E-Z-GO 602080 User Manual

602080
TM
REVISED DATE: JAN. 2007
SAFETY
r
For any questions on material contai ned in this manual, contact an authorized representative for clarification. Read and understand all labels located o n the vehi cle. Always replace any damaged or missing labe ls. See APPENDIX
A. 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 drive train 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.
Be sure that this manual remains as part of th e permanent service record should the vehicle be sold. For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.
NOTES, CAUTIONS AND WARNINGS
Throughout this guide NOTE, CAUTION and WARNING will be used.
A CAUTION indicates a condition that may result in damage to the vehicle.
A WARNING indicates a
! !
hazardous condition that could result in severe
injury or death.
Observe these NOTES, CAUTIONS and WARNINGS; 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.
Engine exhaust from this
! !
product contains chemi-
cals 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 Envi­ronmental 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 require-
ments of the Canadian Interference-Causing Equipment Regulations.
Ce système d'allumage par étincelle de véhicule respecte toutes les exigences du Règlement sur le matériel brouilleu du Canada.
Read and understand the following warnings before attempting to operate the vehicle:
To prevent personal
! !
injury or death, observe the following:
When vehicle is to be left unattended, engage parking brake, move direction selector to ‘F’ (forward) position, turn key to ‘OFF’ position and remove key.
Drive vehicle only as fast as terrain and safety considerations allow. Consider the terrain and traffic conditions. Consider environmental factors which effect the terrain and the ability to control the vehicle.
Avoid driving fast down hill. Sudden stops or change of direction may result in a loss of control. Use service brake to control speed when traveling down an incline.
Use extra care and reduced speed when driving on poor surfaces, such as loose dirt, wet grass, gravel, etc.
All travel should be directly up or down hills. Use extra care when driving the vehicle across an
incline. Stay in designated areas and avoid steep slopes. Use
the parking brake whenever the vehicle is parked. Keep feet, legs, hands and arms inside vehicle at all
times. Avoid extremely rough terrain.
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
OWNER’S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED
UTILITY VEHICLE
ST 4x4
STARTING MODEL YEAR 2005
E-Z-GO Division of TEXTRON, Inc. reserves the right to make design changes without obligation to make these changes on units previously sold and the infor­mation contained in this manual is subject to change without notice.
E-Z-GO Division of TEXTRON, Inc. is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual.
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: 010-1-706-798-4311, FAX: 010-1-706-771-4609
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852
Owner’s Manual and Service Guide
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).
Page ii
Owner’s Manual and Service Guide
TABLE OF CONTENTS
SAFETY ................................................................................................................ inside covers
GENERAL INFORMATION ...................................... ... ... ... ... .... ... ....................................... ... ... . ii
SAFETY INFORMATION ......................................................................................................... vii
WELCOME ............................... ....................... ...................... ....................... .................... .......... 1
BEFORE INITIAL USE ..............................................................................................................1
Fig.1 Initial Service Chart ...........................................................................................................1
CAPABILITIES .......................................................................................................................... 1
TERRAIN .............................................................................................................................................................1
VEHICLE CAPACITY ..........................................................................................................................................1
MODIFICATIONS TO VEHICLE ..........................................................................................................................2
COMMON SENSE OPERATION ...............................................................................................2
RUN-IN ............................ ................................................... ........................................................ 2
CONTROLS & INDICATORS ....................................................................................................3
SERVICE BRAKE PEDAL ...................................................................................................................................3
Fig. 2 Service Brake Pedal ........................................................................................................3
CHOKE ................................................................................................................................................................3
IGNITION SWITCH ..............................................................................................................................................3
DIRECTION SELECTOR .....................................................................................................................................4
2WD/4WD SELECTOR ....................................................................................................................................... 5
DIFFERENTIAL LOCK ........................................................................................................................................5
ACCELERATOR ..................................................................................................................................................6
FUEL .......................................................................................................................................... 6
FUEL GAUGE ......................................................................................................................................................6
LOW OIL PRESSURE INDICATOR LIGHT .........................................................................................................6
LIGHT SWITCHES ..............................................................................................................................................7
12 VOLT POWER OUTLET .................................................................................................................................7
STARTING AND DRIVING ... ... ... ....................................... ... .... ... ... ... .... ... ................................. 8
STARTING VEHICLE ON A HILL ........................................................................................................................8
COASTING ..........................................................................................................................................................8
LOAD BED ................................................................................................................................. 8
TAILGATE ...........................................................................................................................................................9
MANUAL LIFT BED .............................................................................................................................................9
ELECTRIC LIFT BED OPERATION ....................................................................................................................9
WINCH ....................................................................................................................................... 9
