Bad Boy HD G, LTO G, 617816 Owner's Manual

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HD & LTO GAS

OWNER'S MANUAL

ISSUED JANUARY 2011 REVISED AUGUST 2012

617 816

SAFETY

WASH HANDS

AFTER HANDLING!

Battery posts,

terminals and related

accessories contain

lead and lead compounds,

chemicals known

to cause cancer and

reproductive harm.

BATTERY WARNING

WASH HANDS

AFTER HANDLING!

WARNING: Battery posts, terminals and related accessories contain lead and lead compounds,

chemicals known to cause cancer and reproductive harm.

BATTERIES

CONTAIN LEAD

AND RELATED PARTS

DO NOT

DRIVE ACROSS

SLOPES IN

EXCESS OF 14˚

NOTICE

Ce système d'allumage par étincelle de véhicule respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.

For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre-

vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.

Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered abuse and will not be covered under warranty.

For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”. If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of

situation that could result in an unsafe condition.

Be sure that this manual remains as part of the permanent service record should the vehicle be sold. Throughout this guide NOTE, CAUTION, WARNING

and DANGER will be used.

Address practices not related to personal injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Please observe these NOTES, CAUTIONS, WARN-

INGS and DANGERS; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe.

(NOTES, CAUTIONS, WARNINGS and DANGERS CONTINUED ON INSIDE OF BACK COVER)

Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects, or other reproductive harm.

The exhaust emissions of this vehicles’ engine complies with regulations set forth by the Environemntal Protection Agency (EPA) of the United States of America (USA) at time of manufacture. Significant fines could result from modifications or tampering with the engine, fuel, ignition or air intake systems.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

This spark ignition system meets all requirements of the Canadian Interference-Causing Equipment Regulations.

OWNER’S GUIDE

GASOLINE POWERED

UTILITY VEHICLE

HD G

LTO G

Starting Model Year 2011

The E-Z-GO Division of Textron Inc. (e-z-go) reserves the right to incorporate engineer ing and design ch anges to products in th is Manual, without obligation to include these changes on units leased/sold previously.

The information contained in this Manu al may be revised periodically by E-Z-GO and therefore is subject to chan ge without notice. E-Z-GO DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUEN-

TIAL DAMAGES RESULTING FROM THE USE OF THE INFORMATION AND MATERIALS IN THIS MANUAL. These are the original instruct ions as defined by 2006/42 EC.

TO CONTACT US NORTH AMERICA: TECHNICAL ASSISTANCE & WARRANTY PHONE: 1-800-774-3946, FAX: 1-800-448-8124 SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 INTERNATIONAL: PHONE: 001-706-798-4311, FAX: 001-706-771-4609 E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Page i

GENERAL INFORMATION

This vehicle has been designed and manufactured in the United States of America (USA) as

a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in

the USA unless otherwise indicated.

The use of non Original Equipment Manufacturer (OEM) approved parts may void the

warranty.

Overfilling battery may void the warranty.

Tampering with or 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 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 STORAGE

All batteries will self discharge over time. The rate of self discharge varies depending on the

ambient temperature and the age and condition of the batteries.

A fully charged battery will not freeze in winter temperatures unless the temperature falls

below -75° F (-60° C).

BATTERY DISPOSAL

Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer

or lead smelter for recycling. For neutralized spills, place residue in acid-resistant

containers with absorbent material, sand or earth and dispose of in accordance with local,

state and federal regulations for acid and lead compounds. Contact local and/or state

environmental officials regarding disposal information.

Page ii

TABLE OF CONTENTS

SAFETY ................................................................................................................ inside covers

GENERAL INFORMATION ........................................................................................................ii

SAFETY INFORMATION ...........................................................................................................v

LABELS AND PICTOGRAMS ...................................................................................................ix

WELCOME .......................... ............................................. ............................................. .............1

BEFORE INITIAL USE ...............................................................................................................1

Initial Service Chart ................................................................................................................... 1

CONTROLS AND INDICATORS ..................................... ...... ....... ...... ....... ...... ....... ...... ....... ...... 1

KEY/LIGHT SWITCH.......................................................................................................................................... 2

DIRECTION SELECTOR..................................................................................................................................... 2

CHOKE ................................................................................................................................................................ 2

FUEL GAUGE...................................................................................................................................................... 2

LOW OIL PRESSURE INDICATOR LIGHT......................................................................................................... 2

ACCELERATOR PEDAL .....................................................................................................................................3

COMBINATION SERVICE AND PARK BRAKE PEDAL......................................................................................3

HORN...................................................................................................................................................................3

12 VOLT POWER OUTLET ................................................................................................................................. 3

TERRAIN.....................................................................................................................................3

WINCH................................................................................................................................................................. 3

OPERATION OF THE WINCH............................................................................................................................. 3

WINCH APPLICATIONS................ ......................................................................................................................4

COMMON SENSE OPERATION ................................................................................................6

ENVIRONMENTAL CONCERNS................................................................................................7

VEHICLE CAPACITY..................................................................................................................7

MODIFICATIONS TO VEHICLE .......................... ...... ....... ...... ....... ...... ....... ...... ....... ...... ....... ...... 7

LOAD BED..................................................................................................................................7

MANUAL LIFT BED ................... ..........................................................................................................................8

ELECTRIC LIFT BED OPERATION....................................................................................................................8

TAIL GATE OPERATION..................................................................................................................................... 8

SEATING.....................................................................................................................................8

VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER............................. .....................................................8

STORAGE...................................................................................................................................9

REAR STORAGE COMPARTMENT................................................................................................................... 9

GLOVE COMPARTMENTS...................... ........................................................................................................... 9

OPERATING THE VEHICLE ...................................................................................................... 9

RUN-IN...............................................................................................................................................................10

Key/Light Switch and Fuel Gauge .................................. ................... ................... ................... ..2

Direction Selector ......................................................................................................................2

Choke ........................................................................................................................................ 2

Accelerator, Brake and Horn .....................................................................................................3

12 Volt Power Outlet .............. ................................................................................................... 3

Winch Mounted to Vehicle ........................................................................................................ 4

Winch Remote Control .............................................................................................................. 4

Winch Clutch Knob .................................................................................................................... 4

Never Operate Winch with Less Than Five Turns Around Drum .............................................. 5

Use a Nylon Sling and Install a Damper when Winching .......................................................... 5

Do Not Hook Cable to Itself ....................................................................................................... 6

Do Not Pull at Angle .................................................................................................................. 6

Load Bed Configurations and Capacities ..................................................................................8

Manual Bed Latch .................... ................................................................................................. 8

Electric Lift Switch .............. .......................................................................................................8

Cargo Platform.............. .......................................................................................................................... 9

Cargo Platform and Rear Compartment ...................................................................................9

Check Oil Level on Dipstick .....................................................................................................10

Page iii

TABLE OF CONTENTS

Clean Entire Dipstick ...............................................................................................................10

COLD STARTING.............................................................................................................................................. 10

STARTING AND DRIVING.................................................................................................................................11

STARTING THE VEHICLE ON A HILL........... ...................................................................................... .............11

COASTING.........................................................................................................................................................11

FUEL..................................................................................................................................................................11

BATTERY........................................................................................................................................................... 12

LABELS AND PICTOGRAMS............................................................................................................................12

SUN TOP & WINDSHIELD (If Equipped) ..........................................................................................................12

VEHICLE CLEANING AND CARE........................................................................................... 12

VEHICLE CLEANING......................................................................................................................................... 12

REPAIR..................................................................................................................................... 13

LIFTING THE VEHICLE..................................................................................................................................... 13

WHEELS AND TIRES........................................................................................................................................13

LIGHT BULB REPLACEMENT..........................................................................................................................14

FUSE REPLACEMENT......................................................................................................................................15

VEHICLE WITH A DISCHARGED BATTERY.................................................................................................... 15

TRANSPORTING VEHICLE........... ....... ...... ....... ...... ....... ...... ....... ...... ...................................... 15

TOWING.............................................................................................................................................................15

HAULING ...........................................................................................................................................................15

NEUTRAL LOCK................................................................................................................................................16

SERVICE AND MAINTENANCE.............................................................................................. 16

SERIAL NUMBER LABEL LOCATION..............................................................................................................17

PERIODIC SERVICE SCHEDULE .......................................................................................... 18

TIRE INSPECTION............................................................................................................................................ 20

FOUR CYCLE ENGINE............................................................................................................ 20

ENGINE SPECIFICATIONS....... ........................................................................................................................20

ENGINE DESCRIPTION.............. ......................................................................................................................20

CHECKING OIL LEVEL .................................... ................................................................................................. 20

CHANGING THE OIL ......................................................................................................................................... 21

STARTER/GENERATOR BELT TENSION........................................................................................................22

ADJUSTING THE BELT.................................... .................................................................................................23

BATTERY CLEANING ....................................................................................................................................... 23

BRAKES.............................................................................................................................................................24

PERIODIC BRAKE TEST FOR MECHANICAL BRAKES ..................................................................................24

LUBRICATION...................................................................................................................................................25

Fuel Tank Location ....................................................... ................... ................... .....................12

Lifting the Vehicle ....................................................................................................................13

Tire Repair.............................................................................................................................................13

Wheel Installation................... ...............................................................................................................14

Wheel Installation .......................................... ..........................................................................14

Headlight Replacement............................................................................................................15

Tail and Brake Light Bulb Replacement ............... ...................................................... .............15

Neutral Lock ............... .............................................................................................................16

Serial Number Label Location .................................................................................................17

Periodic Service Schedule ......................................................................................................18

Clean Entire Dipstick................................................................................................................20

Check Oil Level on Dipstick................................... ................... ................... .................. ...........20

Oil Viscosity Chart................. ...................................................................................................21

Cleaning Top of Engine............................................................................................................21

Remove Oil Filter......................................................................................................................21

Inspect Oil Filter .......................................................................................................................21

Oil Drain Plug .................. .........................................................................................................22

Add Engine Oil .........................................................................................................................22

Check Belt Tension with Guage................................ ................... ................... ................... ......22

Check Belt Tension Manually..................... ..............................................................................23

Adjust Belt Tension..................................................................................................................23

Preparing Acid Neutralizing Solution........................................................................................23

Typical Brake Performance Test..............................................................................................24

Lubrication Points.....................................................................................................................25

Page iv

TABLE OF CONTENTS

AIR INTAKE AND COOLING FINS ....................................................................................................................25

REAR AXLE........................................................................................................................................................ 25

CHECKING THE LUBRICANT LEVEL...............................................................................................................25

AIR CLEANER INSPECTION AND REPLACEMENT........................................................................................26

SPARK PLUG.....................................................................................................................................................26

PROLONGED STORAGE..................................................................................................................................27

CAPACITIES AND REPLACEMENT PARTS..................................................................................................... 27

HARDWARE.......................................................................................................................................................28

Cleaning Cooling System with Air.............................................................................................25

Add, Check and Drain Rear Axle Lubricant ..............................................................................26

Air Cleaner................................................................................................................................26

Gapping the Spark Plug........................................... .................................................................27

Capacities and Replacement Parts ..........................................................................................27

Torque Specifications and Bolt Grades....................................................................................28

GENERAL SPECIFICATIONS.................................................................................................. 35

Vehicle Dimensions .................................... ..............................................................................40

Vehicle Dimensions (Continued) ..............................................................................................41

Vehicle Incline Specifications and Turning Clearance Diameter ..............................................42

LABELS AND PICTOGRAMS................................................................................................ A-1

Label Location ........................................................................................................................A-3

VEHICLE WARRANTIES........................................................................................................ B-1

DOMESTIC WARRANTY.................................................................................................................................B-2

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT.......... .........................................................B-3

FEDERAL EMISSION COMPONENT DEFECT WARRANTY ......................................................................... B-5

DECLARATION OF CONFORMITY (EUROPE ONLY).......................................................... C-1

Page v

TABLE OF CONTENTS

NOTES:

Page vi

SAFETY INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury or property damage, the following must be carefully observed:

Certain replacement parts can be used independently and/or in combination with other accessories to modify an EZ-GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z- GOmanufactured vehicle is modified in any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER FEDERAL 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 Distributor or Dealer MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accorda nce with the State laws applicable in the places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the Final Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.

E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s. The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE

OPERA TED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH A PPLICABLE STATE REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-Z-GO, I am directing that 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 to believe may be operated in personal transportation applications.

Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or through the Internet at the web site for the U.S. Department of Transportation - at Dockets and Regulation, then to Title 49 of the Code of Federal Regulations (Transportation).

GENERAL

All vehicles can be used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible to anticipate and warn against every possible combination of circumstances that may occur. No warning can take the place of good common sense and prudent driving practices.

Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined. E-Z-GO strongly suggests that all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.

If you have any questions regarding this vehicle, contact your E-Z-GO Dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.

E-Z-GO reserves the right to make design changes without obligation to make these changes o n units previously sold and the information contained in this manual is subject to change without notice.

E-Z-GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL. E-Z-GO IS NOT LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL.

This vehicle conforms to the current applicable standard(s) for safety and perform ance require ments. These vehicles are designed and manufactured for off-road use. They DO NOT conform to Feder al 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 on a limited basis and in accordance with local ordinances.

Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.

Page v

SAFETY INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed beyond the factory specification. Such modificatio ns can cause se rious pers onal injury or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance

and may reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions, terrain and common sense.

Operation of the vehicle is limited to persons above the height of 59 inches (150 cm).

GENERAL OPERATION

ALWAYS:

• Use the vehicle in a responsible manner and maintain the vehicle in safe operating cond ition.

• 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.

• Leave the vehicle when there is a risk of lightning.

• Reduce speed to compensate for poor terrain or conditions.

• Apply service brake to control speed on steep grades.

• Maintain adequate distance between vehicles.

• Reduce speed in wet areas.

• Use extreme caution when approaching sharp or blind turns.

• Use extreme caution when driving over loose terrain.

• Use extreme caution in areas where pedestrians are present.

MAINTENANCE

ALWAYS:

• Maintain the vehicle in accordance with the manufacturer’s periodic service schedule.

• Ensure that repairs are performed by those that are trained and qualified to do so.

• Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.

• Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cove r exposed terminals with an insulating material.

• Check the polarity of each battery terminal and be sure to rewire the batteries correctly.

• Use specified replacement parts. Never use replacement parts of lesser quality.

• Use recommended tools.

• Determine 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 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 from exposed flame or persons who are smoking.

• Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.

• Test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic.

• Replace damaged or missing warning, caution or information labels.

• Keep complete records of the maintenance history of the vehicle.

Page vi

SAFETY INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations th at could result in severe personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury, refer the repair or maintenance to a qualified mech anic.

VENTILATION

Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating. Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane

water heaters and furnaces. Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Car-

bon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

Page vii

SAFETY INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

NOTES:

Page viii

LABELS AND PICTOGRAMS

Page - ix

LABELS AND PICTOGRAMS

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

74443G01

1. To Prevent Roll-Back

On a Hill From a Stopped Position

2. Apply Service

Brake With

Left Foot

Maximum weight in basket is 25 lbs. (11 kg). Excess weight may cause injury resulting from vehicle instability and/or frame damage.

< 14° 25%

71084G01

4. Depress Accelerator While

3. Fully

Releasing Service Brake As

Release

Vehicle Starts

Park Brake

35493-G01

35493G01

< 14° 25%

74443G01

71084G01

FAILURE TO FOLLOW THESE

INSTRUCTIONS MAY RESULT IN

SEVERE PERSONAL INJURY

Bed load limit is 250 lbs. (114 kg).

The center of gravity of the load must not exceed 4 inches (10 cm) above the bed oor.

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 in turns.

Do not permit anyone to ride on the platform when used as a load bed.

71093G01

35962-G01

OFF

71131-G01

71131G01

35962G01

WARNING

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY

RESULT IN SEVERE PERSONAL INJURY.

Avoid standing in front of or behind vehicle.

No more than 2 occupants per seat.

Always remain seated and hold on while vehicle is in motion.

Keep feet, legs, hands and arms inside the vehicle at all times.

Do not leave children unattended on seat while vehicle is moving.

74132G01

744132G01

27653G01

WARNING

Windshields do not provide protection from golf balls or other ying objects.

EGWHL14

WARNING

Keep entire body

inside car.

74093G01

MAX ??? lbs. ??? kg

MAX 5 in. 12 cm

MAX 100 lbs. 45 kg

MAX

/ 25%

74821G0

74821G0* For Rotomolded Bed

H O

74093-G01

WARNING

DO NOT TAMPER WITH OR CHANGE THIS ADJUSTMENT OF THE GOVERNOR. FAILURE TO COMPLY COULD RESULT IN SERIOUS PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY.

24880G01

This Label Is Located On Governor Cover At Top Of Rear Axle.

Page - x

LABELS AND PICTOGRAMS

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

WARNING

READ MANUAL

< 14

WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL

MAX

XXX lbs. XXX kg

10.

WARNING USE CAUTION IN INCLEMENT WEATHER

WARNING DO NOT OPERATE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL

MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED

WARNING MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED

LOAD WITH HIGH CENTER OF GRAVITY COULD RESULT IN TIP OVER

MAX XX in. XX cm

LOAD CENTER OF GRAVITY, MAXIMUM HEIGHT

13.

14.

< 14

14û / 25

11.

12.

MAX LOAD

XXX LBS XXX KG

x in

xx cm

SECURE LOAD AS FAR FORWARD AS POSSIBLE. MAXIMUM LOAD BED CAPACITY

DO NOT RIDE IN LOAD BED

DANGER OF EXPLOSION DO NOT FILL GAS CAN IN LOAD BED

WARNING MAXIMUM LOAD & CENTER OF GRAVITY. KEEP LOAD AS FAR FORWARD AS POSSIBLE. DO NOT RIDE IN LOAD BED

KEEP HANDS & FINGERS AWAY FROM DUMP BED DO NOT STAND BEHIND DUMP BED

NOTE: All Pictograms may not apply to your product

Page - xi

LABELS AND PICTOGRAMS

H O

CLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE

15.

UNLEADED GASOLINE

16.

DO NOT SPILL FUEL ON A HOT ENGINE

17.

GROUND FUEL PUMP

18.

LOW OIL PRESSURE

19.

NEGATIVE GROUND BATTERY

20.

DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND

21.

SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION

22.

NO TAMPERING. KEEP HANDS OUT

23.

WARNING CORROSIVE

24.

WARNING EXPLOSIVE

25.

WARNING LETHAL VOLTAGE

26.

DO NOT EXPOSE TO FLAME

27.

DO NOT DISPOSE OF BATTERIES IN LANDFILL

28.

DO NOT DRIVE ON HIGHWAY

29.

WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS

30.

BATTERIES ARE HEAVY. USE CARE LIFTING

31.

USE INSULATED TOOLS

32.

WEAR EYE PROTECTION

33.

NO SMOKING

34.

HOT SURFACE

35.

NOTE: All Pictograms may not apply to your product

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Page - xii

LABELS AND PICTOGRAMS

OPERATE FROM DRIVERS SIDE ONLY

KEEP ARMS AND LEGS WITHIN VEHICLE

TO OPERATE VEHICLE IN FORWARD:

TURN KEY TO ON MOVE DIRECTION SELECTOR TO

FORWARD

DEPRESS ACCELERATOR PEDAL

AND ACCELERATE SMOOTHLY

TO OPERATE VEHICLE IN REVERSE:

TURN KEY TO ON MOVE DIRECTION 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 SELECTOR TO

FORWARD

TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK:

APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO

NEUTRAL

OFF

KEEP CLEAR HAND OR FINGERS CAN BE TRAPPED

ON POSITION

OFF POSITION

HEADLIGHTS

UNLOCKED

LOCKED

DIFFERENTIAL LOCKED

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

WARNING KEEP ENTIRE BODY INSIDE CAR

MAXIMUM TAILGATE LOAD

50.

NOTE: All Pictograms may not apply to your product

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Page - xiii

LABELS AND PICTOGRAMS

ENGINE CRANKING POSITION

51.

START

PULL HANDLE UP TO ENGAGE PARK BRAKE

52.

PULL HANDLE UP, PUSH BUTTON IN, PUSH HANDLE DOWN TO RELEASE PARK BRAKE

53.

AUXILIARY LIGHTS

62.

HORN BUTTON

63.

PUSH TOP OF SWITCH TO 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 READ OWNER'S MANUAL BEFORE OPERATING VEHICLE IN FORWARD OR REVERSE

WARNING READ OWNER'S MANUAL BEFORE ENGAGING TWO OR FOUR WHEEL DRIVE

57.

55.

WARNING READ OWNER'S MANUAL BEFORE PARKING VEHICLE AND LEAVING IT UNATTENDED

56.

FORWARD

NEUTRAL

REVERSE

FRONT DIFFERENTIAL LOCK SWITCH WARNING READ OWNER'S MANUAL BEFORE ENGAGING FRONT DIFFERENTIAL LOCK. DO NOT ENGAGE LOCK WHILE FRONT WHEELS ARE TURNED AND VEHICLE IS AT SPEED.

60.

NOTE: All Pictograms may not apply to your product

150

MINIMUM HEIGHT TO OPERATE VEHICLE IS 59 INCHES (150 CM)

64.

DO NOT OPERATE VEHICLE WHEN LIGHTNING IS IN THE AREA

65.

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Page - xiv

LABELS AND PICTOGRAMS

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

NOTES:

Page - xv

LABELS AND PICTOGRAMS

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

NOTES:

Page - xvi

OPERATION AND SERVICE INFORMATION

ITEM SERVICE OPERATION

Battery Charge battery

Seats Remove protective plastic covering

Brakes Check operation and adjust if necessary

Establish acceptable stopping distance

Tires Check air pressure (see SPECIFICATIONS)

Fuel Fill tank with correct fuel

Engine Check oil level

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Thank you for purchasing a Gas Powered Light Duty Utility Vehicle. Before driving the vehicle, we ask you to spend some time reading this Owner’s Guide. This Guide contains the information that will assist you in the safe operation of the vehicle. It will also assist you in maintaining this highly reliable vehicle . So me illus trations show items that may be optional for your vehicle. This guide covers the operation of several vehicles; therefore, some pictorial views may not represent your vehicle. Physical differences in controls will be illustrated.

This vehicle has been designed and manufactured as a ‘World Vehicle’. Some countries have individual requirements to comply with their specifications; therefore, some sections may not apply in your country.

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 accordance with the Periodic Service Schedule.

Service Parts Manuals and Technician’s Repair and Service Manuals are available from a local Distributor, an authorized Branch or the Service Parts Department. When ordering parts or requesting information for your vehicle, provide vehicle model, serial number and manufacture code.

concentration of hydrogen gas is explosive and could cause severe injury or death. Charging must take place in an area that is adequately ventilated (minimum of 5 air exchanges per hour).

To reduce the chance of battery explosion that could result in severe injury or death, never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc.

Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%. Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five air exchanges per hour is considered the minimum requirement.

Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane gas water heaters and furnaces.

Before a new vehicle is put into operation, the items shown in the INITIAL SERVICE CHART must be performed

BEFORE INITIAL USE

Read, understand and follow the safety label on the instrument panel. Be sure you understand how to operate the vehicle, its equipment and how to use it safely. Maintaining good performance depends to a large extent on the operator.

Improper use of this vehicle could result in severe injury or death. The ST series are light duty utility vehicles, NOT All Terrain Vehicles (ATV’s).

This 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 may take many hours to walk out should you run out of

fuel or be stranded by becoming stuck on unsuitable terrain.

Hydrogen gas is generated as a natural part of the lead acid battery charging process. A 4%

Fig. 1 Initial Service Chart

Vehicle battery must be fully charged before initial use. Check for oil or fuel leaks that could have developed in

shipment from the factory. Determine and record braking distance required to stop

vehicle for future brake performance tests. Remove the protective clear plastic, that protect the

seat bottom and back rest during shipping, before placing the vehicle in service.

CONTROLS AND INDICATORS

Vehicle controls and indicators consist of:

• key/light switch

• direction selector

• choke

Page 1

OPERATION AND SERVICE INFORMATION

OFF

FUEL

Key/Light Switch

Low Oil Pressure Light

Fuel Gauge

NOTICE

Forward

Reverse

Choke

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• fuel gauge

• low oil pressure indicator light

• accelerator pedal

• combination service and park brake pedal

• horn

• 12 volt power outlet

KEY/LIGHT SWITCH

Fig. 2 Key/Light Switch and Fuel Gauge

Located on the dash panel, this switch enables the basic electrical system of the vehicle to be turned on and off by turning the key . To prevent inadvertent operation of the vehicle when left unattended, the key should be turned to the ‘OFF’ position and removed.

