake to control spee d on st eep grades. • Maintain adequate distance betw ee n ve hic les. • Reduce speed in wet area s. • Use extreme caution when appro aching sharp or blind tur ns. • Use extreme caution when drivin g over loose terrain. • Use extreme c[...]

Owner’s Manual and Service Guide SAFETY INFORMA TION Page ix VENTILA TION Always store gasoline vehicles in a well vent ilat ed area. V entilation prevents ga soline fumes from accu mul ating. Never fuel a vehicle in an area that is subject to fla me or spar k. Pay p articular at tention to nat ural gas or prop ane water heaters and f urnaces. Ne[...]

Owner’s Manual and Service Guide SAFETY INFORMA TION Page x Notes:[...]

SAFETY INFORMA TION Page xi Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s GENERAL The following text is provided as recommended b y part II of SAE J2258 DEC 2003. E-Z-GO strongly en dorses the contents of this specification. B.1[...]

SAFETY INFORMA TION Page xii Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attentio n to all Notes, Cautions and W arning s B.1.1.4.2 The controlling party shall supervise the handling of liquefied petr oleum gas fuels (when used) to be certain it is in accordance with appro[...]

SAFETY INFORMA TION Page xiii Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s B.2.3.4 Riding on the veh icle by person s other than the operator is autho rized only on sea t(s) p rovided by the vehicle manu facturer . All parts of[...]

SAFETY INFORMA TION Page xiv Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attentio n to all Notes, Cautions and W arning s equipped, is closed, following vehicle man ufacturer's rec- ommended practi ce. (e) Before disconn ectin g any p art of the fuel system of LP/CNG [...]

OPERA TION AND SER VICE INFORMA TION Page 1 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s WELCOME Thank you for purchasing this utility vehicle. Before driv- ing vehicle, we ask you to spend some time reading this Owner ’s Man[...]

OPERA TION AND SER VICE INFORMA TION Page 2 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s ways the vehicle may be u sed, it is important the operator consider any potent ial hazards before use to prevent serious in jury or dea[...]

OPERA TION AND SER VICE INFORMA TION Page 3 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s CONTROLS & INDICA TORS SERVICE BRAKE PEDAL The service brake is a hydraulic front disc/rear drum brake system. Push foot oper ated ser[...]

OPERA TION AND SER VICE INFORMA TION Page 4 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s If vehicle is equipped with factory installed cus- tom accessories, some accessories remain operational with key switch in ‘OFF’ pos[...]

OPERA TION AND SER VICE INFORMA TION Page 5 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s Place direction selector in fo rward and set pa rk brake when leaving vehicle unatt ended. 2WD/4WD SELECT OR To reduce possibility of driv[...]

OPERA TION AND SER VICE INFORMA TION Page 6 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s To prevent draining the battery, always place differential lock switches in the ‘unlocked’ positi on, turn the key sw itch to ‘off[...]

OPERA TION AND SER VICE INFORMA TION Page 7 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s LOW OIL PRESSURE INDICA T OR LIGHT Low oil pressure in dicator lig ht is loca ted in gauge cluste r at left of dash panel. Indica to r lig[...]

OPERA TION AND SER VICE INFORMA TION Page 8 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s Overuse of accessories may drain bat- tery and leave insufficient reserve to start vehicle. A 12 volt power out let, rated at 15 amps , [...]

OPERA TION AND SER VICE INFORMA TION Page 9 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s Before operating , verify no one is behind vehi cle . Always place a gas can on gro und for filling. Never fill a gas can in load bed o f [...]

OPERA TION AND SER VICE INFORMA TION Page 10 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s Do not pull at an angle (Ref. Fig. 16 on page 10). This will cause cable to pile up on one end, jam- ming and damaging winch. The winch[...]

OPERA TION AND SER VICE INFORMA TION Page 11 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s Pull out desired amount of cable an d secure. Engage drum by rotating knob until it snaps in place. Never operate winch unless clutch is [...]

OPERA TION AND SER VICE INFORMA TION Page 12 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s as possible from side of vehicle. Do not operate winch while sitting in passenger seat. Read ‘Winch Applica- tions’ section before [...]

OPERA TION AND SER VICE INFORMA TION Page 13 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s V ehicle may be equipped with a receive r that accept s a standar d 2" ball hitch. T rail er range of motion is limited by the ball [...]

OPERA TION AND SER VICE INFORMA TION Page 14 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s MAINTENANCE To reduce possibility of severe injury or death from improper servicing techniques: Do not attempt any type of servicing op[...]

OPERA TION AND SER VICE INFORMA TION Page 15 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s PERIODIC SER VICE SCHEDULE ITEM BEFORE EACH USE WEEKL Y EVER Y 20 HOURS EVER Y 50 HOURS EVER Y 100 HOURS EVER Y 200 HOURS EVER Y 300 HOUR[...]