WINCH APPLICATIONS .....................................................................................................................................9
WINCH MOUNTING ..........................................................................................................................................10
WINCH OPERATION ........................................................................................................................................10
Fig. 3 Park Brake and Indicator .................................................................................................3
Fig. 4 Choke ..............................................................................................................................4
Fig. 5 Ignition Switch ..................................................................................................................4
Fig. 6 Direction Selector and Differential Locks .........................................................................4
Fig. 7 2WD/4WD Selector ..........................................................................................................5
Fig. 8 Differential Lock ...............................................................................................................5
Fig. 9 Accelerator Pedal ............................................................................................................6
Fig. 10 Fuel Tank and Gauge ....................................................................................................7
Fig. 11 Low Pressure Oil Light ...................................................................................................7
Fig. 12 Light Switches ................................................................................................................7
Fig. 13 Power Outlet ..................................................................................................................7
Fig. 14 Manual Lift Bed Release ................................................................................................9
Fig. 15 Electric Lift Bed Switch ..................................................................................................9
Fig. 16 Do Not Pull at Angle ....................................................................................................10
Fig. 17 Mounting Winch ...........................................................................................................11
Fig. 18 Use Nylon Sling and Install a Damper when Winching ................................................11
Fig. 19 Winch Operation ..........................................................................................................12
Owner’s Manual and Service Guide
Page iii
TABLE OF CONTENTS
TOP AND WINDSHIELD ..........................................................................................................12
TRANSPORTING VEHICLE ....................................................................................................12
TOWING ........................................................................................................................................................... 12
HAULING .................................................................................................................................12
TOWING A TRAILER .............................. ... ....................................... ... ... ... .... ... .......................12
OPENING THE COWL (HOOD) ........................................................... ... ... .... ... ... ....................13
Fig. 20 Unlatching Cowl .......................................................................................................... 13
DATA LABEL LOCATION .......................................................................................................13
MAINTENANCE .......................................................................................................................14
PERIODIC SERVICE SCHEDULE ...........................................................................................15
Fig. 21 Periodic Service Schedule .......................................................................................... 15
BASIC SERVICE PARTS .........................................................................................................16
Fig. 22 Basic Service Parts ..................................................................................................... 16
LIFTING THE VEHICLE ................................................ .... ... ... ... ... ....................................... ... .17
Fig. 23 Lifting the Vehicle ........................................................................................................ 17
OIL .................................... .................................... ................................ ....................................17
OIL LEVEL CHECK .......................................................................................................................................... 18
OIL CHANGE .................................................................................................................................................... 18
OIL FILTER CHANGE ...................................................................................................................................... 18
SPARK PLUGS ........................................................................................................................19
ALTERNATOR BELT ...............................................................................................................19
ADJUSTING BELT ............................................................................................................................................ 19
AIR CLEANER .............................. ... ... .... ...................................... .... ... ... ... .... ..........................20
CANISTER TYPE AIR CLEANER .................................................................................................................... 20
CLEANING AIR FILTER ELEMENT ................................................................................................................. 20
FUEL FILTER ................................ ... ....................................... ... ..............................................20
LUBRICATION POINTS ...........................................................................................................21
BATTERY ...................................... .................................... ...................................... .................21
BATTERY CLEANING ...................................................................................................................................... 22
JUMP STARTING ......................................................... .... ... ... ... ....................................... ... ....22
VEHICLE CLEANING AND CARE ..........................................................................................22
CLEANING ........................................................................................................................................................ 22
CARE PRODUCTS ........................................................................................................................................... 23
LABELS AND PICTOGRAMS .................................................................................................23
WHEELS AND TIRES ..............................................................................................................24
TIRE INSPECTION AND INFLATION .............................................................................................................. 24
REMOVAL AND INSTALLATION ..................................................................................................................... 24
Fig. 24 Recommended Oil ...................................................................................................... 17