CHOKE

The choke is used to aid cold starting (Ref. Fig. 4 on page 2). See (Refer to COLD STARTING on page 10).

Fig. 4 Choke

FUEL GAUGE

The fuel gauge (if equipped) will either be located on the dash panel or directly on the fuel tank (Ref Fig. 2 on page 2).

If the vehicle is equipped with factory installed custom accessories, some accessories remain operational with the key switch in the ‘OFF’ position.

If the vehicle is equipped with lights, the key switch has a position to operate them, indicated by the light icon.

DIRECTION SELECTOR

To reduce the possibility of component damage, the vehicle must be completely stopped before moving the direction selector.

Located on the seat support panel, this lever permits the selection of either ‘F’ (forward) or ‘R’ (reverse). The vehicle should be left in ‘F’ when unattended.

Page 2

LOW OIL PRESSURE INDICATOR LIGHT

A low oil pressure indicator light is located on the dash panel (Ref Fig. 2 on page 2). The light illuminates when the oil pressure is low. Check oil level. If oil level is between ADD and FULL mark on dipstick, a mechanical problem exists within the engine and the vehicle must not be driven (Ref Fig. 18 on page 10). Contact a local distributor or authorized branch.

To prevent engine damage, do not operate engine until oil pressure is corrected. Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.

If oil level is below ADD mark on dipstick, add oil to bring level to FULL mark. Drive vehicle a short distance and check oil pressure. If oil light does not come on, continue to use vehicle.

Fig. 3 Direction Selector

OPERATION AND SERVICE INFORMATION

NOTICE

Service Brake

Accelerator

Horn

Park Brake

12V Power

Outlet

OFF

FUEL

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ACCELERATOR PEDAL

HORN

The horn is operated by pushing the horn button located on the floor to the left of the brake pedal.

Unintentional movement of the accelerator pedal will release the park brake and may cause the 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 (Ref Fig. 5 on page 3). To stop the vehicle more quickly, depress the service brake. If key switch is ‘ON’ and park brake is set, depressing the accelerator inadvertently will release the park brake and will cause the vehicle to move which could cause severe injury or death.

Depressing the accelerator pedal will release the park brake if it is engaged. This is a feature to assure the vehicle is not driven with the park brake engaged. Depressing the accelerator pedal is not the preferred method of releasing the park brake.

Depressing the lower section of the brake pedal is the preferred method of releasing the park brake to assure the longest service life of brake components.

COMBINA TION SERVICE AND P ARK BRAKE PEDAL

The brake pedal incorporates a park brake feature (Ref Fig. 5 on page 3). To e ngage, pu sh down on the uppe r section of the pedal until it locks in place. The park brake will release when the service brake pedal is depressed. Use the lower section of the brake pedal to operate the service brake system.

12 VOLT POWER OUTLET

Overuse of accessories may drain the battery and leave insufficient reserve to start the vehicle.

A 12 volt power outlet, rated at 15 amps, is located to the left side of the key/light switch (Ref Fig. 6 on page

3). It provides constant power for accessories equipped with a 12 volt plug.

Fig. 6 12 Volt Power Outlet

TERRAIN

The vehicle is designed for use on improved roads (but not on public highways). The vehicle may also be used on established trails or open terrain that is free from stumps, large rocks or holes.

The vehicle should not be used to cross water.

WINCH

HD ONLY

Fig. 5 Accelerator, Brake and Horn

The HD may be equipped with an optional winch. Read, understand and follow all of the following information on the operation and use of winch before attempting to operate it.

OPERATION OF THE WINCH

The winch may be mounted at the front or rear of the vehicle and moved to accommodate different situations. At the front, it is mounted under the center of the front cowl to a bracket attached to the front axle as shown (Ref Fig. 7 on page 4). At the rear, the winch is mounted upside down in the hitch receiver.

Page 3

OPERATION AND SERVICE INFORMATION

NOTICE

Front Axle

Clevis Pin

Spring Pin

Winch shown mounted at front of vehicle

Receptacle

Remote Control

Pull out

ENGAGED

Clutch Knob

LOCKED OUT

Turn 90°

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If mounting winch at rear of vehicle, the winch must be mounted upside down.

Fig. 9 Winch Clutch Knob

To win d cable, use han dsave r bar to keep te nsion on the cable while activating remote. When winding cable, make sure the cable winds tightly and evenly onto the drum leaving no gaps that could cause premature wear to the cable. When using winch under a load, operate the remote control from as far to the side of the vehicle as possible. Do not operate winch while sitting in passenger seat. Read the following section (WINCH

Fig. 7 Winch Mounted to Vehicle

APPLICATIONS) before attempting to operate winch.

Before moving the winch, unplug the winch connector from the wire harness. To move the winch from one end of the vehicle to the other, remove the spring pin, pull out the clevis pin and remove the winch mount tube from the receiver. Move to opposite end of vehicle and install by inserting clevis pin and securing with spring pin. Plug the winch connector into wire harness.

The winch remote control plugs into the receptacle on the seat support.

To unwind the cable, locate the clutch kn ob on the winch. Pull out knob and rotate 90° to lock out. Using handsaver bar, pull cable from winch drum. Leave at least five turns of cable on drum. Re-engage drum by turning clutch knob 90°, returning it to original position.

Fig. 8 Winch Remote Control

WINCH APPLICATIONS

The winch may be used for a number of purposes, including pulling the vehicle if it loses traction on unsuitable terrain.

Improper use of the winch could result in a number of conditions that could cause severe injury or death to operator, occupants of vehicle or bystander.

It is impossible to predict all conditions that the winch could be used, therefore the following warnings should not be considered as complete. Before operating the winch, consider the possible dangers and take precautions to protect yourself, your passenger and any bystanders.

To prevent severe injury or death to operator, occupants or bystanders, select the object to which the cable is attached with the following considerations:

Make sure the object cannot be pulled over or otherwise damaged.

The object the winch is attached to could fall on the vehicle and it’s occupants.

Page 4

OPERATION AND SERVICE INFORMATION

Nylon Sling

Damper

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

If attaching the winch to a dead tree, a section could fall.

When pulling vehicle with winch, pull straight only. Do not permit the cable to contact the side of the drum.

Do not pull vehicle at angle. If the vehicle is pulled at an angle, it could turn over causing severe injury or death to anyone in the area. The winch cable could also become overstressed and break causing severe injury or death to anyone struck by the cable.

Fig. 10 Never Operate Winch with Less Than Five

Turns Around Drum

Do not attempt to pull loads exceeding 1500 lbs. (680 kg).

If the vehicle becomes stuck or ‘hung up’ on an obstruction, the vehicle may be moved using the winch.

The winch may be installed in either the front or rear receiver and held in place with the locking pin provided.

To prevent severe injury or death, read and understand the following before attempting to use the winch:

The winch is not intended to be used in any hoisting operation.

The rolling load capacity 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 uncomfortably hot to the touch, stop winching and allow the motor to cool.

To pull out the cable, the free spool clutch knob must be used. Pull out and rotate the knob. If the cable is under any load the clutch may not release easily. Jog out some of the cable to release the tension and operate clutch. Pull out the desired amount of cable and secure. Engage the drum by rotating the knob until it snaps in place. Never operate the winch unless the clutch is engaged.

Have all persons and pets leave the area while operating winch. Never allow anyone to remain in the vehicle.

To prevent damage to the wire cable, never hook the cable to itself. Always use a nylon sling (Ref Fig. 11 on page 5) (Ref Fig. 12 on page 6).

Stay clear of the winch, the cable and the cable hook. Place a heavy cloth, jacket or blanket over the cable to act as a damper should the cable break when operating the winch (Ref Fig. 11 on page 5).

Always wear thick leather gloves when handling the wire cable.

Replace frayed wire cable with a direct factory replacement only.

Never operate the winch with less than five (5) full turns of cable around the drum (Ref Fig. 10 on page 5). If the winch motor stalls from overloading, do not continue to activate the winch remote control. The wire cable may become overstressed.

Fig. 11 Use a Nylon Slin g and Ins tall a Damper when

Winching

Page 5

OPERATION AND SERVICE INFORMATION

Correct

Incorrect

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

If the vehicle is being used as an anchor to winch a load, it should have the park brake set and chocks installed on all wheels.

Never use the winch to lift people or other overhead loads.

Do not use the winch to secure loads. Use a tie down designed for the job.

Do not apply shock loads to the winch.

Fig. 12 Do Not Hook Cable to Itself

Remember that the winch operation will drain the battery and may leave insufficient power to start the vehicle.

When operating the winch, keep the entire area in view.

Never release the free spool clutch while the cable is under load.

Never work around the winch drum or the winch cable while it is under tension.

Unplug the winch switch before working on the winch drum in order to prevent inadvertent operation.

When operating winch, take up slack slowly. Stop winch before cable becomes tight and inspect all winching connections. Check winch attachment, hook attachment, 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. This may jam the winch causing damage to the cable and/or the winch. Pulling the vehicle at an angle can cause damage to the front suspension and may cause the vehicle to overturn. When pulling vehicle, pull straight only.

Do not attempt to modify or weld the winch.

COMMON SENSE OPERATION

To prevent severe injury or death, observe the following:

Never transport loaded firearms on or in vehicle.

Check that firearms are unloaded with the safety engaged and are properly secured with muzzle pointing in a safe direction before operating vehicle.

Be aware of other firearms in proximity to operator and passengers.

This vehicle is not a toy. If not operated properly and responsibly, it can cause severe injury or death to the operator, passengers or bystanders. All operators should possess a valid driver’s license. Children should not be permitted to operate the vehicle. Children may not have the skill, judgement or strength to operate this or similar vehicles.

Alcohol, drugs and many over the counter medications reduce the ability of the driver to operate the vehicle safely. Always review side effects of any medication with a doctor or pharmacist before operating vehicle.

Fig. 13 Do Not Pull at Angle

Page 6

Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when operating vehicle in rough or densely wooded 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. When operating vehicle in wet weather conditions, remember that the brakes may need to be lightly applied in order to provide enough friction to dry the brake unit. If wet, the brakes will lose much of their effect.

OPERATION AND SERVICE INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

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 climb. If you attempt to climb a hill that is too steep or if you are unable to achieve adequate traction, do not attempt to turn around on

the hill. Slowly back straight down the hill using the service brake to control speed.

ENVIRONMENTAL CONCERNS

As a responsible user, practice respect for all wildlife and their habitat. Respect private property and comply with all local laws and regulations governing the use of light duty utility vehicles. Do not tamper with the exhaust system or governor of gasoline powered vehicles. The exhaust system has been tuned to the engine for maximum performance. Removal or modification of the exhaust is annoying to other people and will not improve the performance of the vehicle.

MODIFICATIONS TO VEHICLE

Changes to the weight distribution or the center of gravity may make vehicle unstable or prone to roll over which could result in severe injury or death to the operator or passengers.

Do not modify the vehicle in any manner that will 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 the operator or passengers.

LOAD BED

To prevent severe injury or death while driving, be aware of the following:

Environmental hazards such as steep slopes, overhanging limbs, etc.

Danger of fire when vehicle is operated over dry combustible organic material.

When driving, be aware of environmental hazards such as steep slopes, overhanging limbs, etc. Be aware of the danger of fire when the gasoline powered vehicle is operated over dry combustible organic material.

VEHICLE CAPACITY

Due to the variety of ways the vehicle may be used, it is important that the operator consider any potential hazards before use to prevent serious injury or death.

The vehicle may be configured with a variety of load bed options. (Ref Fig. 14 on page 8). The weight of the driver and passengers plus any options or accessories must be deducted from the total payload rating to determine the cargo capacity. ity of the load bed.

Never exceed the rated capac-

To reduce the possibility of severe injury or death, read, understand and follow the Warning label affixed to the front of the load bed. An electric lift bed is the standard bed for the ST

400. Lower capacity vehicles have 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 warning label for maximum load. The load must be positioned in the bed as far forward as possible, distributed in such a way that its center of gravity must not be higher than height noted on label, and secured. Failure to follow these instructions may result in severe injury, damage the vehicle and/or cause the vehicle to tip over. Use extra care when operating loaded vehicle.