OPERA TION AND SER VICE INFORMA TION Page 16 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s ** First occurrence only # More frequent ly in dust y cond itions T o perform service that is listed in this schedule b ut not de scrib[...]

OPERA TION AND SER VICE INFORMA TION Page 17 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s LIF TING THE VEHICLE T ool List Qty . Required Floor jack ................... ... ... ............. ... ... .... ... ... ............. . [...]

OPERA TION AND SER VICE INFORMA TION Page 18 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s OIL LEVEL CHECK To reduce possibility of engine damage, do not run engine with oil level too low. Park vehicle on level surf ace, shut [...]

OPERA TION AND SER VICE INFORMA TION Page 19 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s Fill engine to upper hole on dipstick with appropriate oil (Ref. OIL CHA NGE on page 18) . Return oil fill cap and dipstick and lower sea[...]

OPERA TION AND SER VICE INFORMA TION Page 20 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s AIR CLEANER CANISTER TYPE AIR CLEANER Air cleaner element is acce ssible by unsnapping two clips on air canister and removin g cover an[...]

OPERA TION AND SER VICE INFORMA TION Page 21 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s LUBRICA TION POINTS D o not use more than three (3 ) pumps of grease in any grease fitting at any one time. Excess grease may cause greas[...]

OPERA TION AND SER VICE INFORMA TION Page 22 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s BA TTER Y CLEANING To reduce possibility of damage to vehicle or floor, n eutralize acid before rinsing battery. To reduce possibility [...]

OPERA TION AND SER VICE INFORMA TION Page 23 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s tem. Do not use p ressure in excess of 700 p si (4800 kPa) to wash exte rior of vehicle. Clean windshield with lo ts of water and a clean[...]

OPERA TION AND SER VICE INFORMA TION Page 24 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s WHEELS AND TIRES Tires are uni-directional and shou ld never be moved from one side of vehicle to the other. This vehicle comes standar[...]

OPERA TION AND SER VICE INFORMA TION Page 25 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s LIGHT BULB REPLACEMENT Replacement bulbs are available from a local Distr ibutor , an authorized Br anch or the Serv ice Parts Department[...]

OPERA TION AND SER VICE INFORMA TION Page 26 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s • Add fuel stabilizer to fu el tank following instruc- tions on stabilizer cont ainer . • Attach fuel line to t ank and drive vehic[...]

OPERA TION AND SER VICE INFORMA TION Page 27 Owner’s Manual and Service Guide Read all of manual to be come thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and Warning s After every off road use, allow to cool an d then chec k for build up of dirt and debr is in air intake a nd cooling fins (Ref. Fig. 39 o[...]

OPERA TION AND SER VICE INFORMA TION Page 28 Owner’s Manual and Service Guide Read all of manual to bec ome thoroughly familiar with this vehicle. P ay par ticular attention to all Notes, Cautions and W ar ning s HARDW ARE Periodically , vehicle shou ld be inspected for loose fasten- ers. Fasteners should be tightened in accordance wit h the T or[...]

Page 29 GENERAL SPECIFICA TIONS Owner’s Manual and Service Guide GENERAL SPECIFICA TIONS[...]

Page 30 Owner’s Manual and Service Guide GENERAL SPECIFICA TIONS ST 4X4 ST ANDARD EQUIPMENT : CHASSIS W elded steel, ho t-di p galvanized, front hitch receiver BODY (Front) Flexible, Impact Resistant DuraShield™ Injection Mo lded TPE (Thermoplastic Elastomer) wi th Base Coat/Clear Coa t BODY (Rear) Ligh twe igh t, replaceable steel panels, plas[...]

Page 31 GENERAL SPECIFICA TIONS Owner’s Manual and Service Guide Fig. 42 V ehicle Dimensions Fig. 43 V ehicle I ncline Specifica tions F ront 43 3/8" (110 cm) Rear 43 3/4" (111 cm) 76" (193 cm) 112" (285 cm) 50" (127 cm) 16" (40.6 cm) 8 3/8" (21.3 cm) Clearance At Lowest P oint Of V ehicle (On Rear Axle) 31.5&qu[...]

Page 32 Owner’s Manual and Service Guide GENERAL SPECIFICA TIONS Fig. 44 V ehicle T urning Clearance Diameter and I ntersecting Ai sl e Clearance TURNING CLEARANCE DIAMETER Approx. 25'-6" (7.8 m) Ref Dim 3-3[...]

Page 33 Owner’s Manual and Service Guide VEHICLE WARRANTIES VEHICLE W ARRANTIES[...]