Fig. 25 Oil Fill and Level Check .............................................................................................. 18
Fig. 26 Oil Change .................................................................................................................. 18
Fig. 27 Oil Filter Change ......................................................................................................... 19
Fig. 28 Adjusting Alternator Belt ..............................................................................................20
Fig. 29 Air Cleaner .................................................................................................................. 20
Fig. 30 Fuel Filter .................................................................................................................... 21
Fig. 31 Lubrication Points ........................................................................................................ 21
Fig. 32 Cleaning Battery .......................................................................................................... 22
Fig. 33 Jump Starting .............................................................................................................. 23
Fig. 34 Wheel Tightening Sequence ....................................................................................... 24
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Owner’s Manual and Service Guide
TABLE OF CONTENTS
LIGHT BULB REPLACEMENT ............................................................................................... 25
Fig. 35 Headlight Replacement ...............................................................................................25
FUSE REPLACEMENT ........................................................................................................... 25
SPARK ARRESTER ................................................................................................................25
Fig. 36 Cleaning Spark Arrester ..............................................................................................25
PROLONGED STORAGE ................................. ... .... ... ... ... ... ....................................... ... .... ... .. 25
FRONT AND REAR AXLES ....................................................................................................26
CHECKING LUBRICANT LEVEL ......................................................................................................................26
TRANSFER CASE ................................................................................................................... 26
CHECKING LUBRICANT LEVEL ......................................................................................................................26
AIR INTAKE AND COOLING FINS ............................... ... ... .... ... ... ... .... ... ... ............................ 26
BRAKES .................................................................................................................................. 27
PERIODIC BRAKE TEST FOR HYDRAULIC BRAKES ....................................................................................27
CAPACITIES ............................ ....................... ...................... ....................... .................... ........ 27
HARDWARE ............................................................................................................................ 28
GENERAL SPECIFICATIONS.................................................................................................. 29
VEHICLE WARRANTIES ......................................................................................................... 33
EMISSION CONTROL SYSTEM WARRANTY STATEMENT .................................................35
ENGINE OWNER WARRANTY POLICY ................................................................................. 35
INTERNATIONAL WARRANTY STATEMENT........................................................................ 35
DECLARATION OF CONFORMITY (EUROPE ONLY)............................................................ 37
LABELS AND PICTOGRAMS..... .... ... ... ... ....................................... ... .... ... ... ... ... .... ... ........... A - 1
Fig. 37 Checking Axle Lubricant ..............................................................................................26
Fig. 38 Checking Transfer Case Lubricant ..............................................................................26
Fig. 39 Cleaning Air Intake and Cooling Fins ..........................................................................27
Fig. 40 Capacities ....................................................................................................................27
Fig. 41 Torque Specifications and Bolt Grades .......................................................................28
Fig. 42 Vehicle Dimensions......................................................................................................31
Fig. 43 Vehicle Incline Specifications .......................................................................................31
Fig. 44 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance.......................32
Fig. 45 Label Locations......................................................................................... Appendix A - 3
Fig. 46 Pictogram Definitions................................................................................ Appendix A - 4
Fig. 47 Pictogram Definitions................................................................................ Appendix A - 5
Fig. 48 Pictogram Definitions................................................................................ Appendix A - 6
Fig. 49 Pictogram Definitions................................................................................ Appendix A - 7
Owner’s Manual and Service Guide
Page v
N
TABLE OF CONTENTS
otes:
Page vi
Owner’s Manual and Service Guide
SAFETY INFORMATION
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:
GENERAL
Many vehicles are 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 warnings can take the place of good common sense and pruden t dr ivin g pr ac tice s.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined. The manufacturer strongly suggests that all users and maintenance personnel read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein.
If you have any questions regardin g this vehicle, contact your closest representative or write to the address o n the back cover of this publication, Attention: Product Service Department.
The manufacturer reserves the right to make design changes without obligation to make these changes on units previ­ously sold and the information contained in this manual is subject to change without notice.
The manufacturer is not liable for errors in this manual or 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 performance requirements. These vehicles are designed and manufactured for off-road use. They do not conform to Federal 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.
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 modifications can cause serious personal 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 sp eed of other vehicles when used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions, terrain and common sense.
GENERAL OPERATION
Always:
• Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
• Read and observe all warnings and operation instruction labels affixed to the vehicle.
• Follow all safety rules established in the area where the vehicle is being operated.
• Reduce speed to compensate for poor terrain or conditions.
Owner’s Manual and Service Guide
Page vii
SAFETY INFORMATION
• 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.
• 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.
• Empty the fuel tank or plug fuel hoses to prevent fuel leakage.
• Maintain the vehicle in an area away from exposed flame or perso ns 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 sa f e area th at 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.
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 that 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 mechanic.