Do not permit any one to ride in the load bed. Do not drive the vehicle with the load bed raised or with

the tailgate unsupported. When using a load bed, be sure to avoid backing up to

the edge of a drop off, such as a loading dock or ravine. A misjudgment of distance or an unstable surface could result in the vehicle falling backwards.

Never fill a gas can in the bed of a vehicle. Static discharge could ignite gasoline vapor and cause an explosion.

Page 7

OPERATION AND SERVICE INFORMATION

CONVERTIBLE CARRIER (Rear Facing Seat/Cargo Deck) 2 Persons. or Cargo not to exceed 250 Lbs (113 kg) Maximum Vehicle Capacity 800 lbs. (360 kg)

ROTOMOLDED BED with Manual Dump or Optional Electric Dump Maximum Bed Capacity 500 lbs. (225 kg) Maximum Vehicle Capacity 800 lbs. (360 kg)

Front of Vehicle

Manual Load Bed Latch Move Rearward to release

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Always place a gas can on the ground before filling. Never fill a gas can in the bed of the vehicle. Static electricity is built up during the fueling process and could discharge causing the gasoline vapor to ignite.

Fig. 14 Load Bed Configurations and Capacities

MANUAL LIFT BED

Exercise caution while operating the manual lift bed to ensure the bed is not released during lifting or lowering procedure. Severe injury could result if bed is released and traps fingers or other body parts.

To lift the manual lift bed, p ull back on th e latch relea se handle immediately behind the driver seat. Raise the bed using the handle on the side of the bed.

ELECTRIC LIFT BED OPERATION

Exercise caution while operating the electric lift bed to ensure clothing is not caught during lifting or lowering procedure. Severe injury could result if bed is lowered and traps fingers or other body parts.

The electric lift switch is located on the driver side of the front seat panel. Move the toggle switch lever up to raise the load bed and down to lower.

Before operating load bed, check to ensure no one is behind the vehicle.

Fig. 16 Electric Lift Switch

Raise

Lower

TAIL GATE OPERATION

To o pen 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 tail gate, remove the side cables from the load b ed an d open tail gate until it is straight down, move tail gate panel straight up to remove from pins and remove from the load bed. Reassemble in reverse order.

SEATING

VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER

Fig. 15 Manual Bed Latch

Page 8

To prevent severe injury or death, rear seat passengers should hold on to both the hip restraints and the rear hand hold when the vehicle is in motion. Always be sure that all passengers are seated and holding on before operating vehicle.

Be sure that all passengers are seated and holding onto both the hip restraint and the rear hand hold (rear facing passengers) before operating vehicle.

OPERATION AND SERVICE INFORMATION

Cargo Platform

Rear Handrail

REAR SEAT FOLDED UP

REAR SEAT FOLDED DOWN

Rear Storage Compartment

Front of Vehicle

NOTICE

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STORAGE

VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER

Cargo Platform

center of gravity must not be higher than 4" (10 cm) above the platform, and securely fastened down. Failure to follow these instructions could cause personal injury, damage to the vehicle and/or cause the vehicle to tip over. Be aware that increased loads may effect driving characteristics.

REAR STORAGE COMPARTMENT

Passengers should never be allowed to ride on the cargo platform. Severe injury or death could result if they should fall out or the vehicle is involved in an accident or 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 rear storage compartment is not weather tight.

The rear storage compartment can be accessed with the rear seat folded down by reaching under the central portion of the cargo platform and lifting the platform up.

GLOVE COMPARTMENTS

A lockable glove compartment is located on each side of the instrument panel.

OPERATING THE VEHICLE

Improper use of the vehicle or the lack of proper 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 resulting from loss of vehicle control, the following warnings must be observed:

Fig. 17 Cargo Platform and Rear Compartment

The cargo platform is accessed by folding the rear seat down (Ref Fig. 17 on page 9). Be careful when loading the vehicle. Tie down loads to prevent shifting. Do not

overload vehicle. The cargo platform is limited to a maximum load of 250 lbs. (115 kg). The load must be positioned on the platform as far forward as possible, its

When driving vehicle, consider the terrain, traffic conditions and the environmental factors which effect the terrain and the ability to control the vehicle.

Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.

Stay in designated areas and avoid extremely rough terrain.

Maintain a safe speed when driving down hill. Use service brake to control speed when traveling down an incline. A sudden stop or change of direction may result in loss of control.

Slow down before and during turns. All turns should be made at reduced speed.

Page 9

OPERATION AND SERVICE INFORMATION

Maximum Oil Level For Hot Engine Do Not Overfill

Fill Cold Engine To This Point

Safe

Operating Range

Hot Engine

Add Oil

NOTICE

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Never drive vehicle up, down, or across an incline that exceeds 14° (25% grade).

To reduce the possibility of severe injury or death resulting from improper vehicle operation, the following warnings must be observed:

Refer to GENERAL SPECIFICATIONS for seating capacity.

Depressing accelerator pedal will release foot operated park brake and may cause inadvertent vehicle movement. Turn the key to the ‘OFF’ position whenever the vehicle is parked.

To prevent inadvertent movement when the vehicle is to be left unattended, engage the 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.

Always bring the vehicle to a complete stop before shifting the direction selector.

Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.

The oil dipstick/fill cap must be in place before operating the engine. Failure to install the dipstick/fill cap will result in oil becoming contaminated and/or being discharged into the engine compartment.

Oil Dipsticks are unique to this model vehicle. Do not interchange oil dipsticks between models

The oil should be changed in accordance with the Periodic Service Schedule while the engine is warm.

Fig. 18 Check Oil Level on Dipstick

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 vehicle is in motion.

RUN-IN

Check for oil or fuel leaks that could have developed in shipment from the factory. Avoid full throttle starts and rapid acceleration until the engine has achieved operating temperature.

All engines consume more oil than normal during the first hours of operation. As internal moving parts are run-in, oil consumption should gradually decrease until the rate of consumption stabilizes.

Check the oil level per the Periodic Service Schedule (Ref Fig. 27 on page 18). Add oil if the level on the dipstick indicates that oil is in the add oil range.

Fig. 19 Clean Entire Dipstick

COLD STARTING

Starting a cold engine may require use of the choke. Depress the accelerator approximately 1" (2.5 cm) or until the starter just begins to operate. Pull the choke out if required. Accelerate slowly and push the choke in completely when the engine runs smoothly.

Do not allow the starter to operate continuously for more than 10 seconds. Allow 30 seconds between starting attempts. If the vehicle does not start on the third attempt, turn the key switch off, set the park brake and determine the cause of the problem.

If the vehicle had been running and the engine does not start within 10 seconds, use the choke.

Page 10

OPERATION AND SERVICE INFORMATION

NOTICE

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

STARTING AND DRIVING

To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release service brake until engine has started.

To op erate ve hicle:

• Apply the service brake, place the key in the key

switch and turn it to the ‘ON’ position.

• Move the direction selector to the direction

desired.

• Release the park brake by depressing the ser vice

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 circuit is de-energized and the engine stops. To stop the vehicle more quickly, depress the ser- vice brake pedal.

When the direction selector is in the reverse position, a warning signal will sound to indicate that the vehicle is ready to run in reverse.

STARTING THE VEHICLE ON A HILL

death from coasting at above recommended speeds, limit speed with service brake.

On steep hills, it is possible for the vehicle to coast at greater than normal speeds encountered on a flat surface. To reduce the p ossible lo ss of vehicle control a nd severe drivetrain damage, speeds should be limited to no more than the maximum governed speed on level ground (see GENERAL SPECIFICATIONS). 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 electrical

items which could produce a spark. Always handle gasoline in a well ventilated

area. Always wear eye protection to protect

against splashed fuel and fuel vapors. Always allow adequate space for the expan-

sion of gasoline. Leave at least 1" (2.5 cm) space below bottom of filler neck.

To reduce the possibility of roll-back which could result in severe injury or vehicle damage, do not release service brake until engine has started.

Do not hold vehicle on hill by using accelerator and engine. This will cause premature and excessive wear to drive train components.

To red uce the possibility of p ermanen t dama ge to the drive system, it is important to prevent excessive rollback when starting the vehicle on a hill.

Place left foot on service brake and release the park brake. Depress accelerator with right foot and release the service brake by lifting left foot.

COASTING

To reduce the possibility of severe injury or

Inspect fuel cap, tank and other components for leaks or deterioration that could cause a hazardous condition.

Some fuels, called oxygenated or reformulated gasoline, are gasoline blended with alcohols or ethers. Excessive amounts of these blends can damage the fuel system or cause performance problems. If any undesirable operating symptoms occur, use gasoline with a lower percent age of alcohol or ether .

Use fresh regular grade unleaded fuel. Ethanol blend fuel up to 10% is permissible.

The fuel tank is located under the seat on the passenger side of the vehicle. Fill the tank with fresh, clean, automotive grade gasoline. High altitude or heavy use/ load applications may benefit from higher octane gasoline.

Do not use gasoline which contains Methanol.

Page 11

OPERATION AND SERVICE INFORMATION

1" Min. (2.5 cm)

Fuel

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over or falling objects. The windshield does not provide protection

from tree limbs or flying objects.

The top and windshield provide some protection from the elements; however, they will not keep the operator and passengers dry in a downpour. For complete protection from the elements, a weather enclosure can be installed. This vehicle is not equipped with seat belts and has not been designed to provide roll over protection.

Fig. 20 Fuel Tank Location

BATTERY

Clean windshield with lots of water and a clean cloth. Minor scratches may be removed using a commercial plastic polish or Plexus plastic cleaner available from the Service Parts Department.

VEHICLE CLEANING AND CARE

Excessive use of accessories may drain the battery and leave insufficient reserve to start the vehicle.

The vehicle uses a combination starter/generator to both start the engine and charge the battery. The engine will not idle; therefore, the battery cannot be charged while the vehicle is stopped. Do not operate accessory items (such as accessory lights, radios, winch, etc.) excessively while the vehicle is stopped.

The generator is capable of supplying 35 amps; therefore, operation of all accessories could result in the discharge of the battery even though the engine is running and the generator operating. Discharging the battery is known as deep cycling. The battery is not a deep cycle model, but 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 at 10 amps or less and in accordance with all instructions provided by the manufacturer of the charger.

LABELS AND PICTOGRAMS

Vehicles may be labeled with pictograms as a method of conveying information or warnings. The section LABELS AND PICTOGRAMS illustrates and explains pictograms that may appear on the vehicle. Not all pictograms shown in LABELS AND PICTOGRAMS will be found on your vehicle.

SUN TOP & WINDSHIELD (If Equipped)

The top does not provide protection from roll

Page 12

VEHICLE CLEANING

To reduce the possibility of severe injury or vehicle damage, read and understand all instructions supplied by manufacturer of pressure washer.

When pressure washing exterior of vehicle, do not use pressure in excess of 700 psi (4800 kpa). To reduce the possibility of cosmetic damage, do not use any abrasive or reactive solvents to clean plastic parts.

It is important that proper techniques and cleaning materials be used. Using excessive water pressure may cause severe 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 with lots of water and a clean cloth. Minor scratches may be removed using a commercial plastic polish or Plexus the service parts department.

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, tar, asphalt, shoe polish, etc. will require the use of a commercially available vinyl/rubber cleaner.

The painted surfaces of the vehicle provide attractive appearance and durable protection. Frequent washing

plastic cleaner available from

OPERATION AND SERVICE INFORMATION

Center of Front Axle

Flat Portion of Frame

Outside End of Rear Axle

View from Underside of Vehicle

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

with lukewarm or cold water and mild detergent is required to preserve the painted surfaces.

Occasional cleaning and waxing with non-abrasive products designed for ‘clear coat’ automotive finishes will enhance the appearance and durability of the painted surfaces.

Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle. These materials will cause corrosion of underbody parts unless flushed occasionally with plain water. Thoroughly clean any areas where mud or other debris can collect. Sediment packed in closed areas should be loosened to ease it’s removal, taking care not to chip or otherwise damage paint.

If the engine does not start or runs improperly after washing, remove the spark plug wires (by pulling the spark plug boots, never the wires). Dry all connections with forced air. Reinstall the wires.

REPAIR

To ra ise the en tire vehicle , install chocks in front and behind each front wheel. Center 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 test the stability of the vehicle on the two jack stands.

Place the jack at the center of the front axle. Raise the vehicle enough to place jack stands under the frame crossmember as indicated.

Lower the jack and test the stability of the vehicle on all four jack stands.

If only the front or rear of the vehicle is to be raised, place the chocks in front and behind each wheel not being raised to stabilize the vehicle.