Page 34 Owner’s Manual and Service Guide VEHICLE WARRANTIES[...]

Page 35 VEHICLE WARRANTIES Owner’s Manual and Service Guide EMISSION CONTROL SYST EM W ARRANTY ST A TEMENT (Owner ’ s Defect W arranty Right s and Obligations) Refer to the H ONDA Emission Control Syste m W arranty she et, provided with vehicle, for in formation. ENGINE OWNER W ARRANTY POLICY Refer to the W arranty sheet, pr ovided with vehicle[...]

Page 36 Owner’s Manual and Service Guide VEHICLE WARRANTIES N otes:[...]

Page 37 Owner’s Manual and Service Guide DECLARA TION OF CONFORMITY DECLARA TION OF CONFORMITY (EUROPE ONL Y) Declaration of Conformi ty is p ackaged with vehicle. For additional inf ormation, cont act: Ransomes Jacobsen Limit ed West Road , Ransomes Europ ark, Ipswich, Eng land, IP3 9TT[...]

Page 38 Owner’s Manual and Service Guide DECLARA TION OF CONFORMITY N otes:[...]

Appendix A - 1 LABELS AND PICTOGRAMS Owner’s Manual and Service Guide LABELS AND PICT OGRAMS[...]

Appendix A - 2 Owner’s Manual and Service Guide LABELS AND PICTOGRAMS Notes:[...]

Appendix A - 3 LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Fig. 45 Label Locations 75696G01 74099G01 See Following Pages For Explanation Of These Pictograms: (14) 74099-G01 72939G01 (Lift Cowl) T o release cowl, raise and hold cowl, lift lever and lower cowl carefully 72939G01 H O 2 1 2 3 P P P P P P 74093-G01 74093G01 24880G1 75696G01[...]

Appendix A - 4 Owner’s Manual and Service Guide LABELS AND PICTOGRAMS Fig. 46 Pictogram Definitions 1. 2. 4. MAX M A X 14 ° / 25 % 14 ° / 25 % 5. ! < 14 ° 25 % < 14 ° 25 % 6. P P 12. x in x in xx cm xx cm MAX LO AD M A X L O AD XXX LBS X X X LBS XXX KG X X X K G 13. ! < 14 ° 25 % < 14 ° 25 % 9. 11. 7. MA X M AX xxx lbs. xxx lbs.[...]

Appendix A - 5 LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Fig. 47 Pictogram Definitions 26. 27. 1 3 H O 2 P P 15. 2 P P 16. P P 18. P P 17. 23. 21. 22. 24. 25. 19. 20. 28. 29. 30. 31. 32. 33. 34. 35. CLEAN UP GASOLINE SPILLS WITH W A TER BEFORE ST ARTING ENGINE UNLEAD GASOLINE DO NOT SPILL FUEL ON A HOT ENGINE GROUND FUEL PUMP L OW OI[...]

Appendix A - 6 Owner’s Manual and Service Guide LABELS AND PICTOGRAMS Fig. 48 Pictogram Definitions 36. 37. F 38. 42. R 39. P F 40. P N 41. ON 43. OFF 44. 45. 46. 47. 48. 49. 50. 51. ST ART 52. P 53. 1 2 3 OPERA TE FROM DRIVER’S SIDE ONL Y KEEP ARMS AND LEGS WITHIN VEHICLE TO OPERA TE VEHICLE IN FORW ARD: * TURN KEY TO ON * MOVE DIRECTION SELEC[...]

Appendix A - 7 LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Fig. 49 Pictogram Definitions 62. 63. 56. 57. 58. 59. 60. 61. 55. 54. W ARNING READ OWNER’S MANUL BEFORE OPERA TING VEHICLE IN FORWARD OR REVERSE W ARNING READ OWNER’S MANUAL BEFORE P ARKING VEHICLE AND LEA VING IT UNA T TENDED FORWARD NEUTRAL REVERSE W ARNING READ OWNER’[...]

Appendix A - 8 Owner’s Manual and Service Guide LABELS AND PICTOGRAMS Notes:[...]

Check area behind the vehicle before operating in reverse. Make sure the direction select or is in cor rect position before attempting to start the vehicle. Slow down before and during turns. All turns should be executed at reduced speed. Always bring vehicle to a complete stop before shifting the direction selector. See GENERAL SPECIFICATIO NS for[...]

Copyrighted Material This manual may not be reproduc ed in whole or in part without the express permission of E-Z-GO Division of T extron, Inc. T echnical Communications Department S ta r ting M odel Y ear 2005 P/N 602080 ISSUED: April 2005 E-Z -GO Division O f T extron, Inc., 1451 Mar vin Grin Road, Augusta, Geor gia USA 30906-3852 T O CONT ACT[...]