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Owner’s Manual and Service Guide
SAFETY INFORMATION
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 spar k. Pay p articular att ention to natur al gas or prop ane water
heaters and furnaces. Never work around or operate a vehicle in an e nvironment t hat does no t ventilat e exhaust ga ses f rom the ar ea. Carb on
monoxide is a dangerous gas that can cause unconsciousne ss and is potentially lethal.
Owner’s Manual and Service Guide
Page ix
Notes:
SAFETY INFORMATION
Page x
Owner’s Manual and Service Guide
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
GENERAL
The following text is provided as recommended by part II of SAE J2258 DEC 2003. E-Z-GO strongly endorses the contents of this specification.
B.1 PART II FOR THE CONTROLLING PARTY
B.1.1 Maintenance and Operations
B.1.1.1 Introduction
B.1.1.1.1 Like other machines, light utility vehicles
can cause injury if improperly used or maintained. Part II contains broad safety practices applicable to vehicle operations. Before operation, the controlling party shall follow such additional specific safety practices as may reasonably be required for safe operation.
B.1.1.1.2 Safety Survey-The controlling party shall perform a safety survey of their premises periodically, and as conditions warrant, identify areas where vehicles should not be operated and to identify possible hazards.
(a) Steep Grade-In areas where steep grades exist, vehicle operation should be restricted to the designated vehicle's pathways where possible, and shall be identi­fied with a suitable warning giving the following informa­tion: “Warning, steep grade, descend slowly.”
(b) Wet Areas-Wet areas could cause a vehicle to lose traction and could affect steering, stability and braking.
(c) Sharp Turns, Blind Corners, Bridge Approaches­Sharp turns, blind spots, bridge approaches, and other potentially hazardous areas shall be identified with a suit­able warning to the operator of the nature of the hazard and stating the proper precautions to be taken to avoid the hazard.
(d) Loose Terrain-Loose terrain could cause a vehicle to lose traction and could affect steering, stability, and braking.
B.1.1.1.3 Utility Vehicle/Pedestrian Interference Areas-Areas where pedestrian and vehicle traffic could interfere should be avoided by rerouting the vehicle or the pedestrian traffic to eliminate t he int erf erence. If elim ­ination of the interference is not possible or is highly impractical, signs shall be erected warning pedestrians and vehicle operators of traffic cond itions and to u se cau­tion.
B.1.1.1.4 The controlling party shall train vehicle operators to adhere strictly to the operating instructions stated in vehicle operator's manual and those additional operating instructions provided by controlling party.
B.1.1.1.5 The controlling party shall survey specific operating conditions and environment, establish safety practices, and train vehicle operators to comply with these practices.
B.1.1.2 Operation Experience has shown that vehi­cles which comply with the provisions stated in 7.8 are stable when properly operated in accordance with spe­cific safety rules and practices established t o meet actua l operating terrain and conditions. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard. Some conditions which could affect stability are failure of the operator to follow safety practices, surface conditions, grade, speed, loading, braking, turning, improper loads, towing, attachments, dynamic forces, and the judgment exercised by the vehi­cle operator.
B.1.1.3 Nameplates, Markings, Capacity, And Mod­ifications.
B.1.1.3.1 The controlling party shall maintain in a legi-
ble condition all nameplates, warnings, and instructions which are supplied by the vehicle manufacturer.
B.1.1.3.2 The controlling party shall not perform any modification or addition which affects capacity or safe operation, or make any change not in accordance with the vehicle manual(s) without the vehicle manufacturer's prior written authorization. Where authorized modifica­tions have been made, the controlling party shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, or decals are changed accord­ingly.
B.1.1.3.3 As required under B.1.1.3.1 or B.1.1.3.2, the vehicle manufacturer shall be contacted to secure new nameplates, warnings, or instructions which shall then be affixed in their proper place on the vehicle.
B.1.1.4 Fuel Handling
B.1.1.4.1 The controlling party shall supervise the
handling of liquid fuels (when used) to be certain that it is in accordance with appropriate sections of ANSI/NFPA 505 and ANSI/NFPA 30 or as required by local ordi­nance.
Owner’s Manual and Service Guide
Page xi
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
B.1.1.4.2 The controlling party shall supervise the handling of liquefied petroleum gas fuels (when used) to be certain it is in accordance with appropriate sections of ANSI/NFPA 505 and ANSI/NFPA 58 or as required by local ordinance.
B.1.1.5 Charging Storage Batteries
B.1.1.5.1 The controlling party shall require battery-
charging procedures to be in accordance with appropri­ate sections of ANSI/NFPA 505, ISO 3691, or local ordi­nance and meet any other requirements such as OSHA.