Lower the vehicle by reversing the lifting sequence.

LIFTING THE VEHICLE

Tool List Qty.

Floor jack ...... ...................................... ........................ 1

Jack stands......................... ... .... ... .............................. 4

Chocks........................................................................ 4

Some servicing operations may require the front wheels, the rear wheels, or the entire vehicle be raised.

To reduce the possibility of severe injury or death from a vehicle falling from a jack:

Be sure the vehicle is on a firm and level surface.

Never get under a vehicle while it is supported by a jack.

Use jack stands and test the stability of the vehicle on the stands.

Always place chocks in front and behind the wheels not being raised.

Fig. 21 Lifting the Vehicle

WHEELS AND TIRES

Use extreme care since the vehicle is extremely unstable during the lifting process.

When lifting vehicle, position jacks and jack stands at the areas indicated only.

Tire Repair

Tool List Qty.

Lug wrench, 3/4”.......................................................... 1

Impact socket, 3/4”, 1/2” drive.....................................1

Impact wrench, 1/2” drive............................................1

Torque wrench, 1/2” drive............................................1

Page 13

OPERATION AND SERVICE INFORMATION

NOTICE

Tire style may vary

'Cross Sequence'

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Immerse the tire in water to locate the leak and mark with chalk. Insert tire plug in accordance with manufacturer’s instructions.

A tire explosion can cause severe injury or death. Never exceed inflation pressure rating on tire sidewall.

To reduce the possibility of tire explosion, pressurize tire with small amount of air applied intermittently to seat beads. Due to the low volume of the small tires, over inflation can occur in seconds. Never exceed the tire manufacturer’s recommendation when seating a bead. Protect face and eyes from escaping air when removing valve core.

To reduce the possibility of severe injury caused by a broken socket when removing wheels, use only sockets designed for impact wrench use.

Use caution when inflating tires. Over inflation could cause the tire to separate from the wheel or cause the tire to explode, either of which could cause severe injury.

Use caution when inflating tires. Due to the low volume of the small tires, over inflation can occur in seconds. Over inflation could cause the tire to separate from the wheel or cause the tire to explode.

Tire inflation should be determined by the condition of the terrain. See GENERAL SPECIFICATIONS section for recommended tire inflation pressure. For outdoor applications with major use on grassy areas, the following should be considered. On hard turf, it is desirable to have a slightly higher inflation pressure. On very soft turf, a lower pressure reduces the possibility of tires cutting into the turf. For vehicles being used on paved or hard surfaces, tire inflation pressure should be in the higher allowable range, but under no condition should inflation pressure be higher than recommended on tire sidewall. All four tires should have the same pressure for optimum handling characteristics. Be sure to 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 the tread is to use a commercial tire plug.

To reduce the possibility of severe injury, be sure mounting/demounting machine is anchored to floor. Wear OSHA approved safety equipment when mounting/demounting tires.

If the tire is to be removed or mounted, the tire changing machine manufacturer’s recommendations must be followed 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) torque.

It is important to follow the ‘cross 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. Finger tighten lug nuts in a ‘cross sequence’ pattern (Ref Fig. 22 on page 14). Tighten lug nuts to 50 - 85 ft. lbs. (70 - 115 Nm ) torque in 20 ft. lbs. (30 Nm) increments following the ‘cross sequence’ pattern.

Fig. 22 Wheel Installation

LIGHT BULB REPLACEMENT

Tire plug tools and plugs are available at most automotive parts outlets and have the advantage of not requiring the tire be removed from the wheel.

If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire.

Page 14

For vehicles with headlights, locate the two screws on backside of cowl that secure headlight. Remove screws, pull headlight out and disconnect wires. Connect wires to new headlight, install in cowl and secure with screws previously removed.

OPERATION AND SERVICE INFORMATION

Headlight

Bulb

Turn Signal Lens

Turn Signal

Housing

Inside of Cowl

Rear Fender

Tail/Brake Light

Roll Rubber Bezel Away From Body

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Fig. 23 Headlight Replacement

To rep lace the tu rn signal lig ht bulb, su pport turn signa l housing from backside of cowl while removing two screws securing lens. Install new bulb and replace lens.

erator functions as a starter and with the engine running, it functions as a generator.

With the short running times associated with this kind of vehicle, the generator is more than adequate to maintain the battery charge level. The generator is not designed to charge a discharged battery.

When engine starts, the clutches engage and cause vehicle to move making ‘jump starting’ both dangerous and impractical.

If the vehicle battery has become discharged, it must be charged using a 12 volt charger that is rated at 10 amps or less. Read and understand all instructions provided by the manufacturer of the charger.

TRANSPORTING VEHICLE

To rep lace the tail and brake light bulb , roll the rub ber bezel from around the edge of the taillight and remove lens. Install replacement bulb and replace lens.

Fig. 24 Tail and Brake Light Bulb Replacement

FUSE REPLACEMENT

To repla ce fuses, locate the fuse block und er the driver side seat. Pull out old fuse and replace with a new automotive type fuse. Headlight and taillight bulbs and fuses are available from a local Distributor, an authorized Branch or the Service Parts Department.

VEHICLE WITH A DISCHARGED BATTERY

To reduce the possibility of severe injury or death from inadvertent motion, do not attempt to ‘jump start’ a vehicle.

The vehicle is equipped with a starter/generator and does not idle. When starting the engine, the starter/gen-

TOWING

This vehicle is not designed to be towed.

It is recommended that the vehicle be moved by placing the entire vehicle on a trailer, flatbed truck or other suitable transport.

HAULING

To reduce the possibility of severe injury or death while transporting vehicle:

Secure the vehicle and contents. Never ride on vehicle being transported. Always remove windshield before transport-

ing. Maximum speed with sun top installed is 50

m.p.h. (80 kph).

If the vehicle is to be transported at highway speeds, the sun top must be removed and the seat bottom secured. When transporting vehicle below highway speeds, check for tightness of hardware and cracks in sun top at mounting points. Always remove windshield when transporting. Always check that the vehicle and contents are adequately secured before transporting. The rated capacity of the trailer or truck must exceed the weight of the vehicle (see GENERAL SPECIFICATIONS for vehicle weight) and load. Lock the park brake and secure the vehicle using ratchet tie downs.

Page 15

OPERATION AND SERVICE INFORMATION

Hole in Direction Selector Cam

Unlocked

Sgl 1

Ref Isl 1S

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

NEUTRAL LOCK

To prevent the drive n clutch from turn ing the re ar wheels during service operations and to prevent wear to the belt while being towed, a neutral lock is located on the direction selector.

The neutral lock is located on the direction selector. To operate neutral lock, first turn the key switch to ‘OFF’, place direction selector in ‘R’ and remove seat. Pull out (motion 1) and rotate (motion 2) the neutral lock pin handle so that the pointed portion of the handle is over the side of the direction selector cam (Ref Fig. 25 on page 16). Move direction selector lever towards the area between ‘F’ and ‘R’. During that motion, the pin will snap into the hole in the direction selector mounting bracket, preventing any movement of the lever. When in this position, the direction selector remains locked in the neutral position.

Spring loaded mechanism. To prevent possibility of fingers becoming pinched in the direction selector mechanism, hold direction selector lever when releasing neutral lock pin handle.

tions before reading and understanding all notes, cautions and warnings in this manual.

Any servicing requiring adjustments to be made to the power train while the engine is running must be made with both drive wheels raised and vehicle properly supported on jack stands.

To reduce the possibility of engine damage, never operate vehicle at full throttle for more than 4 - 5 seconds while vehicle is in a ‘no load’ condition.

Wear eye protection when working on the vehicle. Use extra care when working around batteries, or using solvents or compressed air.

To reduce the possibility of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the battery before removing battery wires.

Wrap wrenches with vinyl tape to reduce the possibili-

ty of a dropped wrench ‘shorting out’ a battery, which could result in an explosion.

Fig. 25 Neutral Lock

SERVICE AND MAINTENANCE

To reduce the possibility of severe injury or death from improper servicing techniques:

Do not attempt any type of servicing opera-

Reduce the possibility of accidental starting by disconnecting battery at negative terminal before servicing.

The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes. Treat 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) sodium bicarbonate (baking soda) dissolved in 1 quart (1 liters) of water and flushed with water.

Aerosol containers of battery terminal protectant must be used with extreme care. Insulate metal container to reduce the possibility of can contacting battery terminals which could result in an explosion.

It is in the best interest of both vehicle owner and service technician, to carefully follow the procedures recommended in this manual. Preventative maintenance, applied at recommended intervals, is the best guaran-

Page 16

OPERATION AND SERVICE INFORMATION

Label No.

Part A and B

Part C/D

PART A

PART BPART C/D

Serial Number

Labels

Lift Flap on Access Panel

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

tee for keeping the vehicle both dependable and economical.

This vehicle will give years of satisfactory service, providing it receives regular maintenance. Refer to the Periodic Service Schedule for appropriate service intervals (Ref Fig. 27 on page 18). Refer to Lubrication Points for appropriate lubrication locations (Ref Fig. 41 on page 25).

SERIAL NUMBER LABEL LOCATION

Two serial number and manufacture date code plates are on the vehicle. One is placed on the body below the front, driver side of the seat. The other is located on the chassis between the seat back supports.

Design changes take place on an ongoing basis. In

order to obtain correct components for the vehicle, the manufacture date code, serial number and vehicle model must be provided when ordering service parts.

To prolong vehicle life, some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures, extreme dust/debris conditions, frequent use with maximum load.

To acce ss power train for ro utine ma intena nce, lift or remove seat. For major repair, refer to appropriate Technician ’s Repair and Service Manual.

Some service procedures may require the vehicle to be lifted. Refer to LIFTING THE VEHICLE for proper lifting procedure and safety information.

Fig. 26 Serial Number Label Location

Page 17

OPERATION AND SERVICE INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

PERIODIC SERVICE SCHEDULE

 Check  Clean, Adjust, etc.  Replace

To perform service that is listed in this schedule but not described in this manual, contact a local Service Representa-

tive or see the Repair and Service Manual for this vehicle.

NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions

DAILY

BEFORE USE:

 Check service brake general operation  Check park brake operation - does it hold on a hill.  Check warning device function in reverse  Check tire pressure, condition of tires & rims.  Check smooth operation of accelerator.  Check for loose or missing hardware.  Check Battery - state of charge, condition, loose terminals, corrosion, hold down &

hardware

 Check overall vehicle condition

WEEKLY (includes items listed in previous table & the following)

TIRES Examine for cuts, excessive wear & pressure (See GENERAL SPECIFICAT IONS) WHEELS  Check for bent rims, missing or loose lug nuts FUEL GAUGE  Check for proper operation (at fueling), and fuel cap vent is free of dirt ENGINE OIL  Check and add if required - DO NOT OVERFILL COOLING FAN  Check for build up of debris inside blower housing & clean if required. STARTER/GENERATOR BELT  Check for tension, wear, cracks

MONTHLY - 20 HOURS (includes items listed in 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) PARK BRAKE  Check brake performance and adjust if required CHOKE CABLE  Check for smooth movement and adjustment - DO NOT LUBRICATE CABLE CARBURETOR LINKAGE  Check attachment, adjust as required DIRECTION SELECTOR  Check attachment, adjust as required ENGINE  Check for unusual noise, vibration, acceleration, oil leaks COOLING FAN  Check for build-up of foreign matter inside blower housing & fins, clean if required STEERING ASSEMBLY  Check for abnormal play, tightness of all hardware TIE ROD/LINKAGES  Check for excessive play, bent components or loose connections REAR AXLE  Check for leakage, add SAE 30 oil as required

 Conduct brake performance test

QUARTERLY - 60 HOURS (includes items listed in previous tables & the following)

FRONT SHOCK ABSORBERS  Check for oil leakage and loose fasteners FRONT AXLE  Check for damage to axle and loose or missing hard ware FRONT SPRINGS  Check for loose hardware, cracks at attachments

FRONT WHEEL ALIGNMENT  Check for unusual tire wear, align if required

Page 18

Fig. 27 Periodic Service Schedule

OPERATION AND SERVICE INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

 Check for bent/binding linkage rod

PARK BRAKE

REAR SHOCK ABSORBERS  Check for oil leakage, loose mounting hardware ENGINE ELECTRICAL SYSTEM  Check coil/spark plug wires for cracks/loose connections

