Star EV Classic-Series, Sport-Series, SS Limited-Series, H-Series Owner's Manual And Service Manual
Owner’s Manual and Service Guide
Star Classic, Star Sport, SS Limited, H-Series
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Thanks for buying your Star EV. This manual contains information
you will need for proper operation, maintenance, and care of your
Star EV. A thorough understanding of these simple instructions will
help you to obtain maximum enjoyment from your new Star EV.
If you have any questions about the operation or maintenance of
your Star, please consult your Star EV dealer.
Read and understand this manual completely before operating your
Star EV.
This manual should be considered a permanent part of your Star EV
and should remain with the vehicle when lending or resold.
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Models & Names
Vehicle Specifications
Overview
Important labels
Controls
Functions
Safety
Operation
Maintenance
Battery maintenance
Charger maintenance
Motor maintenance
Controller maintenance
Rear axle maintenance
Wheel maintenance
Brake adjustment
Lubrication
Troubleshooting
Periodic Maintenance Chart
Storage
Table of Contents
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7
11
12
15
17
18
19
25
26
27
29
29
30
30
32
32
34
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Important Information
Particularly important information is distinguished by the following notations:
WARNING: Failure to follow Warning instructions could result in severe injury to the
vehicle occupants, bystanders or persons inspecting or repairing the vehicle.
CAUTION: Failure to follow Caution instructions could cause damage to the vehicle.
Special Notice: Because the seat & backrest wrapping film may stick to the seat vinyl and cause seat vinyl to fade or stain, remove the seat & backrest wrapping film
when you start to use the vehicle. Even if you plan to store the vehicle for a long
time, remove the seat & backrest wrapping film.
1: Models and Names
* Some models are shown with options like one-piece windshields and custom wheels.
Classic 36-2 Classic 36-2+2
Classic 48-2 Classic 48-2+2
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Classic 48-4 Classic 48-4+2
Classic 48-6 Classic 48-6+2
Classic 36-2H, Classic 48-2H Classic 48-4H
Classic 48-6H
Classic 48-2HCX (with various box attachment
options, not shown)
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Classic 48-4HCX (with various box attachment
options, not shown)
Sport 2+2
Sport 4+2 Sport 48-2H
Sport 48-4H Sport 48-2HCX
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Star Classic Classic 36-2 and Classic 36-2+2
Passengers 2 or 4 (2 facing backward) Body Material Plastic
Battery System
Six 6 V (36 V) batteries, Trojan
T-105
Front Suspension Leaf spring and shock
Motor Power 4 hp Advanced DC motor Steering System Rack and pinion
Controller Power
300 A Curtis programmable
controller
Brake System Rear drum
Top Speed 18 mph Tire Size 205/50/10, 4-ply DOT tire
Load Capacity 36-2: 600 lbs / 36-2+2: 660 lbs Tire Pressure 30 psi
Dimensions
36-2: 94” x 47” x 72” (L x W x H)
36-2+2: 115” x 47” x 77” (L x
W x H)
Wheel Type 10” aluminum
Weight w/ Batteries
36-2: 1075 lbs / 36-2+2: 1245
lbs
Roof
36-2: Molded plastic, beige
36-2+2: Fiberglass, color-matched
Ground Clearance 5” Windshield Foldable, tinted
Turning Radius 10 Drive Train
Direct rear drive with 10.25:1
ratio
Wheel Base 67” Voltage Reducer
20 A, 36 V to 12 V reducer
included
Top Climbing Grade
36-2: 25%
36-2+2: 20%
Warranty
Four year limited warranty,
two year bumper-to-bumper
warranty (less wear items)
Star Classic Classic 48-2 and Classic 48-2+2
Passengers 2 or 4 (2 facing backward) Body Material Plastic
Battery System
Eight 6 V (48 V) batteries,
Trojan T-105
Front Suspension Leaf spring and shock
Motor Power 5.5 hp Advanced DC motor Steering System Rack and pinion
Controller Power
400 A Curtis programmable
controller
Brake System Rear drum
Top Speed