B.1.1.5.2 The controlling party shall periodically review procedures to be certain that appropriate sections of ANSI/ NFPA 505 or local ordinance and OSHA are strictly complied with, and shall familiarize vehicle opera­tors with it.
B.1.1.6 Lighting For Operating Areas
B.1.1.6.1 The controlling party, in accordance with his
responsibility to survey the environment and operating conditions, shall determine if the vehicle requires lights and, if so, shall equip the vehicle with appropriate lights in accordance with the vehicle manufacturer's recom­mendations.
B.1.1.7 Warning Device(s)
B.1.1.7.1 The controlling party shall make periodic
inspections of the vehicle to be certain that the sound­producing and visual device(s), if so equipped, are main­tained in good operating conditioning condition.
B.1.1.7.2 The controlling party shall determine if oper­ating conditions require the vehicle to be equipped with additional sound-producing and/or visual devices com­patible with the vehicle manufacturer's recommenda­tions, and be responsible for providing and maintaining such devices, in accordance with the vehicle manufac­turer's recommendations.
B.1.1.8 Safety Interlocks
B.1.1.8.1 The controlling party shall make periodic
inspections of the vehicle to be certain that the safety interlock system, if so equipped, is operating properly.
B.2 Operating Safety Rules and Practices
B.2.1 Operator Qualifications
B.2.1.1 Only persons who are trained in the proper
operation of the vehicle shall be authorized to operate the vehicle. Operators shall be qualified as to visual, auditory , physical, and mental ability to safely operate the vehicle according to Section 5 and all other applicable parts of this document and vehicle oper ator's manual.
B.2.2 Operator’s T raining
B.2.2.1 The controlling party shall develop and con-
duct an operator training program.
B.2.2.2 Successful completion of the operator train­ing program by the operator shall be required before operation of the vehicle. The program shall be presented in its entirety to all new operators and not condensed for those claiming previous experience.
B.2.2.3 The controlling party should include, as a minimum, in the operator training progra m the follo wing :
(a) Instructional material provided by the vehicle man­ufacturer, including vehicle operator's manual.
(b) Emphasis on safety of passengers, vehicle opera­tor, and other persons.
(c) Safe loading practice, including securing material loads.
(d) General safety rules contained within this docu­ment and the additional specific rules determined by the controlling party in accordance with this document, and why they were formulated.
(e) Introduction of equipment, control locations, and functions, and explanation of how they work when used properly and the consequences of improper use; expla­nation of surface conditions, grade, and othe r conditions of the environment which could affect vehicle operation .
(f) Operator competency evaluations.
B.2.3 Operator Responsibility
B.2.3.1 Read and follow operator's manual.
B.2.3.2 Do not operate vehicle under the influence of
drugs or alcohol.
B.2.3.3 Safeguard the pedestrians at all times. Do not drive vehicle in a manner that could endanger other persons.
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Owner’s Manual and Service Guide
SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
B.2.3.4 Riding on the vehicle by persons other than the operator is authorized only on seat( s) pro vided by the vehicle manufacturer. All parts of each person's body shall remain within the plan view outline of the vehicle while the vehicle is in motion.
B.2.3.5 When a vehicle is to be left unattended, stop vehicle, apply the parking brake, turn off the control or ignition circuit, and remove the key if provided. Block the wheels if vehicle is on an incline.
B.2.3.6 Maintain a safe distance from potential haz­ards.
B.2.3.7 Use only approved vehicles in hazardous locations, as defined in the appropriate safety standards.
B.2.3.8 Report all accidents involving personnel, building structures, and equipment.
B.2.3.9 Do not add to, or modify, the vehicle.
B.2.3.10 Slow down or stop, as conditions dictate, and
activate a sound-producing warning device, if so equipped, at intersections and when visibility is obstructed at other locations.
B.2.3.11 Ascend or descend grades slowly, avoid turning if possible; normally travel straight up and down.
B.2.3.12 Under all travel conditions, operate vehicle at speeds that will permit it to be brought to a stop in a safe manner.
B.2.4.4 Avoid material loads exceeding the physical dimensions of the vehicle or as specified by the vehicle manufacturer.
B.2.5 Operator Care of Light Utility Vehicles
B.2.5.1 Follow Operator's Manual.
B.2.5.2 At the beginning of each operating period
during which the vehicle will be used, the operator shall check the vehicle condition and inspect the tires, warning devices, safety interlocks, lights, battery(s), fuel system, speed and directional controllers, brakes, and steering mechanism. If the vehicle is found to be in nee d of rep air, or in any way unsafe, the matter shall be reported imme­diately to the controlling party and the vehi cle shall not be operated until it has been restored to safe operating con­dition.
B.2.5.3 If during operation the vehicle becomes unsafe in any way, the matter shall be reported immedi­ately to the controlling party, and the vehicle shall not be operated until it has been restored to safe operating con­dition.
B.2.5.4 Repairs and adjustments shall only be per­formed by specifically trained and authorized persons.
B.3 Maintenance Practices
B.2.3.13 Use caution and slow down when approach-
ing or on wet or slippery surfaces, loose or unfamiliar ter­rain.
B.2.3.14 Avoid sudden starts, stops, turns, or direction reversals so as not to shift the load, endanger passen­gers, or lose control of the vehicle.
B.2.3.15 Do not operate vehicle in a dangerous man­ner, such as stunt driving or horseplay.
B.2.3.16 Avoid running over loose objects, potholes, and bumps.
B.2.4 Loading
B.2.4.1 Refer to operator's manual for loading
instructions.
B.2.4.2 Transport only stable and safely arranged loads secured to prevent movement. Avoid loads which cannot be centered.
B.2.4.3 Transport only loads within the gross vehi cle weight capacity.
Owner’s Manual and Service Guide
B.3.1 Maintenance Procedures
B.3.1.1 Maintenance and inspection of all vehicles
shall be performed in conformance with the vehicle man­ufacturer's recommendations and the following practices, if applicable. Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect vehi­cles.
(a) A scheduled preventive ma intenance, lubrication,
and inspection system shall be followed.
(b) Before undertaking maintenance or repair, follow the vehicle manufacturer's recommendations for immobi­lizing the vehicle.
(c) Chock wheels and block chassis before working underneath it.
(d) Before disconnecting any part of the fuel syste m of a gasoline-powered vehicle, be sure shutoff valve, if so equipped, is closed, and run engine until fuel system is depleted, engine stops running, and is allowed to cool. Before disconnecting any part of the engine fuel system of a diesel-powered vehicle, be sure shutoff valve, if so
Page xiii
SAFETY INFORMATION
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equipped, is closed, following vehicle manufacturer's rec­ommended practice.
(e) Before disconnecting any part of the f ue l syst em of LP/CNG powered vehicles, close the fuel cylinder valve and run the engine until fuel in the system is depleted, the engine stops running, and is allowed to cool
(f) Disconnect battery(s).
(g) Operation to check performance of the vehicle shall be conducted in an authorized area where suitable conditions exist, free of vehicular and pedestrian traffic.to cool.
(h) Before returning the vehicle to s ervice, follow the vehicle manufacturer's recommended procedures.
(i) Avoid fire hazards and have fire protection equip­ment present in the work area. Do not use an open flame to check level or leakage of fuel, battery electrolyte, or coolant.
(j) Properly ventilate the work area in accordance with applicable regulations or local ordinances.
(k) Handle fuel cylinders carefully. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken cylinders and make them unsafe for use.
(l) Brake mechanisms, steering mechanisms, speed and directional control mechanisms, warning devices, electrical systems, governors, guards, exhaust system, and safety devices shall be inspected regularly and maintained in accordance with the vehicle manufac­turer's recommended procedures.
(m) Vehicles or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved oper­ating features.
(n) Fuel systems shall be checked for leaks and condi­tion of parts. If a leak is found, action shall be taken to prevent the use of the vehicle until the cause of the leak has been repaired.
(o) The vehicle manufacturer's capacity, operation, and maintenance instruction plates, tags, and safety labels shall be maintained in legible condition.
(p) Batteries, motors, speed and directional control­lers, limit switches, protective devices, electrical conduc­tors/insulators, and connections shall be inspected and maintained in accordance with vehicle manufacturer's recommended procedures.
(q) Vehicles shall be kept in a clean condition to mini­mize fire hazards and facilitate the detection of compo­nents needing service.
(r) Hydraulic systems, if so equipped, shall be checked for leaks and condition of parts. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or card­board, not hands, to search for leaks.
(s) Modifications and additions which affect capacity and safe machine operation sha ll not be pe rformed wit h­out vehicle manufacturer's prior written authorization. Where authorized modifications have been made, the controlling party shall ensure that capacity, operation, warning, and maintenance instruction plates, tags, and safety labels are changed accordingly.
(t) Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a specification at least equal to that provided in the original equipment.
End of SAE J2258 DEC 2003, Part II
Page xiv
Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
WELCOME
Thank you for purchasing this utility vehicle. Before driv­ing vehicle, we ask you to spend some time reading this Owner’s Manual and Service Guide and the Owner’s Manual provided by Honda Motor Co., Ltd. These manu­als contain information to assist you in safe operation of vehicle. They will also assist you in maintaining vehicle. Some illustrations may show items that are optional.
Most service procedures in this guide can be accom­plished using common automotive hand tools. Other­wise, contact your service representative to schedule maintenance performed by a technician. Any servicing must be done per the Periodic Service Sched ule foun d in this manual and the Maintenance Schedule found in the engine manual.
Service Parts Manuals, Technician’s Repair and Service Manuals and engine Repair 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 date code.
Maintaining good performance depends, to a large extent, on owner/operator.
To reduce possibility of
! !
severe injury or death,
do not use vehicle improperly such as engaging in horseplay or attempt­ing to perform tasks for which it is not designed.
This vehicle is a utility vehicle. It is NOT a toy or an all terrain vehicle (ATV).
Before new vehicle is put into opera tion, items shown in INITIAL SERVICE CHART must be performed (Ref. Fig. 1 on page 1).
CAPABILITIES
TERRAIN
To reduce possibility of
! !
of the following:
Environmental hazards such as steep slopes, overhanging limbs, etc.
Danger of fire when vehicle is operated over dry combustible organic material.
severe injury or death
while driving, be aware
Ref Int 1
BEFORE INITIAL USE
ITEM SERVICE OPERATION
Seats Remove protective plastic covering Brakes Check operation and brake fluid level Tires Check air pressure (see SPECIFICATIONS) Fuel Fill tank with correct fuel Engine Check oil level Keys Record key number and store in a safe location
Fig. 1 Initial Service Chart
Read, understand and follow safety label on driver side fender well (Ref Appendix A). Be sure you understand how to safely operate vehicle and its equipment.
Vehicle is designed for: improved roads (not public high­ways), established trails, open terrain free from stumps, large rocks or holes, crossing water no deeper than 8 inches (20 cm).
Slow down when: traveling unfamiliar terrain, cresting a hill.
Be aware of hazards such as: steep slopes, overhanging limbs, danger of fire when vehicle is operated over dry combustible organic material.
On steep slopes: do not turn vehicle or stop and turn around, always travel straight up and down, control speed with service brake when going downhill.
Vehicle stop ping distance increases: when driving on wet grass, dirt roads or loose surfaces, when crossing streams or bodies of water that soak the brakes. Remember to lightly apply brakes and use friction to dry braking surfaces.
VEHICLE CAPACITY
To reduce possibility of
! !
severe injury or death
due to the variety of
Owner’s Manual and Service Guide
Page 1
OPERATION AND SERVICE INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
ways the vehicle may be used, it is important the operator consider any potential hazards before use to prevent serious injury or death.
See GENERAL SPECIFICATIONS section of this man­ual for load and seating capacity.
Never carry passengers in load bed. The weight of driver and passenger plus any options or
accessories must be deducted from total payload rating to determine load bed capacity.
Stopping distance increases as vehicle load increases. Load weight can be misleading. Loads consisting of dry
sand, fertilizer, sod, etc. will, when wet, grossly overload vehicle and increase potential for roll over and vehicle damage.
Towing a loaded trailer reduces capacity of vehicle load bed. (Ref. TOWING A TRAILER on page 12)
MODIFICATIONS TO VEHICLE
Changes to weight distri-
! !
bution or center of gravi-
ty may make vehicle unstable or prone to roll over which could result in injury or death to operator or passenger.
Do not modify vehicle in any manner that will change weight distribution.
Changes to weight distribution or center of gravity may make it unstable or prone to roll over which could result in injury or death to operator or passenger.
Do not tamper with governor. It is set for maximum safe vehicle speed.
Do not tamper with exhaust system. It is matched with engine for optimum performance.
Removal of muffler or other mod ificat ion s to exhaust sys­tem will: annoy others, not improve performance of vehi­cle, increase possibility of starting a fire.
COMMON SENSE OPERATION
To reduce possibility of
! !
bystanders, do not operate vehicle improperly and/or irresponsibly.
If vehicle is operated improperly and/or irresponsibly, severe injury or death to operator, passenger or bystand­ers can occur.
All operators should possess a valid driver’s license.
severe injury or death to
operator, passenger or
Children may not have the skill, judgement or strength to operate this or similar vehicles and shou ld not be perm it­ted to do so.
Alcohol, drugs and many over-the-counter medications reduce ability of driver to operate vehicle safely. Always review side effects of any medication with a doctor or pharmacist before operating vehicle.
If the vehicle is to be used in areas where steep slopes, overhanging limbs or other adverse conditions may be encountered, protective clothing an d a n a pp r ove d mo to r­cycle helmet are recommended for both operator and passenger.
Plan carefully before using vehicle to go significant dis­tances over questionable terrain. Remember that a one hour drive may take many hours to walk out should vehi­cle run out of fuel or be stranded by becoming stuck on unsuitable terrain.
Respect private property and comply with all local laws and regulations governing use of utility vehicles.
RUN-IN
Check for oil or fuel leaks that could have developed in shipment from factory. Avoid full throttle starts and rapid acceleration until 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 rate of consumption stabilizes.
Check oil level See OIL LEVEL CHECK on page 18. Add oil if level on dipstick is at lower hole.
Do not overfill engine. Too much oil may cause smoking or allow oil to enter
the air filter enclosure.
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 becoming contam­inated and/or being discharged into the engine compartment.
Oil should be changed, while engine is warm, at end of run-in period (Ref. Periodic Service Schedule on page
15).
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Owner’s Manual and Service Guide
OPERATION AND SERVICE INFORMATION
8 16 0 4/4
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CONTROLS & INDICATORS
SERVICE BRAKE PEDAL
Front of Vehicle
HOURS
P
Ref Sbp 1
Fig. 2 Service Brake Pedal
The service brake is a hydraulic front disc/rear drum brake system.
Push foot operated service brake pedal to activate wheel brakes, slowing or stopping vehic le (Ref. Fig. 2 on page
3).
PARKING BRAKE
Drive vehicle with park brake fully released. Failure to do so will prema-
turely wear rear brakes.
The park brake is a mechanical system using rear drum service brakes.
To engage, pull park brake handle up. An indicator light will illuminate in gauge cluster reminding operator to release park brake before driving (Ref. Fig. 3 on page 3).
To disengage, pull up slightly and push in release button at end of handle, then fully lower park brake handle.
Ref Pbh 2
Fig. 3 Park Brake and Indicator
CHOKE
Starting a cold engine may require use of choke. To use, pull choke knob out and hold while starting engine (Ref. Fig. 4 on page 4). Once started and engine begins to warm, release choke knob.
Do not allow starter to operate continu-
ously for more than 10 seconds. Allow 30 seconds between starting attempts. If vehicle does not start on third attempt, turn key switch off, set park brake and deter­mine cause of problem.
IGNITION SWITCH
Ignition switch has three positions: ‘OFF’, ‘ON’ and ‘START’ (Ref. Fig. 5 on page 4).
Insert key into switch and turn clockwise to ‘ON’ to enable starting system.
Continue to turn clockwise to “START” to activate starter. Once engine starts, release key allowing return to ‘ON’. To prevent inadvertent operation of vehicle when left
unattended, turn key to ‘OFF’ position and remove key.
Owner’s Manual and Service Guide
Page 3
OPERATION AND SERVICE INFORMATION
R
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Choke
Pull Out
ef Chk 4
Fig. 4 Choke
If
vehicle is equipped with factory installed cus-
tom accessories, some accessories remain
operational with key switch in ‘OFF’ position.
To prevent draining the battery, always
place differential lock switches in the ‘unlocked’ position, turn the key switch to ‘off’ and remove the key.
If one or both of the differential locks is engaged and the key left in the ‘on’ position, the differential lock sole­noid(s) will be activated (Ref. Fig. 6 on page 4) and (Ref. Fig. 8 on page 5). Over time the solenoids will drain the battery to a point where the vehicle will be unable to be started.
Ref Kes 5
OFF
ON
START
73767G01
Fig. 5 Ignition Switch
Forward Engaged
DIRECTION SELECTOR
73777G01
To reduce possibility of drivetrain dam-
age, vehicle must completely stop before moving direction selector (Ref. Fig. 6 on page 4).
Reverse
Ref Dsl 5
Neutral Disengaged
Direction selector offers choice of three positions: for­ward, neutral and reverse (Ref. Fig. 6 on page 4).
Selector must be in neutral to start engine.
Fig. 6 Direction Selector and Differenti al Locks
Always bring vehicle to a complete stop before changing selection.
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Owner’s Manual and Service Guide
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