FUEL SYSTEM THROTTLE/GOVERNOR LINKAGE  Check operation and governed speed HARDWARE AND FASTENERS

SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following)

BATTERY DIRECTION SELECTOR  Check for wear and smooth movement (lubricate shaft with light oil if required)

KING PINS  Check for excessive play and tightness of retaining nuts STEERING ASSEMBLY RACK END BALL JOINT  Lubricate, use wheel bearing grease

REAR AXLE  Check for unusual noise and loose or missing mounting hardware AIR FILTER ELEMENT  Check filter element, clean/replace as required OIL FILTER  Replace (at oil change)

ENGINE OIL DRIVE BELT  Check for cracks, fraying and excessive wear

 Check for damage or wear to latch arm or catch bracket

 Lubricate as required, use light oil. DO NOT LUBRICATE CABLES OR BRAKE

LATCH

 Check for leaks at tank, cap, system lines, filters, pump, carburetor  Check system lines for cracks/deterioration

 Check for loose or missing hardware and components

 Tighten or replace missing hardware

 Clean battery & terminals

 Check charge condition and all connections

 Lubricate, use wheel bearing grease

 Check bellows and pinion seal for damage or grease leakage

 Replace with SAE 10W-30 or 10W-40 that meets or exceeds SF, SG, CC oil,

DO NOT OVERFILL

ANNUAL - 250-300 HOURS (includes items listed in previous tables & the following)

FRONT WHEEL BEARINGS  Check and adjust as required, see Technician’s Repair and Service Manual REAR AXLE  Check lubricant, add lubricant (Ref Fig . 43 on page 26) as required

SERVICE BRAKES FUEL FILTER  Replace

SPARK PLUG  Replace, gap new plug (Ref. Capacities and Replacement Parts on page 27) MUFFLER/EXHAUST  Check mounting hardware; check for leaks at head and muffler gaskets VALVES  Check cold (intake/exhaust) per Technician’s Repair and Service Manual

 Clean and adjust, see Technician’s Repair and Service Manual

 Check brake shoe linings, see Technician’s Repair and Service Manual

500 HOURS (includes items listed in previous tables & the following)

CARBURETOR  Clean CYLINDER HEAD AND PISTON

 Remove carbon from cylinder head and piston

 Check valve seats for carbon buildup and clean as required

Fig. 27 Periodic Service Schedule

Page 19

OPERATION AND SERVICE INFORMATION

Maximum Oil Level For Hot Engine Do Not Overfill

Fill Cold Engine To This Point

Safe

Operating Range

Hot Engine

Add Oil

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

TIRE INSPECTION

Tire condition should be inspected per the Periodic Service Schedule (Ref. Fig. 27 on page 18). Inflation pressures should be checked when the tires are cool. Be sure to install the valve dust cap after checking or inflating.

FOUR CYCLE ENGINE

Engine Specifications

Engine model ................................... ...... ... .... ... FJ400D

Type.....................................................Four cycle, OHV

Number of cylinders.....................................................1

Displacement...................................................... 401 cc

Rated horsepower..... ... ....................................... .13 hp

Spark plug type.......................................NGK BPR2ES

Spark plug gap.....................028" - .031" (.70 - .80 mm)

Cooling ................................ ... ... ... .... . Forced air cooled

Oil Filter........... .... ... ... ... .... ..Cartridge type full flow filter

Oil Pump . ... ... ... .... ... ... ... .... Positive displacement pump

Engine Description The engine is an air cooled, 4-stroke, OHV,

single cylinder gasoline engine. It incorporates a pressure fed lubrication positive displacement oil pump with a cartridge type full flow oil filter and a counter rotating balance shaft.

CHECKING THE OIL LEVEL

Do not overfill engine. Too much oil may cause engine to smoke or spark plug fouling.

Fig. 28 Clean Entire Dipstick

Insert the dipstick fully into the dipstick hole and remove. Examine the level of the oil on the dipstick.

Fig. 29 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 stick. Do not operate vehicle if oil level is below the

safe area indicated on the dipstick.

Oil should be added to bring the level into the safe operating range. Remember that oil expands as it gets hot, Do not overfill. Check that the oil cap is firmly in place.

NOTICE

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 operating the engine. Failure to install the dipstick/fill cap will result in oil becoming contaminated and/or oil being discharged into the engine compartment.

Too much oil may cause smoking or allow oil to enter the air filter enclosure.

The oil should be checked with the engine warm. The vehicle should be on a level surface with the parking (PARK) brake engaged. Allow adequate time for oil to drain into the crankcase before checking.

Remove the dipstick and wipe off the entire area with a lint free cloth.

Page 20

OPERATION AND SERVICE INFORMATION

-20 0 20 40 60 80 100

-30 -20 -10 0 10 20 30

10W-30

10W-40

HEAVY DUTY WORK

LIGHT DUTY WORK

(AIR TEMPERATURE)

10W-30

NOTICE

Oil Fill Cap

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Changing the Oil

Tool List Qty.

Socket, ........................................................................1

Ratchet........................................................................ 1

Extension, 8" ............................................................... 1

Oil Drain Pan............. .... ... ... ....................................... . 1

Wrench 3/4”................................................................. 1

For maximum performance and longevity, the engine oil should be replaced after the first 8 hours of operation. After the initial oil change, it should be changed every 125 hours of operation or semi-annually, whichever comes first.

The selection of oil is dependent upon the service that the vehicle will perform. Most vehicles require 10W-30 oil, whereas vehicles used at capacity or near capacity load applications will utilize 10W-40 oil after a break-in period of 100 hours.

Clean the area around filter. Using a filter wrench, strap wrench or other suitable wrench (A), remove the filter

Fig. 31 Cleaning Top of Engine

Fig. 30 Oil Viscosity Chart

If vehicle is to be stored over winter months, it can be stored with old oil left in engine. The oil should be changed as part of spring maintenance. This will remove any moisture that has accumulated during storage.

(B) from the engine and allow the oil to drain. The ‘O’ rings may remain on engine (A) or filter (B)

Fig. 32 Remove Oil Filter

Inspect the filter. Make sure the ‘O’ ring is not left on the engine surface.

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 degreaser.

The oil should be changed with engine warm. Park vehicle on a level surface, engage parking brake and remove key. Place a drain pan under engine. Wipe top of the engine clean with a cloth. Remove the oil fill cap.

Fig. 33 Inspect Oil Filter

Page 21

OPERATION AND SERVICE INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Be careful of hot oil when drained. It may be hot enough to burn you severely

Drain the oil by removing the drain plug found at the rear of the engine base. Remove using a 3/4” wrench. At the first oil change, small metal chips and lint may be found. This is normal, resulting from the break-in period. Inspect the filter at every oil change. The presence of large metal chips could indicate possible damage to the engine.

Fig. 34 Oil Drain Plug

Wipe the area around the drain plug mount with a lint free cloth and inspect the drain plug (A) for damage; replace if necessary . Replace the “O”-ring (B) with a new one and tighten to 61 in. 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 HAND(S). Pour in the specified type and amount of oil See “Capacities and Replacement Parts” on page 27.

Oil capacity is 1 1/3 quarts (1.3 liters). Add slightly less than 1 1/3 quarts (1.3 liters) to allow for possible residual oil left in engine. The oil must be high quality oil that meets or exceeds API SF, SG, CC standards (Ref Fig. 35 on page 22). Check oil level on dipstick. Oil should be slightly below ‘H’ to allow for expansion. If necessary, continue to add oil slowly and allow time for oil to flow down into engine. Check oil level on dipstick. Do not

overfill.

Both the oil dipstick and fill cap must be in place before operating the engine. Failure to install the dipstick and fill cap will result in oil being discharged into the engine compartment.

As a final check, check the oil level again with the vehicle on level ground. Like all liquids, oil increases in volume when warm. The full ‘H’ mark on the dipstick is calibrated for an engine at operating temperature. When the engine is cold, the oil will be below the full mark. The engine can be operated safely as long as the oil is within the safe operating range as indicated on the dipstick. Do

not operate vehicle if oil level is below the safe area indicated on the dipstick.

STARTER/GENERATOR BELT TENSION

Tool List Qty.

Belt Tension Gauge .....................................................1

Wrench, 3/4” ................................................................1

Wrench, 9/16” ..............................................................2

Ratchet ........................................................................1

Socket, 3/4”..................................................................1

The starter/generator belt tension should be checked after the first 15 - 20 hours and set to 75 - 80 lbs. (34 36 kg).

Fig. 35 Add Engine Oil

NOTICE

Do not overfill engine. Too much oil may cause smoking or allow oil to enter the air filter enclosure.

Page 22

Fig. 36 Check Belt Tension with Gauge

OPERATION AND SERVICE INFORMATION

NOTICE

3/8" (1 cm) Maximum Deflection (New Belt)

1/2" (1.3 cm) Maximum Deflection (Existing Belt)

1 1/2 gallons

(6 liters)

Clear Water

1/4 Cup (60 ml)

Sodium Bicarbonate

(Baking Soda)

2 Gallon

(7.5 liter)

Garden Sprayer

1 quart (1 liter)

Clear Water

2 Teaspoons

(10 ml)

Sodium

Bicarbonate

(Baking Soda)

Plastic

Spray

Bottle

Non

Metallic

Wand

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

A loose belt can cause audible vibration and squeal.

Tighten a new starter/generator belt to 90 - 110 lbs. (41-50 kg) tension when a gauge is applied half way between the tw o pulleys.

Fig. 37 Check Belt Tension Manually

BATTERY CLEANING

To reduce the possibility of damage to vehicle or floor, neutralize acid before rinsing battery.

To reduce the possibility of damage to electrical components while cleaning, do not use a pressure washer.

Cleaning should take place per the Periodic Service Schedule (Ref. Periodic Service Schedule on page 18).

When cleaning the outside of the battery and terminals, first spray with a solution of sodium bicarbonate (baking soda) and water to neutralize any acid deposits before rinsing with clear water.

Use of a water hose without first neutralizing any acid, will move acid from the top of the battery to another area of the vehicle or storage facility where it will attack the metal structure or the concrete/asphalt floor. Additionally, a residue will be left on the battery which is conductive and will contribute to the discharge of the battery.

Fig. 38 Adjust Belt Tension

Tighten a new starter /generator belt to 115 - 125 lbs. (5257 kg) tension when a gauge is applied half way b etween the two pulleys. A new belt may be checked manually. A maximum deflection of 3/8” (10 mm) is acceptable (Ref Fig. 37 on page 23). Tighten an existing belt to 75 - 80 lbs. (34 - 36 kg) tension using the same technique and inspect for cracking or wear. A maximum deflection of 1/ 2” (13 mm) is acceptable

Adjusting The Belt

Loosen the starter/generator pivot bolt. While holding the lower adjusting nut with a wrench,

loosen the upper jam nut with another wrench. Move the lower nut up or down the adjustment bolt until proper belt tension is achieved. Hold the lower nut in place and tighten the upper jam nut against it.

Tighten the starter/generator pivot bolt.

To reduce the possibility of battery explosion that could result in severe injury or death, do not use metallic spray wand to clean battery and keep all smoking materials, open flame or sparks away from the battery.

Fig. 39 Preparing Acid Neutralizing Solution

Page 23

OPERATION AND SERVICE INFORMATION

NOTICE

4 ft. (1.2 m)

Dry, Level, Clean, Paved Surface

Accelerate to Maximum Speed

Line or Marker

Latch Parking Brake and Take Foot Offf Pedal

Acceptable Stopping Distance

Line or Marker

Normal Range of Stopping Distance

Any vehicles that stop more than 4 ft. (1.3 m) beyond the Acceptable Stopping Distance or pulls to one side should be removed from service and inspected by a qualified mechanic.

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

The correct cleaning technique is to spray the top and sides of the battery with a solution of sodium bicarbonate (baking soda) and water. This solution is best applied with a garden type sprayer equipped with a non metallic spray wand or a plastic spray bottle. The solution should consist of the amounts of sodium bicarbonate (baking soda) and clear water shown below. In addition to the battery, special attention should be paid to metal components adjacent to the battery which should also be sprayed with the sodium bicarbonate (baking soda) solution.

Allow the solution to sit for at least three minutes; use a soft bristle brush or cloth to wipe the tops of the battery to remove any residue that could contribute to the self discharge of the battery. Rinse the entire area with low pressure clear water. Do not use a pressure washer.