19.5 mph (20-25 mph if street
legal)
Tire Size 205/50/10, 4-ply DOT tire
Load Capacity 48-2: 600 lbs / 48-2+2: 660 lbs Tire Pressure 30 psi
Dimensions
48-2: 94” x 47” x 72” (L x W x H)
48-2+2: 115” x 47” x 77” (L x
W x H)
Wheel Type 10” aluminum
Weight w/ Batteries
48-2: 1200 lbs / 48-2+2: 1370
lbs
Roof
48-2: Molded plastic, beige
48-2+2: Fiberglass, color-matched
Ground Clearance 5” Windshield Foldable, tinted
Turning Radius 10 Drive Train
Direct rear drive with 10.25:1
ratio
Wheel Base 67” Voltage Reducer
20 A, 48 V to 12 V reducer
included
Top Climbing Grade 20% Warranty
Four year limited warranty,
two year bumper-to-bumper
warranty (less wear items)
2: Vehicle Specifications
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Star Classic Classic 48-4 and Classic 48-4+2
Passengers 4 or 6 (2 facing backward) Body Material Plastic
Battery System
Eight 6 V (48 V) batteries,
Trojan T-105
Front Suspension Leaf spring and shock
Motor Power 5.5 hp Advanced DC motor Rear Suspension Leaf spring and shock
Controller Power
400 A Curtis programmable
controller
Steering System Rack and pinion
Top Speed
19.5 mph (20-25 mph if street
legal)
Brake System
Four-wheel hydraulic drum
brakes
Load Capacity 48-4: 660 lbs / 48-4+2: 1,000 lbs Tire Size
48-4: 205/50/10, 4-ply DOT tire
48-4+2: 20.5x8-10, 6-ply DOT
tire
Dimensions
48-4: 123” x 47” x 77”
48-4+2: 144” x 47” x 77”
(L x W x H)
Tire Pressure
48-4: 30 psi
48-4+2: 50 psi
Weight w/ Batteries
48-4: 1430 lbs
48-4+2: 1570 lbs
Wheel Type 10” aluminum
Ground Clearance 5” Roof Fiberglass, color-matched
Turning Radius 12 Windshield Foldable, tinted
Wheel Base 96” Drive Train
Direct rear drive with 10.25:1
ratio
Top Climbing Grade 20% Voltage Reducer
20 A, 48 V to 12 V reducer
included
Warranty Four year limited warranty, two year bumper-to-bumper warranty (less wear items)
Star Classic Classic 48-6 and Classic 48-6+2
Passengers 6 or 8 (2 facing backward) Body Material Plastic
Battery System
Eight 6 V (48 V) batteries,
Trojan T-105
Front Suspension Leaf spring and shock
Motor Power 5.5 hp Advanced DC motor Rear Suspension Leaf spring and shock
Controller Power
400 A Curtis programmable
controller
Steering System Rack and pinion
Top Speed
19.5 mph (20-25 mph if street
legal)
Brake System
Four-wheel hydraulic drum
brakes
Load Capacity 48-6: 990 lbs / 48-6+2: 1290 lbs Tire Size 20.5x8-10, 6-ply DOT tire
Dimensions
48-6: 153” x 47” x 77”
48-6+2: 173” x 47” x 77”
(L x W x H)
Tire Pressure 50 psi
Weight w/ Batteries
48-6: 1625 lbs / 48-6+2: 1800
lbs
Wheel Type 10” aluminum
Ground Clearance 5” Roof Fiberglass, color-matched
Turning Radius 15 Windshield Foldable, tinted
Wheel Base 125” Drive Train
Direct rear drive with 12.49:1
ratio
Top Climbing Grade 20% Voltage Reducer
20 A, 48 V to 12 V reducer
included
Warranty Four year limited warranty, two year bumper-to-bumper warranty (less wear items)
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Sport Sport 2+2 and Sport 4+2
Passengers
4 of 6 (2 facing backwards on
both)
Body Material Plastic
Battery System
Eight 6 V (48 V) batteries,
Trojan T-105
Front Suspension Leaf spring and shock
Motor Power 5.5 hp Continuous Rear Suspension Leaf spring and shock
Controller Power 400 A Curtis controller Steering System Rack and pinion
Top Speed
17 mph (20-25 mph if street
legal)
Brake System Rear drum
Load Capacity 2+2: 600 lbs / 4+2: 900 lbs Tire Size 23x10.5-12 DOT tire
Dimensions
2+2: 116” x 52” x 79” (L x W x H)
4+2: 138” x 52” x 85” (L x W x H)
Tire Pressure 15 psi
Weight w/ Batteries 2+2: 1430 lbs / 4+2: 1650 lbs Wheel Type 12” steel
Ground Clearance 7" Roof Fiberglass, color-matched
Turning Radius 2+2: 10 / 4+2: 13 Windshield Foldable, tinted
Wheel Base 2+2: 68” / 4+2: 96” Drive Train Direct rear drive with 12:1 ratio
Top Climbing Grade 28% Voltage Reducer
20 A, 48 V to 12 V reducer
included
Warranty Four year limited warranty, two year bumper-to-bumper warranty (less wear items)
H-Series Classic 36-2H, 48-2H, 48-4H, and 48-6H
Passengers 2, 4, or 6 Top Climbing Grade
36- and 48-2H: 25% / 48-4H
and 6H: 20%
Battery System
36 V: Six 6 V batteries, Trojan
T-105 / 48 V: Eight 6 V batteries,
Trojan T-105
Brake System
36- and 48-2H: Rear drum
48-4H and 6H: Hydraulic drum
Motor Power
36 V: 4 hp Advanced DC motor
48 V: 5.5 hp Advanced DC
motor
Tire Size
36-2H, 48-2H, 4H: 205/50/10,
4-ply DOT
48-6H: 20.5 x 8x 10, 6-ply DOT
Controller Power 36 V: 300 A / 48 V: 400 A Tire Pressure
36-2H, 48-2H, 4H: 30 psi / 486H: 50 psi
Top Speed
36 V: 18 mph
48 V: 19.5 mph (20-25 mph if
street legal)
Roof
36- and 48-2H: Molded plastic,
beige / 48-4H and 6H: Fiberglass, color-matched
Total Load Capacity
36- and 48-2H: 650 lbs / 48-4H:
960 lbs 48-6H: 990 lbs
Drive Train
36- and 48-2H: Direct rear
drive, 10.25:1 / 48-4H and 6H:
Direct rear drive, 12.49:1
Cargo Capacity 300 lbs Front Suspension Leaf spring and shock
Body Material Plastic Rear Suspension Leaf spring and shock
Dimensions
36- and 48-2H: 115” x 47” x 72”
48-4H: 144” x 47” x 77”
48-6H: 153” x 47” x 77”
Weight w/ Batteries
36-2H: 1100 lbs / 48-2H: 1230
lbs / 48-4H: 1460 lbs / 48-6H:
1800 lbs
Box Dimensions 30” x 43” x 8.5” (L x W x H) Wheel Type 10” aluminum
Turning Radius
36- and 48-2H: 10 / 48-4H: 12
/ 48-6H: 15
Wheel Base
36- and 48-2H: 67” / 48-4H: 96”
/ 48-6H: 125”
Ground Clearance 5” Steering System Rack and pinion
Windshield Foldable, tinted Voltage Reducer
20 A, 48 V or 36 V to 12 V reducer included
Warranty Four year limited warranty, two year bumper-to-bumper warranty (less wear items)
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H-Series Classic 48-2HCX, Classic 48-4HCX
Passengers 2 or 4 Top Climbing Grade 20%
Battery System
Eight 6 V batteries, Trojan
T-105
Brake System Hydraulic drum
Motor Power 5.5 hp Advanced DC motor Tire Size 20.5 x 8x 10, 6-ply DOT
Controller Power 400 A Tire Pressure 50 psi
Top Speed
19.5 mph (20-25 mph if street
legal)
Roof
2HCX: Molded plastic, beige
4HCX: Fiberglass, colormatched
Load Capacity 2HCX: 960 lbs / 4HCX: 1290 lbs Drive Train Direct rear drive, 12.49:1
Cargo Capacity 2HCX: 600 lbs / 4HCX: 800 lbs Front Suspension Leaf spring and shock
Body Material Plastic Rear Suspension Leaf spring and shock
Dimensions
2HCX: 132" x 47" x 73"
4HCX: 162" x 47" x 78"
(L x W x H)
Weight w/ Batteries
2HCX: 1500 lbs
4HCX: 1625 lbs
Box Dimensions 54" x 43" x 9.5" (L x W x H) Wheel Type 10” aluminum
Turning Radius 2HCX: 12 / 4HCX: 15 Wheel Base 2HCX: 96” / 4HCX: 125”
Ground Clearance 5” Steering System Rack and pinion
Windshield Foldable, tinted Voltage Reducer
20 A, 48 V to 12 V reducer
included
Warranty Four year limited warranty, two year bumper-to-bumper warranty (less wear items)
H-Series Sport 48-2H, Sport 48-4H, Sport 48-2HCX
Passengers 2 or 4 Top Climbing Grade
Battery System
Eight 6 V batteries, Trojan
T-105
Brake System
Motor Power 5.5 hp Advanced DC motor Tire Size
Controller Power 400 A Tire Pressure
Top Speed
19.5 mph (20-25 mph if street
legal)
Roof
Load Capacity 2H: 600 lbs / 4H: 930 lbs Drive Train
Cargo Capacity 2H: 300 lbs / 4H: 330 lbs Front Suspension
Body Material Plastic Rear Suspension
Dimensions Weight w/ Batteries
Box Dimensions Wheel Type
Turning Radius Wheel Base
Ground Clearance Steering System Rack and pinion
Windshield Foldable, tinted Voltage Reducer
20 A, 48 V to 12 V reducer
included
Warranty Four year limited warranty, two year bumper-to-bumper warranty (less wear items)
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3: Overview
WARNING: Always confirm whether there are restrictions in the area where you intend to use the vehicle. It is recommended that only people who possess a valid
motor vehicle driver’s license be allowed to operate golf cars.
Important Labels
Safety Label
Read carefully and understand the contents on the safety label. The label is attached on the dash panel.
Vehicle Information
The name plate is either on the back of the seat pod or below the dashboard.
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