BRAKES

To reduce the possibility of severe injury or death, always evaluate pedal travel before operating a vehicle to verify some braking function is present.

Establish the acceptable stopping distance by testing a new or ‘known to be good’ vehicle and recording the stopping location or stopping distance. For fleets of vehicles, several vehicles should be tested when new and the range of stopping locations or distances recorded.

All driving brake tests must be done in a safe location with regard for the safety of all personnel.

Over time, a subtle loss of performance may take place; therefore, it is important to establish the standard with a new vehicle.

The Periodic Brake Performance Test should be performed regularly as an evaluation of braking system performance. It is useful as a method of identifying subtle loss of performance over time.

Periodic Brake Test For Mechanical Brakes

The purpose of this test is to compare the braking performance of the vehicle to the braking performance of new or ‘known to be good’ vehicles or to an established acceptable stopping distance. Actual stopping distances will be influenced by weather conditions, terrain, road surface condition, actual vehicle weight (accesso-

ries 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 pressures and to include the affects of linkage misadjustment.

Page 24

Fig. 40 Typical Brake Performance Test

Drive the vehicle at maximum speed on a flat, dry, clean, paved surface (Ref Fig. 40 on page 24). Quickly depress the brake pedal to latch the parking brake at

OPERATION AND SERVICE INFORMATION

Steering Unit

Ball Joint on Rack and Rod

King PinKing Pin

Idler Arm

View From Underside Of Vehicle

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the line or marker in the test area and remove foot from pedal. The vehicle should stop aggressively. The wheel brakes may or may not lock. Observe the vehicle stopping location or measure the vehicle stopping distance from the point at which the brakes were latched. The vehicle 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 should be tested again.

If the vehicle fails the second test, it should immedi- ately be removed from service. The vehicle must be inspected by a qualified mechanic who should refer to the TROUBLESHOOTING section in the Technician’s Repair and Service Manual.

AIR INTAKE AND COOLING FINS

To prevent possible burns, engine parts should be kept clean to reduce risk of overheating and ignition of accumulated debris. After every off road use, allow to cool and then check for a build up of dirt and debris in the air intake and cooling fins. Dirt and debris may clog the engine’s air cooling system. Clean areas shown to prevent engine damage. Keep linkages, springs and controls clean. Keep area around muffler free of any combustible material.

LUBRICATION

Do not use more than three (3) pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components.

Putting more than three pumps of grease in a grease fitting could damage grease seals and cause premature bearing failure.

At least once a year, or more often under adverse conditions) the cooling system should be cleaned. Cleaning will assure an adequate supply of air to the cooling fins. Compressed air may be used for routine cooling system maintenance.

Fig. 42 Cleaning Cooling System with Air

REAR AXLE

Fig. 41 Lubrication Points

The rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing. Unless leakage of rear axle lubricant is evident, an annual lubricant check is sufficient.

Checking The Lubricant Level

Tool List Qty.

Socket, 13 mm ............................................................1

Ratchet........................................................................ 1

Funnel .........................................................................1

Page 25

OPERATION AND SERVICE INFORMATION

NOTICE

Dust Collector

Air Cleaner Cover

Air Cleaner Canister

Air Filter Element

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Cleaning the Air Filter Element

For vehicles with LSD axle, add 2 ounces of friction modifier during refill.

Clean the area around the check and fill plugs. Remove the check plug. The correct lubricant level is just below the bottom of the threaded hole. If lubricant is to be added, remove the fill plug and add lubricant using a funnel. Add lubricant slowly until lubricant starts to seep from the check plug hole. Install the check plug / fill plug. In the event that the lubricant is to be replaced, a drain plug is provided at the bottom of the differential housing.

Fill / Check Plug

Do not use compressed air 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 cover and air filter element (Ref Fig. 44 on page 26). 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 fastened securely.

Drain Plug

Fig. 43 Add, Check and Drain Rear Axle Lubricant

AIR CLEANER INSPECTION AND REPLACEMENT

The air cleaner unit on the vehicle is a dry unit. Do not use oil on the filter element or any part of the unit. To aide installation and sealing, petroleum jelly may be applied to back side of cover tabs and each side of filter seal.

Page 26

Fig. 44 Air Cleaner

If the element is in acceptable condition, loose dirt may be removed by tapping the filter lightly. Do not use oil on the filter element or any part of the unit.

SPARK PLUG

Tool List Qty.

Spark Plug Socket, 13/16”...........................................1

Ratchet........................................................................1

Plug Gauge, Wire Type ...............................................1

Anti-seize Compound ................................................ Ar

Torque Wrench, Ft. Lbs. ..............................................1

Use care not to over-tighten the plug. Over-tightening can cause damage to the aluminum cylinder head threads.

Remove and inspect the spark plug at intervals indicated in the Periodic Service Schedule (Ref Fig. 27 on page 18). Spark plug should be properly gapped. Tighten to 16 ft. lbs. (22 Nm) torque.

OPERATION AND SERVICE INFORMATION

0.7 - 0.8 mm

(.028” - .031”)

Gap

Plug

Fuel Tank / Fuel

Engine Oil

Oil Filter

Air Filter

Spark Plug

Starter/Generator Belt

Clutch Belt

Rear Axle Oil

Fuse

Headlight Sealed Beam

Turn Signal Bulb

Tail Light Bulb

5.3 gal (20.0 liters) / 87 Octane Min.

1.4 US qt (1.3 liters)

51 oz (1.5 liters) / SAE 30

15 amp (P/N 18392G1)

(P/N 20209G3)

(P/N 20574G3)

#1157 (P/N 611242)

P/N 607454

P/N 28463G01

NGK BPR2ES (P/N 607462)

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

P/N 26414G1

P/N 618630

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

Friction Modifier (Rear Axle)

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Preparing the engine for a prolonged storage period (30 days or more) calls for a few simple steps to prevent a build up of varnish and gum in the carburetor and corrosion in the engine.

• Raise the rear of the vehicle and support on jack

stands. Refer to ‘Lifting the Vehicle’ for proper lifting procedure and safety information.

• Disconnect the fuel hose at the fuel tan k and plug

hose.

• With proper ventilation, depress the accelerator

pedal and allow engine to run until it stops due to lack of fuel.

Fig. 45 Gapping the Spark Plug

Fouled spark plug is indicated by a wet, black appearance. This could be caused by a dirty air filter element or other restrictions in the air intake system. Incorrectly adjusted valves, spark plug wire which is in poor condition or poor quality fuel could also contribute to the problem.

PROLONGED STORAGE

• Remove spark plug and pour about 1 oz. (30 ml)

of engine oil into the cylinder . Rep lace sp ar k plug, ground spark plug wire and use starter to turn engine over a few seconds to distribute oil.

• Add a gasoline additive to the tank in accordance

with the manufacturer’s recommendations.

• Reattach fuel line to tank and drive the vehicle for

several minutes to circulate the additive through the carburetor.

• While engine is still warm, change oil.

• Clean body, chassis and engine of debris, mud,

chaff or grass.

To reduce the possibility of severe injury or death resulting from a possible explosion:

Do not handle fuel in an area that is not adequately ventilated. Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark.

Store vehicle in a clean, dry area. Do not store in same area as a stove, furnace, water heater, or other appliance that uses a

pilot 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 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 on jack stands before attempting to run the engine.

CAPACITIES AND REPLACEMENT PARTS

Fig. 46 Capacities and Replacement Parts

Page 27

OPERATION AND SERVICE INFORMATION

BOLT SIZE

Grade 2

1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"

(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)

M4 M5 M6 M8 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

ALL TORQUE VALUES ARE IN FT. LBS. (Nm)

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.

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

HARDWARE

Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref Fig. 47 on page 28).

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 (Ref Fig. 47 on page 28).

Fig. 47 Torque Specifications and Bolt Grades

Page 28

OPERATION AND SERVICE INFORMATION

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

NOTES:

Page 29

OPERATION AND SERVICE INFORMATION

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NOTES:

Page 30

GENERAL SPECIFICATIONS

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GENERAL SPECIFICATIONS

Page 27

GENERAL SPECIFICATIONS

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MODEL: HD G TYPE: GASOLINE POWERED TRUC MODEL YEAR: 2011

Part No:. 617791

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki

Valve Train: Overhead valve Fuel System: Fixed float bowl with remote pulse fuel pump Lubrication: Pressurized oil system, spin-on oil filter Ignition: Electronic spark/magneto Balancer: Internal counter rotating balance shaft Air Cleaner: Replaceable dry cartridge

Electrical: Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve) Drive Train: Automatic, continuously variable transmission (CVT) Brakes: Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with self-compensating system Transaxle: Differential with helical gears, ground speed governor, forward/reverse Cargo Bed: Roto-molded cross-linked polyethelene. Lifts for access to powertrain. Removable hinged multi-position tailgate requires no latch mechanism

PRODUCT OVERVIEW

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) gk 014 ( b l 009thgieW yrD)mc 621 ( n i 5 . 94htdi W l l are v O

Overall Height (No Canopy) 49.5 in (126 cm) (Top of steering wheel) Curb Weight 940 lb (430 kg)

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) gk 063 ( b l 008y t i capac dao l e l c i heV)mc 691 ( n i 0 . 77esaB l eehW

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A/Necnar ae l C e l s i A gn i t ces r e t n I)m c 79( ni 5.83kca r T l eeh W r aeR

) hpk 8 . 0 ± hp k 4 . 72 ( hpm 5 . 0 ± hpm 71) dnuo rG l eveL ( deepS)mc 51 ( n i 3 . 5l a i t ne r e f f i D @ ecna r ae l C dnG

dao l xam ) gk 522 ( b l 005y t i capaC gn i woT)mc 211 ( n i 0 . 44) ed i sn i ( h t d iW xoB og r aC

Cargo Box Length (inside) 36.0 in (91 cm) Steering & Suspension

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Cargo Box material/capacity Roto-molded poly/9.6 cu ft (0.27 m3) Rear Suspension Leaf springs with hydraulic shock absorbers

Vehicle Power Service Brake Rear wheel mechanical self-adjusting drum

Power Source 4 Cycle 24.5 cu in (401 cc) Parking Brake Self-compensating, single point engagement

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Horsepower (kW) 13 hp (9.7 kW) Exceeds SAE J1940 Std. Rear Tires Stryker 22 x 9 - 10 Uni-Directional Electrical System Starter/Generator. Solid State Regulator Body & Chassis

Batteries (Qty, Type) One, 12 Volt Maintenance Free Frame Welded steel. DuraShield™ powder coat

OP T dedlo M noi tcejnIhs i n i F & ydoB t no r Fl adePt ra tS l adeP ro yeK

Air Cleaner Replaceable Dry Cartridge Rear Body & Finish Steel. Base coat/clear coat

Lubrication Pressurized Oil System Standard Color Realtree AP

Oil Filter Spin On

Cooling System Air Cooled

Fuel Capacity 5.3 gallons (20.0 L) tank

Drive Train Continuously variable transmission (CVT)

Transaxle Differential with helical gears

Gear Selection Forward - Reverse

Rear Axle Ratio 11.42:1 (Forward) 15.78:1 (Reverse)

Some items shown may be optional equipment

* Field installed accessories may require installation charges

Page 28

Specifications are subject to change without notice

GENERAL SPECIFICATIONS

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

MODEL: LTO TYPE: GAS POWERED PERSONNEL CARRIER MODEL YEAR: 2011

Part No: 617795

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

Engine: 13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki

Electrical: Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve) Drive Train: Automatic, continuously variable transmission (CVT) Brakes: Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release with self-compensating system Transaxle: Differential with helical gears, ground speed governor, forward/reverse Capacity: Seating for 4 persons. Rear Seat converts to Cargo Bed

PRODUCT OVERVIEW

Dimensions

Overall Height (No Canopy) 49.0 in (125 cm) (Top of steering wheel) Curb Weight 900 lb (410 kg)

Gnd Clearance @ Differential 6.0 in (15 cm) Load Bed Width 40.0 in (102 cm)

Power Source 4 Cycle 24.5 cu in (401 cc). Low E Steering Self-compensating rack and pinion

Horsepower (kW) 13 hp (9.7 kW) Exceeds SAE J1940 Std. Rear Suspension Leaf springs with hydraulic shock absorbers Electrical System Starter/Generator. Solid State Regulator Service Brake Rear wheel mechanical self-adjusting drum Batteries (Qty, Type) One, 12 Volt Maintenance Free Parking Brake Self-compensating, single point engagement

Air Cleaner Replaceable Dry Cartridge Rear Tires Trail Wolf 20 x 11 - 10 Uni-directional Lubrication Pressurized Oil System Body & Chassis

Fuel Capacity 5.3 gallons (20.0 L) tank Drive Train Continuously variable transmission (CVT) Standard Color Realtree AP Transaxle Differential with helical gears Gear Selection Forward - Reverse Rear Axle Ratio 11.42:1 (Forward) 15.78:1 (Reverse)

Performance

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) gk 011 ( b l 052y t i capaC daoL deB daoL)mc 891 ( n i 0 . 87) yponaC h t iW( t hg i eH l l a r evO ) gk 063 ( b l 008y t i capa c dao l e l c i heV)mc 661 ( n i 5 . 56esaB l eeh W

)m 1.7( t f 3.02el cr iC ecnarae lC edi stu O)mc 69 ( n i 0 . 83kca r T l eeh W t no r F

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Speed (Level Ground)

Rear Body & Finish Injection molded TPO

Fwd - 17.0 mph ± 0.5 mph (27.4 kph ± 0.8 kph) Rev - 13.0 mph ± 0.5 mph (20.9 kph ± 0.8 kph)

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no i snepsuS & gn i r ee t Sre w oP elciheV

s r eb r osba kcohs c i l uar dyh h t iw sgn i r ps f aeLno i snep suS t no r FV HO redni lyC elgniSniarT evlaV

lanoi tcer id- inU 01 - 11 x 02 f lo W l iarTser i T tn orFl adePt ra tS l adeP ro yeK

taoc red wop ™dleihS aru D ht iw leets dedleWema r FnO-nipSret l iF l iO

OPT dedlom noi tcejnIhs i n i F & ydoB t no r Fde l ooC r i Am etsyS gni loo C

Some items shown may be optional equipment

Page 29

GENERAL SPECIFICATIONS

107 in (272 cm)

65.5 in (166 cm)

Rear

38 in (96 cm)

Front

38.5" (97 cm)

46.5 in

(118 cm)

76 in

(193 cm)

50 in

(127 cm)

5 in

(12.7 cm)

LTO VEHICLE DIMENSIONS

103 in (262 cm)

(Rear)

38 in (97 cm)

(Front)

38 in (97 cm)

35 in (89 cm)

10 in

(25 cm)

47 in

(119 cm)

47 in

(119 cm)

66 in (168 cm)

HD VEHICLE DIMENSIONS

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Page 30

GENERAL SPECIFICATIONS

RECOMMENDED MAX RAMP GRADE

25% or 14o MAX

RECOMMENDED MAX SIDE TILT

25% or 14o MAX

TURNING CLEARANCE DIAMETER

LTO 20.5 ft (6.3 m) HD 23.5 ft (7.2 m)

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

Page 31

GENERAL SPECIFICATIONS

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NOTES:

Page 32

VEHICLE WARRANTIES

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VEHICLE WARRANTIES

Page 33

VEHICLE WARRANTIES

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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 vehicle serial number and manufacturer date code.

Page 34

VEHICLE WARRANTIES - CALIFORNIA

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and E-Z-GO are pleased to explain the evaporative emission control system warranty on your 2010 vehicle. In California, new vehicles must be designed, built and equipped to meet the State’s stringent anti-smog standards. E-Z-GO must warrant the EECS on your vehicle for the period of time listed below provided there has been no abuse, neglect or improper maintenance of your vehicle.

Your EECS may include parts such as the carburetor, fuel-injection system, the ignition system, catalytic converter, fuel tanks, fuel lines, fuel caps, valves, canisters, filters, vapor hoses, clamps, connectors, and other associated emission-related components.

Where a warrantable condition exists, E-Z-GO will repair your vehicle at no cost to you including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE:

This evaporative emission control system is warranted for two years. If any evaporative emission-related part on your equipment is defective, the part will be repaired or replaced by E-Z-GO.

OWNER’S WARRANTY RESPONSIBILITIES:

s the vehicle owner, you are responsible for performance of the required maintenance listed in your owner’s manual. E-Z-GO recommends that you retain all receipts covering maintenance on your vehicle, but E-Z-GO cannot deny warranty solely for the lack of receipts.

s the vehicle owner, you should however be aware that E-Z-GO may deny you warranty coverage if your vehicle or a part has failed due to abuse, neglect, 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 exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty coverage, you should contact your nearest authorized E-Z-GO service center or call the E-Z-GO Warranty Department at 1-800-448-7476

GENERAL EMISSIONS WARRANTY COVERAGE:

E-Z-GO warrants to the ultimate purchaser and each subsequent purchaser that the vehicle is: Designed, built and equipped so as to conform with all applicable regulations; and Free from defects in materials and workmanship that cause the failure of a warranted part to be identical

in all material respects to that part as described in E-Z-GO’s application for certification. The warranty period begins on the date the vehicle is delivered to an ultimate purchaser or first placed

into service. The warranty period is two years. Subject to certain conditions and exclusions as stated below, the warranty on emission-related parts is as

follows: (1) Any warranted part that is not scheduled for replacement as required maintenance in the written

instructions supplied, is warranted for the warranty period stated above. If the part fails during the period of warranty coverage, the part will be repaired or replaced by E-Z-GO according to subsection (4) below.

ny such part repaired or replaced under warranty will be warranted for the remainder of the period. (2) Any warranted part that is scheduled only for regular inspection in the written instructions supplied is

warranted for the warranty period stated above. Any such part repaired or replaced under warranty will be warranted for the remaining warranty period.

Page 35

VEHICLE WARRANTIES - CALIFORNIA

(3) Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part. If the part fails before the first scheduled replacement, the part will be repaired or replaced by ABC, Inc. according to subsection (4) below. Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part.

(4) Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner.

(5) Notwithstanding the provisions herein, warranty services or repairs will be provided at all of our distribution centers that are franchised to service the subject engines or equipment.

(6) The vehicle owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective, emission-related warranted part, provided that such diagnostic work is performed at a warranty station.

(7) E-Z-GO is liable for damages to other engine or equipment components proximately caused by a failure under warranty of any warranted part.

(8) Throughout the vehicle warranty period stated above, E-Z-GO will maintain a supply of 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 to the owner. Such use will not reduce the warranty obligations of E-ZGO.

(10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of any non-exempted add-on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claims. E-Z-GO will not be liable to warrant failures of warranted parts caused by the use of a non-exempted add-on or modified part.

WARRANTED PARTS:

The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if E-Z-GO demonstrates that the vehicle has been abused, neglected, or improperly maintained, and that such abuse, neglect, or improper maintenance was the direct cause of the need for repair or replacement of the part. That notwithstanding, any adjustment of a component that has a factory installed, and properly operating, adjustment limiting device is still eligible for warranty coverage. The following emission warranty parts list are covered:

(1) Fuel Tank (2) Fuel Cap (3) Fuel Line (4) Fuel Line Fittings (5) Clamps (6) Pressure Relief Valves (7) Control Valves (8) Control Solenoids (9) Electronic Controls (10) Vacuum Control Diaphragms (11) Control Cables (12) Control Linkages (13) Purge Valves (14) Vapor Hoses (15) Liquid/Vapor Separator (16) Carbon Canister (17) Canister Mounting Brackets (18) Carburetor Purge Port Connector

Page 36

VEHICLE WARRANTIES - FEDERAL

FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY

EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California

Kawasaki Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S. Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period.

For the components listed under PARTS COVERED, the distributor, dealer, or service provider authorized by E-ZGO will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations.

EMISSISON COMPONENT DEFECT WARRANTY PERIOD The warranty period for this engine begins on the date of sale to the initial purchaser and continues for a period of

2 years. PARTS COVERED Listed below are the parts covered by the Emission Components Defect Warranty. Some of the parts listed below

may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. Fuel Metering System

Carburetor and internal 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 applicable Air filter. Ignition System Spark plugs. Magneto or electronic ignition system. Spark advance/retard system, if applicable. Exhaust manifold, if applicable Miscellaneous Items Used in Above Systems Electronic controls, if applicable Hoses, belts, connectors, and assemblies.

OBTAINING WARRANTY SERVICE To obtain warranty service, take your engine to the nearest authorized E-Z-GO distributor, dealer, or service

provider. Bring your sales receipts indicating date of purchase for this engine. The distributor, dealer, or service provider authorized by E-Z-GO will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order. All parts and accessories replaced under this warranty become the property of E-Z-GO.

WHAT IS NOT COVERED Conditions resulting from tampering, misuse, improper adjustment (unless they were made by the distributor,

dealer, or service provider authorized by E-Z-GO during a warranty repair), alteration, accident, failure to use

the recommended fuel and oil, or not performing required ma intenance services. The replacement parts used for required maintenance services. Consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc. Diagnosis and inspection charges that do not result in warranty-eligible service being performed. Any non-authorized replacement part, or malfunction of authorized parts due to use of non-authorized parts.

OWNER’S WARRANTY RESPONSIBILITIES As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s

manual. E-Z-GO recommends that you retain all receipts covering maintenance on your engine, but E-Z-GO

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VEHICLE WARRANTIES

Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.

cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible for presenting your engine to the nearest distributor, dealer, or service provider authorized by E-Z-GO when a problem exists.

If you have any questions regarding your warranty rights and responsibilities, you should contact the E-Z-GO Warranty Department at 1-800-241-5855 for the information.

THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance

records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to 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 the lack of required maintenance or failure to keep maintenance records.

MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR, DEALER OR, SERVICE PROVIDER AUTHORIZED BY E-Z-GO. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM.

If other than the parts authorized by E-Z-GO are used for maintenance replacements or for the repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by E-Z-GO in their performance and durability.

HOW TO MAKE A CLAIM All repair qualifying under this limited warranty must be performed by a distributor, dealer, or service provider

authorized by E-Z-GO. In the event that any emission-related part is found to be defective during the warranty period, you shall notify E-Z-GO Warranty Department at 1-800-241-5855 and you will be advised of the appropriate warranty service providers where the warranty repair can be performed.

Page 38

Be sure that no loose clothing or hair can

NOTICE

contact moving parts. Use care not to touch hot objects.

Check area behind the vehicle before operating in reverse.

Make sure the direction selector is in correct 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 SPECIFICATIONS for vehicle load and seating capacity.

Read and understand the following text and warnings before attempting to service vehicle:

In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse.

It is virtually impossible to anticipate all possible component failures or the manner in which each component may fail.

Be aware that a vehicle requiring repair indicates that the vehicle is no longer functioning as designed and therefore should be considered potentially hazardous. Use extreme care when working on any vehicle. When diagnosing, removing or replacing any components that are not operating correctly, take time to consider the safety of yourself and others around you should the component move unexpectedly.

Some components are heavy, spring loaded, highly corrosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide, battery acid and hydrogen gas could result in serious bodily injury to the technician/mechanic and bystanders if not treated 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 listed in the tool list and wear approved safety equipment.

Raise entire vehicle and support on jack stands before attempting to run or adjust power train.

Wear eye protection when working on or around vehicle. In particular, use care when working around batteries, using solvents or compressed air.

Hydrogen gas is formed when charging batteries. Do not charge batteries without adequate ventilation.

Do not permit open flame or anyone to smoke in an area that is being used for charging batteries. A concentration of 4% hydrogen gas or more is explosive.

Engine exhaust gas (carbon monoxide) is deadly. Carbon monoxide is an odorless, colorless gas that is formed as a natural part of incomplete combustion of hydrocarbon fuels. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

The following are symptoms of carbon monoxide inhalation:

• Dizziness

• Vomiting

• Intense headache

• Muscular twitching

• Weakness and sleepiness

• Throbbing in temples

If any of these symptoms are experienced, get fresh air immediately. Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area.

To prevent personal injury or death, observe the following:

Before working on the vehicle, remove all jewelry (rings, watches, necklaces, etc.)

Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124

Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175

E-Z-GO Division Of Textron Inc.,

1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852

TO CONTACT US

North America:

International:

Phone: 001-706-798-4311, FAX: 001-706-771-4609

2011 E-Z-GO Division of Textron Inc.

This manual may not be reproduced in whole or

in part without the express permission of

E-Z-GO Division of Textron Inc.

Technical Communications Department

All ribhts reserved

Bad Boy HD G, LTO G, 617816 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual