Textron E-z-go RXV User Manual

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OWNER’S GUIDE

RXV

GASOLINE POWERED VEHICLE

646286

REVISED NOVEMBER 2015ISSUED MAY 2015

WELCOME

Thank you for purchasing this vehicle. Before you drive the vehicle, read this Owner’s Guide. This guide contains maintenance and operation information. The illustrations can show items that are optional for your vehicle.

You can do most of the service procedures in this guide with common, automotive hand tools. If necessary, contact your service representative for information about how to service the vehicle as shown in the Periodic Service Schedule.

Repair or replacement parts are available from your E-Z-GO dealer or E-Z-GO Service Parts Department.

When you contact E-Z-GO about service or parts for your vehicle, the information below is needed.

Vehicle Model: ___________________________________________________________

PIN, VIN or Serial Number: _________________________________________________

OWNER’S GUIDE

GASOLINE POWERED VEHICLES

RXV FLEET

RXV FREEDOM

RXV SHUTTLE 2+2

STARTING MODEL YEAR 2016

CALIFORNIA Proposition 65 Warning

WARNING: Motor vehicles may contain fuels, oils and fluids, battery posts, terminals, and related accessories which

contain lead, lead compounds and other chemicals identified by the State of California to potentially cause cancer, birth defects and other reproductive harm. These chemicals are found in vehicles, vehicle parts and accessories, both new and replacements. During maintenance, these vehicles generate used oil, waste fluids, grease, fumes and particulates, all identified by the State of California to potentially cause cancer, birth defects, and other reproductive harm.

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 specifications. Such modifications can cause serious personal injury or death. E-Z-GO Division of Textron, Inc. prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.

E-Z-GO Division of Textron, Inc. reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these changes on units sold previously.

The information contained in this manual may be revised periodically by E-Z-GO Division of Textron, Inc., and therefore is subject to change without notice.

E-Z-GO Division of Textron, Inc. DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.

These are the original instructions as defined by 2006/42/EC.

TO CONTACT US

E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Road. Augusta, Georgia, USA 30906-3852

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

NOTES

This vehicle was designed and manufactured in the United States of America (USA). The

standards and specifications listed in the following text originate in the USA unless other-

wise indicated.

Use Original Equipment Manufacturer (OEM) approved parts to keep the warranty effective.

Overfilling the battery can void the warranty.

Tampering with or adjusting the governor to permit the 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

Batteries discharge over time. The rate of discharge changes according to the ambient tem-

perature, the age and condition of the batteries.

Completely charged batteries will not freeze in winter temperatures unless the temperature

is less than -75°F (- 60°C).

BATTERY DISPOSAL

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

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

with absorbent material such as sand. Dispose of in accordance with local, state and federal

regulations for acid and lead compounds. Contact local or state environmental officials for

the disposal information.

Owner’s Manual

SAFETY

GENERAL ......................................................................................................................... 1

NOTICES, CAUTIONS, WARNINGS AND DANGERS .................................................... 1

GENERAL OPERATION................................................................................................... 3

MAINTENANCE ................................................................................................................ 4

VENTILATION................................................................................................................... 5

LABELS AND PICTOGRAMS........................................................................................... 6

GENERAL SPECIFICATIONS

APPROXIMATE VEHICLE DIMENSIONS ...................................................................... 17

TURNING DIAMETER AND INCLINE INFORMATION .................................................. 19

INTRODUCTION

CONTROLS AND INDICATORS .................................................................................... 21

FEATURES ..................................................................................................................... 22

TABLE OF CONTENTS

General Information ........................................................................................... 22

OPERATING PROCEDURES

SERIAL NUMBER LOCATION ....................................................................................... 27

BEFORE INITIAL USE.................................................................................................... 28

HOW TO OPERATE THE VEHICLE............................................................................... 28

Direction Selector Operation .............................................................................. 29

Accelerator Pedal Operation .............................................................................. 30

Brake and Parking Brake Operation .................................................................. 30

Horn (if equipped) .............................................................................................. 30

Rear Seat and Cargo Platform Operation .......................................................... 30

12-Volt Power Outlet .......................................................................................... 31

STARTING AND DRIVING ............................................................................................. 31

Run-In ................................................................................................................ 32

Cold-Start ........................................................................................................... 32

Starting Vehicle On A Hill ................................................................................... 33

Coasting ............................................................................................................. 33

FUEL ............................................................................................................................... 33

FUEL TANK .................................................................................................................... 34

Early Production Fuel Tank ................................................................................ 34

Late Production Fuel Tank ................................................................................. 34

BATTERY........................................................................................................................ 35

Owner’s Guide

iii

TABLE OF CONTENTS

LABELS AND PICTOGRAMS.......................................................................................... 35

SUN TOP AND WINDSHIELD (IF EQUIPPED)............................................................... 35

MAINTENANCE

VEHICLE CLEANING AND CARE................................................................................... 37

ENVIRONMENTAL CONCERNS .................................................................................... 37

Battery Disposal ..................................................................................................38

LIFTING THE VEHICLE................................................................................................... 38

How to Lift the Entire Vehicle: .............................................................................38

How to Lift the Rear of the Vehicle Only: ............................................................39

How to Lift the Front of the Vehicle Only: ...........................................................39

Lower the Vehicle: ..............................................................................................39

WHEELS AND TIRES...................................................................................................... 39

Tire Repair ..........................................................................................................40

Wheel Installation ................................................................................................40

LIGHT BULB REPLACEMENT ........................................................................................ 41

Headlight (if equipped) ........................................................................................41

Turn Signal (if equipped) .....................................................................................41

Taillight (if equipped) ...........................................................................................41

VEHICLE WITH A DISCHARGED BATTERY ................................................................. 42

TRANSPORTING VEHICLE ............................................................................................ 42

Towing ................................................................................................................42

Neutral Lock ........................................................................................................42

Hauling ................................................................................................................43

SERVICE AND MAINTENANCE ..................................................................................... 43

ROUTINE MAINTENANCE.............................................................................................. 44

Engine Specifications ..........................................................................................44

Checking the Oil Level ........................................................................................44

Changing the Oil .................................................................................................45

Starter Generator Belt Tension ...........................................................................47

Adjusting the Belt ................................................................................................48

Battery Cleaning .................................................................................................48

TIRE INSPECTION.......................................................................................................... 48

BRAKES .......................................................................................................................... 49

LUBRICATION................................................................................................................. 49

CAPACITIES AND REPLACEMENT PARTS .................................................................. 49

Owner’s Guide

HARDWARE ................................................................................................................... 50

AIR INTAKE AND COOLING FINS ................................................................................. 50

REAR AXLE .................................................................................................................... 51

Checking the Lubricant Level ............................................................................. 51

AIR CLEANER INSPECTION AND REPLACEMENT..................................................... 51

Cleaning the Air Filter Element .......................................................................... 51

SPARK PLUGS............................................................................................................... 52

BATTERY REMOVAL AND INSTALLATION .................................................................. 52

PROLONGED STORAGE............................................................................................... 53

PERIODIC SERVICE SCHEDULE

PERIODIC SERVICE SCHEDULE ................................................................................. 53

APPENDIX A

DECLARATION OF CONFORMITY ................................................................................. 1

TABLE OF CONTENTS

Owner’s Guide

TABLE OF CONTENTS

Notes:

Owner’s Guide

SAFETY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

SAFETY

GENERAL

For any questions about material in this manual, contact an authorized representative.

Read and understand all labels on the vehicle. Always replace any damaged or missing labels.

Steep hills allow the vehicle to move at faster speeds than normal speeds on a flat surface. To prevent the loss of vehicle control and possible injury, speeds must be controlled to the maximum level ground speed indicated in the GENERAL SPECIFICATIONS section. Apply the brake to control the speed.

If you operate the vehicle above the maximum specified speed, you can damage the drivetrain components. The damage caused by speeds more than the maximum specified can cause a loss of vehicle control, is abusive, and will not be covered under the warranty.

Use caution when you tow the vehicle. Towing the vehicle above the recommended speed can cause personal injury or damage to the vehicle and other property.

If the vehicle is used in a commercial environment, signs must be in position to inform of possible conditions that can be dangerous. Examples are shown below.

NOTICES, CAUTIONS, WARNINGS AND DANGERS

Read the NOTICES, CAUTIONS, WARNINGS and DANGERS. The person who services a vehicle needs the mechanical skill and experience to see possible hazardous conditions. Incorrect service or repairs can cause damage to the vehicle or make the vehicle dangerous to operate.

A NOTICE indicates and describes information not related to personal injury.

A CAUTION indicates a dangerous condition that can cause injury that is not life threatening.

A WARNING indicates a dangerous condition that can cause death or serious injury.

A DANGER indicates a dangerous condition that will cause death or serious injury.

Owner’s Guide

SAFETY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Engine exhaust from this product contains chemicals known, in certain quantities, to cause can-

cer, birth defects, or other reproductive harm.

The exhaust emissions of this vehicle’s 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 modifi-

cations 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.

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

This manual contains recommended maintenance procedures from the manufacturer. Follow these procedures and fault isolation information to get the best service from the product. To decrease the risk of personal injury or property damage, obey all the information in this manual.

Certain replacement parts can be used independently and/or in combination with other accessories to modify

an E-Z-GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph. When an E-Z-GO

manufactured 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 stric-

tures 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 Identifi-

cation Number to the product in accordance with the requirements of FMVSS 571.565. Pursuant to FMVSS

571.500, and in accordance 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 changes that change an E-Z-GO product into a Low Speed Vehicle (LSV).

Anyone who operates this vehicle must be A LICENSED DRIVER AND OPERATE THE VEHICLE ACCORDING TO APPLICABLE STATE REQUIREMENTS. This rule is important to the SAFE USE AND OPERATION of the product. All customers must obey this SAFETY RULE.

Information on FMVSS 571.500 is found at Title 49 of the Code of Federal Regulations, section 571.500. For information online, go to www.ecfr.gov.

Vehicles are used for different purposes, so it is not possible to know and inform of every possible occurrence. Be careful when you drive to prevent avoidable personal injury or damage to the vehicle. All users must read and obey this manual. Make sure you give special attention to the CAUTIONS, WARNINGS and DANGERS.

For questions about this vehicle, contact your E-Z-GO/CUSHMAN dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.

Owner’s Guide

SAFETY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

E-Z-GO reserves the right to make design changes without obligation to make these changes on units previously sold. 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 meets the current applicable standard for safety and performance requirements.

These vehicles are for off-road use. They DO NOT meet the federal Motor Vehicle Safety Standards of the United States of America (USA) and are not equipped for operation on the public streets. Some areas allow the operation of the vehicles on their streets according to local codes.

Refer to GENERAL SPECIFICATIONS for capacity of the vehicle.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease

its stability, increase the speed or extend the stopping distance beyond the factory specification.

Such modifications can result in serious personal injury or death.

Do not change the vehicle in any manner that changes the weight distribution, decreases stability, increases speed or extends the necessary distance to stop more than the factory specification. E-Z-GO is not responsible for changes that cause the vehicle to be dangerous.

Do not let anyone below the height of 59 inches (150 cm) operate the vehicle.

GENERAL OPERATION

Read the following warnings before attempting to operate the vehicle:

When you leave the vehicle, turn the key to the OFF position and remove the key from the

vehicle.

Drive the vehicle only as fast as terrain and conditions allow. Consider the terrain and traffic

conditions. Consider environmental conditions that change the terrain and your ability to control

the vehicle.

Do not drive fast downhill. Sudden stops or change of direction can cause a loss of control.

Use the brake to control the speed of the vehicle when you drive down a slope.

When possible, stay in approved areas. Do not drive on steep slopes.

Always keep feet, legs, hands and arms inside vehicle.

Do not drive on rough terrain.

Before you drive in the reverse direction, make sure the area behind the vehicle is clear.

Make sure the direction selector is in the correct position before you press the accelerator pedal.

Decrease speed before and during turns.

Make sure you completely stop the vehicle before you move the direction selector.

See GENERAL SPECIFICATIONS for the vehicle load and seat capacity.

Owner’s Guide

SAFETY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Read the following text and warnings before you service the vehicle.

Normal use, wear or abuse can cause some components on the vehicle to fail. The manufacturer cannot know all possible component failures or the methods that failures can occur.

A vehicle in need of repair does not function properly and can be dangerous to operate.

Be careful when you service the vehicle. Be aware of your safety and the safety of other people in the area.

Some components are heavy, spring loaded, corrosive, explosive, can cause high amperage or get hot. Battery acid and hydrogen gas can cause injury. Do not put your hands, face, feet or body in a location that can expose them to injury if an unexpected situation occurs.

Always use the correct tools shown in the tool list and wear safety equipment.

Remove all jewelry before you service the vehicle.

Do not allow loose clothing or hair to contact the moving parts.

Do not touch hot objects.

When you service the vehicle, always wear eye protection. Be careful when you work around batteries, use solvents or compressed air.

ALWAYS:

• Use the vehicle in a responsible manner and keep the vehicle in safe condition for operation.

• Read and obey all warnings and operation instruction labels on the vehicle.

• Follow all safety rules in the area where the vehicle is operated.

• When there is a risk of lightning, leave the vehicle and look for a safe location to wait until the lightning has stopped.

• Drive the vehicle only as fast as terrain and conditions allow.

• Apply the brake to control speed on steep grades.

• Keep enough distance between vehicles.

• Decrease speed in wet areas.

• Be careful when you make sharp turns, or turns you are not familiar with.

• Be careful when you drive on loose terrain.

• Be careful when you operate the vehicle around people.

MAINTENANCE

ALWAYS:

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

• Service the vehicle according to the periodic service schedule in this manual.

• Make sure that approved and qualified personnel do all repairs.

• Follow the manufacturer’s maintenance procedures.

Owner’s Guide

SAFETY

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

• Use insulated tools within the battery area to prevent sparks or battery explosion.

• Use specified replacement parts. DO NOT use replacement parts of less quality.

• Use recommended tools.

• Make sure that tools and procedures not specified by the manufacturer, will not be a safety risk to personnel or operation of the vehicle.

• Use wheel chocks and support vehicle with jack stands. NEVER get below a vehicle that is supported by a jack. Lift the vehicle according to the manufacturers instructions.

• Make sure you service the vehicle in an area away from open flame or sparks.

• Know that a vehicle in need of repair does not operate correctly and can be dangerous to operate.

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

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

People who do maintenance or repairs on the vehicle must have skill and experience to identify and prevent conditions that can cause personal injury or death and damage to the vehicle.

VENTILATION

Always store gasoline vehicles in an area with good ventilation. Good ventilation prevents the accumulation of gasoline fumes within an enclosed area.

Never put fuel in 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 allow ventilation of exhaust gases from the area. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

Owner’s Guide

SAFETY

608528

608527

608528

Failure to follow these instructions can result in SERIOUS INJURY or DEATH

Except where PERMITTED BY LAW:

NEVER drive on public roads. Drivers must possess a valid drivers license in accordance with local state law.

AVOID FALLS from the vehicle:

Do not start moving until all occupants are PROPERLY SEATED and HOLDING ON. KEEP entire body INSIDE VEHICLE while moving.

Reduce the RISK OF ACCIDENTS:

Always DRIVE SLOWLY in congested areas, on wet or loose terrain, and when backing up. DRIVE SLOWLY when turning and AVOID sudden stops. ALWAYS drive straight up and down slopes. Do not coast, use BRAKE when going down a slope. NEVER drive this vehicle under the influence

of drugs or alcohol.

This vehicle is NOT A TOY:

Drive responsibly. NEVER leave children unattended or allow children to play on the vehicle. NEVER leave the key in the vehicle when parked.

DO NOT OVERLOAD this vehicle:

NEVER carry more than 2 occupants on each bench seat. Do not exceed vehicle WEIGHT CAPACITY (see Owner’s Manual).

DO NOT MODIFY this vehicle:

NEVER alter this vehicle to increase travel speeds above factory specifications. ONLY authorized E-Z-GO dealers should alter the vehicle using approved parts. Alterations not approved or tested by E-Z-GO can create unsafe conditions and increase your chance of having an accident.

608522 Fleet Vehicles

608529

608522

Except where PERMITTED BY LAW:

To be operated by persons with valid drivers license, in accordance with state requirements. Operate from Driver’s side only.

Reduce the RISK OF ACCIDENTS:

For non-road use, and in designated areas only. Do not operate under the influence of drugs or alcohol.

AVOID FALLS from the vehicle:

All occupants must be fully seated, keep entire body inside vehicle and hold on while vehicle is in motion.

STARTING the vehicle:

Apply service brake , move direction selector to desired position and accelerate smoothly. On Gas Vehicle, direction selector is the F-N-R. On Electric vehicle, direction selector is the key switch.

DO NOT OVERLOAD this vehicle:

Maximum vehicle payload is 800 lbs. (363 kg) including a maximum of 2 persons, options, and accessories.

Drive with CAUTION:

Drive slowly straight up and down slopes and in turns. Use care in reverse, congested areas, and wet or loose terrain.

STOPPING the vehicle:

To stop, release accelerator pedal and apply service brake.

PARKING the vehicle:

Before leaving vehicle , turn key ‘OFF’. On Gas vehicle, move the direction selector to “FORWARD” and engage park brake.

Failure to follow these instructions can result in SERIOUS INJURY or DEATH

BEFORE OPERATING

READ all warning labels and the owner’s manual. Contact an authorized E-Z-GO dealer or visit www.ezgo.com for a replacement manual.

This vehicle is equipped for personal use in most communities. However, state law or local rules may require additional equipment in your community.

SAFE OPERATION

Turn key to “ON” - select “forward” or “reverse” - release the parking brake (Gas vehicle only) - then slowly depress accelerator pedal.

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

Operate from the driver’s seat ONLY.

PARKING

ALWAYS fully engage the parking brake and remove the key BEFORE leaving the vehicle. In an electric vehicle set the direction selector to “neutral” and in a gasoline vehicle set the selector to “forward”.

MAINTENANCE

This vehicle requires regularly scheduled maintenance (see owner’s manual). ONLY qualified personnel should service this vehicle.

OPERATING INSTRUCTIONS

608529

DO NOT TAMPER WITH OR ATTEMPT TO CHANGE THE ADJUSTMENT OF THE GOVERNOR. GOVERNOR TAMPERING CAN RESULT IN SERIOUS PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY.

608527

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

LABELS AND PICTOGRAMS

Owner’s Guide

SAFETY

WARNING

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

EGWHL14

This device is ONLY to be used for towing E-Z-GO vehicles. NEVER tow other vehicles or equipment. READ Owner’s Manual before towing. NO RIDERS in towed cars.

NEVER tow more than 3 vehicles at one time. Max speed towing 2 or 3 vehicles is 5 mph. Max speed towing 1 vehicle is 12 mph.

MONTHLY INSPECTION: tow bar pins, attaching hardware, and front frame attachment of towed cars. Replace worn or damaged parts. CHECK alignment of wheels on towed cars.

FULLY ENGAGE coupling. Rubber latch-stop must be under latch release lever.

611716

DRIVE SLOWLY, it is not recommended to tow vehicle over rough or unsafe terrain or on grades greater than 10%.

611716

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

SAFETY

610631

MAX 4 in. 10 cm

MAX 14

/ 25%

MAX 250 lbs. 110 kg

610631

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

SAFETY

614043 CE VEHICLES

608818

< 14° 25%

MIN 150

OFF

R F

OFF

614043

OFF

R F

MAXIMUM RAMP OR HILL

MAXIMUM CROSS RAMP OR HILL

OPERATE FROM DRIVER SIDE ONLY

DO NOT STAND UP AND KEEP ENTIRE BODY INSIDE VEHICLE

MINIMUM HEIGHT TO OPERATE VEHICLE IS 150 CM

DO NOT DRIVE ON HIGHWAY

DO NOT OPERATE IF USING DRUGS OR ALCOHOL

DO NOT OPERATE VEHICLE WHEN LIGHTNING IS IN THE AREA

READ THE MANUAL

OPERATE ACCORDING TO LOCAL LAWS AND REGULATIONS

USE CAUTION IN BAD WEATHER

FORWARD OPERATION * TURN KEY TO ‘ON’ * MOVE DIRECTION SELECTOR TO ‘F’ * PRESS ACCELERATOR PEDAL GENTLY

REVERSE OPERATION * TURN KEY TO ‘ON’ * MOVE DIRECTION SELECTOR TO ‘R’ * PRESS ACCELERATOR PEDAL GENTLTY

PARK VEHICLE * MOVE DIRECTION SELECTOR TO ‘F’ * TURN KEY TO ‘OFF’ * APPLY PARKING BRAKE

GASOLINE VEHICLES

FORWARD OPERATION * TURN KEY TO ‘F’ * PRESS ACCELERATOR PEDAL GENTLY

REVERSE OPERATION * TURN KEY TO ‘R’ * GENTLY PRESS ACCELERATOR PEDAL

PARK VEHICLE * TURN KEY TO ‘OFF’

ELECTRIC VEHICLES

WARNING: SHORTING ACROSS TERMINALS MAY CAUSE BATTERY EXPLOSION

READ THE MANUAL REPLACEMENT AVAILABLE AT www.ezgo.com

WARNING: NEGATIVE GROUND ELECTRICAL SYSTEM

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

SAFETY

614044

FFO

R F

FFO

www.ezgo.com

150

FORWARD OPERATION * TURN KEY TO ‘ON’ * MOVE DIRECTION SELECTOR TO ‘F’ * PRESS ACCELERATOR PEDAL GENTLY

REVERSE OPERATION * TURN KEY TO ‘ON’ * MOVE DIRECTION SELECTOR TO ‘R’ * PRESS ACCELERATOR PEDAL GENTLTY

PARK VEHICLE * MOVE DIRECTION SELECTOR TO ‘F’ * TURN KEY TO ‘OFF’ * APPLY PARKING BRAKE

GASOLINE VEHICLES

FORWARD OPERATION * TURN KEY TO ‘F’ * PRESS ACCELERATOR PEDAL GENTLY

REVERSE OPERATION * TURN KEY TO ‘R’ * PRESS ACCELERATOR PEDAL GENTLY

PARK VEHICLE * TURN KEY TO ‘OFF’

ELECTRIC VEHICLES

WARNING READ THE MANUAL

REPLACEMENT IS AVAILABLE AT www.ezgo.com

READ ALL LABELS

OPERATE FROM DRIVER SIDE ONLY

OPERATE ACCORDING TO LOCAL LAWS AND REGULATIONS

MAINTAIN ACCORDING TO SERVICE & REPAIR MANUAL AVAILABLE AT www.ezgo.com

MINIMUM HEIGHT TO OPERATE VEHICLE IS 150 CM

DO NOT OPERATE VEHICLE WHEN LIGHTNING IS IN THE AREA

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

612214

DO NOT TOW MORE THAN 3 VEHICLES MAX 12 mph (19 kph) TOWING 1 VEHICLE DO NOT DRIVE IN REVERSE WHEN TOWING VEHICLES MAX 5 mph (8 kph) TOWING 2 or 3 VEHICLES NO PASSENGERS IN TOWED VEHICLES DO NOT TOW VEHICLES OVER UNEVEN TERRAIN 10% MAX SLOPE FOR TOWING VEHICLES

READ THE MANUAL REPLACEMENT AVAILABLE AT www.ezgo.com

612214

MAX

5 mph

(8 kph)

MAX

12 mph

(19 kph)

MAX 10%

TOW BAR OPERATION * PULL LOCKING COLLAR AWAY FROM LATCH AND PRESS ON LATCH TAB TO OPEN * PLACE LATCH OVER FRONT TOWING BRACKET * CLOSE LATCH AND MOVE LOCKING COLLAR UNDER LATCH TAB * DO NOT TOW MORE THAN 3 VEHICLES * 12 mph (19 kph) MAX SPEED TOWING 1 VEHICLE * DO NOT DRIVE IN REVERSE WHEN TOWING VEHICLES * NO PASSENGERS IN TOWED VEHICLES * DO NOT TOW VEHICLES OVER UNEVEN TERRAIN 10% MAXIMUM SLOPE FOR TOWING VEHICLES

WARNING DO NOT DRIVE FAST

WARNING ENGAGE LOCKING COLLAR

WARNING INSPECT TOW BAR SYSTEM EVERY 30 DAYS

SAFETY

Owner’s Guide

SAFETY

608537

608820

www.ezgo.com

READ THE MANUAL REPLACEMENT AVAILABLE AT www.ezgo.com

WARNING OPERATE ACCORDING

TO LOCAL LAWS AND REGULATIONS

NO MORE THAN 2 OCCUPANTS IN EACH SEAT

DO NOT STAND UP AND KEEP ENTIRE BODY INSIDE VEHICLE

DO NOT STAND IN FRONT OF OR BEHIND VEHICLE

CHILDREN MUST BE ACCOMPANIED BY AN ADULT

DO NOT ALLOW CHILDREN TO RIDE ALONE

DO NOT GET ON OR OFF A MOVING VEHICLE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

GENERAL SPECIFICATIONS

Part No:. 638541G01

z z z

Dimensions

Overall Length Overall Width Overall Height (No Canopy) Overall Height (With Canopy) Wheel Base Front Wheel Track Rear Wheel Track Gnd Clearance @ Differential

Vehicle Power

Power Source Valve Train Horsepower (kW) Electrical System Batteries (Qty, Type) Key or Pedal Start Air Cleaner Lubrication Oil Filter Cooling System Fuel &DSDFLW\

)XHO&DSDFLW\

Drive Train Transaxle Gear Selection Rear Axle Ratio

4 Cycle 24.5 cu in (401 cc). Low E OHV Single Cylinder OHV

13.5 hp (10.1 kW) Exceeds SAE J1940 Std. Starter/Generator. Solid State Regulator One, 12 Volt Maintenance Free Pedal Industrial Rated Dry Filter Pressurized Oil System Spin On Air Cooled

5. Gallon (23.1 L) HDUO\SURGXFWLRQtank

*DOORQ/ODWHSURGXFWLRQWDQN

Continuously variable transmission (CVT) Differential with helical gears Forward - Reverse

11.42:1 (Forward) 15.78:1 (Reverse)

Some items shown may be optional equipment

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

GENERAL SPECIFICATIONS

MODEL: RXV TYPE: GASOLINE POWERED FLEET GOLF CAR MODEL YEAR: 2016

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

Engine: 13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki

Valve Train: Overhead valve z Fuel System: Fixed float bowl with remote pulse fuel pump Lubrication: Pressurized oil system, spin-on oil filter z Ignition: Electronic spark/magneto Balancer: Internal counter rotating balance shaft z 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. Single point park brake release with self-compensating system Transaxle: Differential with helical gears, ground speed governor, forward/reverse Body Protection: 360° energy transfer bumpers maximize vehicle protection from minor impact

PRODUCT OVERVIEW

Performance

94.5 In (240 cm) Seating Capacity 2 Person

47.0 in (119 cm) Dry Weight 697 lb (316 kg)

45.7 in (116 cm) Curb Weight 747 lb (339 kg)

68.5 in (174 cm) Vehicle load capacity 800 lb (360 kg)

65.7 in (167 cm) Outside Clearance Circle 19.0 ft (5.8 m)

35.5 in (90 cm) Intersecting Aisle Clearance N/A

38.0 in (97 cm) Speed (Level Ground) 12 mph ± 0.5 mph (19.3 kph ± 0.8 kph)

3.3 in (8 cm) Towing Capacity 3 E-Z-GO Golf Cars with approved tow bars

Steering & Suspension

Steering Double Ended Rack & Pinion Front Suspension Independent A-Arm Coil Over Shock Rear Suspension Mono-Leaf Springs With Hydraulic Shocks Brake Rear Wheel Mechanical Self-Adjusting Drums Parking Brake Self-compensating, single point engagement Front Tires 18 x 8.50 - 8 (4 Ply Rated) Rear Tires 18 x 8.50 - 8 (4 Ply Rated)

Body & Chassis

Frame Welded Steel. DuraShield™ powder coat Body & Finish Injection molded TPO Standard Color Forest Green

CE Noise, Vibration & Harshness

Noise 6RXQGSUHVVXUHFRQWLQXHG$ZHLJKWHGG%D Vibration, WBV Vibration, HAV Uncertainty of measurement is 0.98 m/s². Measurement methods were applied per ISO 2631 & ISO 5349 standards under conditions of typical vehicle surfaces.

Highest value of weighted acceleration less than 2.5 m/s² Highest value of weighted acceleration less than 2.5 m/s²

Owner’s Guide

GENERAL SPECIFICATIONS

Part No:. 638543G01

z z z

Spin On Air Cooled

5. Gallon (23.1 L) HDUO\SURGXFWLRQtank

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Continuously variable transmission(CVT)

Air Cleaner Lubrication Oil Filter Cooling System Fuel &DSDFLW\

)XHO&DSDFLW\

Drive Train TransaxleGear SelectionRear Axle Ratio

'LIIHUHQWLDOZLWKKHOLFDOJHDUV )RUZDUG5HYHUVH )RUZDUG5HYHUVH

Some items shown may be optional equipment

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

MODEL: RXV FREEDOM™ TYPE: GASOLINE POWERED PERSONAL GOLF CAR MODEL YEAR: 2016

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

Engine: 13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki

PRODUCT OVERVIEW

Dimensions Performance

Overall Length 94.5 In (240 cm) Seating Capacity 2 Person Overall Width 47.0 in (119 cm) Dry Weight 697 lb (316 kg) Overall Height (No Canopy) 45.7 in (116 cm) Curb Weight 747 lb (339 kg) Overall Height (With Canopy) 68.5 in (174 cm) Vehicle load capacity 800 lb (360 kg) Wheel Base 65.7 in (167 cm) Outside Clearance Circle 19.0 ft (5.8 m) Front Wheel Track 35.5 in (90 cm) Intersecting Aisle Clearance N/A Rear Wheel Track 38.0 in (97 cm) Speed (Level Ground) 19 mph ± 0.5 mph (31 kph ± 0.8 kph) Gnd Clearance @ Differential 3.3 in (8 cm) Towing Capacity 3 E-Z-GO Golf Cars with approved tow bars

Vehicle Power Steering & Suspension

Power Source 4 Cycle 24.5 cu in (401 cc) Steering Double Ended Rack & Pinion Valve Train Single Cylinder OHV Front Suspension Independent A-Arm Coil Over Shock Horsepower (kW) 13.5 hp (10.1 kW) Exceeds SAE J1940 Std. Rear Suspension Mono-Leaf Springs With Hydraulic Shocks Electrical System Starter/Generator. Solid State Regulator Brake Rear Wheel Mechanical Self-Adjusting Drums Batteries (Qty, Type) One, 12 Volt Maintenance Free Parking Brake Self-compensating, single point engagement Key or Pedal Start Pedal Front Tires 18 x 8.50 - 8 (4 Ply Rated)

Industrial Rated Dry Filter with Remote Intake Rear Tires 18 x 8.50 - 8 (4 Ply Rated) Pressurized Oil System Body & Chassis

Frame Welded Steel. DuraShield™ powder coat Body & Finish Injection molded TPO Standard Color Forest Green

CE Noise, Vibration & Harshness

Noise 6RXQGSUHVVXUHFRQWLQXHG$ZHLJKWHGG%D

Highest value of weighted acceleration less than 2.5 m/s² Highest value of weighted acceleration less than 2.5 m/s²

Vibration, WBV Vibration, HAV Uncertainty of measurement is 0.98 m/s². Measurement methods were applied per ISO 2631 & ISO 5349 standards under conditions of typical vehicle surfaces.

Owner’s Guide

GENERAL SPECIFICATIONS

MODEL: SHUTTLE™ 2+2 RXV

TYPE: GASOLINE PERSONNEL CARRIER

MODEL YEAR: 2016

Part No:. 638545G01

Engine:

13.5 hp (10.1 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki

z Valve Train: Overhead valve z Fuel System: Fixed float bowl with remote pulse fuel pump

z Lubrication: Pressurized oil system, spin-on oil filter z Ignition: Electronic spark/magneto

z Balancer: Internal counter rotating balance shaft z 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

Body Protection: 360° energy transfer bumpers maximize vehicle protection from minor impact

Dimensions Performance

Overall Length 105.5 in (268 cm) Seating Capacity 4 Person

Overall Width 47.0 in (119 cm) Dry Weight 790 lb (360 kg)

Overall Height (No Canopy) 45.7 in (116 cm) Curb Weight 850 lb (385 kg)

Overall Height (With Canopy) 74.0 in (188 cm) Vehicle load capacity 720 lb (325 kg)

Wheel Base 65.7 in (167 cm) Outside Clearance Circle 19.0 ft (5.8 m)

Front Wheel Track 35.5 in (90 cm) Intersecting Aisle Clearance N/A

Rear Wheel Track 38.0 in (97 cm) Speed (Level Ground) 14 mph ± 0.5 mph (23 kph ± 0.8 kph)

Gnd Clearance @ Differential 3.3 in (8 cm) Towing Capacity N/A

Vehicle Power Steering & Suspension

4 Cycle 24.5 cu in (401 cc) Steering Double Ended Rack & Pinion

Front Suspension

Independent A-Arm Coil Over Shock

Rear Suspension Multi-Leaf Spring with Hydraulic Shocks

Brake

Rear Wheel Mechanical Self-Adjusting Drums

Parking Brake Self-compensating, single point engagement

Front Tires 18 x 8.50 - 8 (4 Ply Rated)

Rear Tires 18 x 8.50 - 8 (4 Ply Rated)

Body & Chassis

Frame Welded steel. DuraShield™ powder coat

Body & Finish Injection molded TPO

Standard Color

Forest Green

CE Noise, Vibration & Harshness

Noise

Sound pressure; continued A-weighted ≤ 70 dB(a)

Vibration, WBV

Highest value of weighted acceleration less than 2.5 m/s²

Power Source Valve Train Horsepower (kW) Electrical System Batteries (Qty, Type) Key or Pedal Start Air Cleaner Lubrication Oil Filter Cooling System Fuel &DSDFLW\

)XHO&DSDFLW\

Drive Train Transaxle Gear SelectionRear Axle Ratio

Single Cylinder OHV

13.5 hp (10.1 kW) Exceeds SAE J1940 Std. Starter/Generator. Solid State Regulator One, 12 Volt Maintenance Free Pedal Industrial Rated Dry Filter Pressurized Oil System Spin On Air Cooled

5. Gallon (22.1 L) HDUO\SURGXFWLRQtank

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Continuously variable transmission (CVT) Differential with helical gears Forward - Reverse

11.42:1 (Forward) 15.78:1 (Reverse)

Vibration, HAV

Highest value of weighted acceleration less than 2.5 m/s²

Uncertainty of measurement is 0.98 m/s². Measurement methods were applied

per ISO 2631 & ISO 5349 standards under conditions of typical vehicle surfaces.

Some items shown may be optional equipment

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

PRODUCT OVERVIEW

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

GENERAL SPECIFICATIONS

Part No:. 638547G01

z z z

Power Source Valve Train Horsepower (kW) Electrical System Batteries (Qty, Type) Key or Pedal Start Air Cleaner Lubrication Oil Filter Cooling System Fuel Capacity

)XHO&DSDFLW\

Drive Train Transaxle Gear SelectionRear Axle Ratio

Single Cylinder OHV 13 hp (9.7 kW) Exceeds SAE J1940 Std. Starter/Generator. Solid State Regulator One, 12 Volt Maintenance Free Pedal Industrial Rated Dry Filter Pressurized Oil System Spin On Air Cooled

6.2 Gallon (23.5 L) HDUO\SURGXFWLRQtank

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Continuously variable transmission (CVT) Differential with helical gears Forward - Reverse

11.42:1 (Forward) 15.78:1 (Reverse)

Some items shown may be optional equipment

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

MODEL: RXV SHUTTLE™ 2+2 High Speed Gas TYPE: GASOLINE PERSONNEL CARRIER MODEL YEAR: 2016

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 Body Protection: 360° energy transfer bumpers maximize vehicle protection from minor impact

PRODUCT OVERVIEW

Dimensions Performance

Overall Length 105.5 in (268 cm) Seating Capacity 4 Person Overall Width 47.0 in (119 cm) Dry Weight 790 lb (360 kg) Overall Height (No Canopy) 45.7 in (116 cm) Curb Weight 850 lb (385 kg) Overall Height (With Canopy) 74.0 in (188 cm) Vehicle load capacity 720 lb (325 kg) Wheel Base 65.7 in (167 cm) Outside Clearance Circle 19.0 ft (5.8 m) Front Wheel Track 35.5 in (90 cm) Intersecting Aisle Clearance N/A Rear Wheel Track 38.0 in (97 cm) Speed (Level Ground) 17.5 mph ± 0.5 mph (28.5 kph ± 0.8 kph) Gnd Clearance @ Differential 3.3 in (8 cm) Towing Capacity N/A

Vehicle Power Steering & Suspension

4 Cycle 24.5 cu in (401 cc) Steering Double Ended Rack & Pinion

Front Suspension Independent A-Arm Coil Over Shock Rear Suspension Multi-Leaf Spring with Hydraulic Shocks Brake Rear Wheel Mechanical Self-Adjusting Drums Parking Brake Self-compensating, single point engagement Front Tires 18 x 8.50 - 8 (4 Ply Rated) Rear Tires 18 x 8.50 - 8 (4 Ply Rated)

Body & Chassis

Frame Welded steel. DuraShield™ powder coat Body & Finish Injection molded TPO Standard Color Forest Green

CE Noise, Vibration & Harshness

Highest value of weighted acceleration less than 2.5 m/s² Highest value of weighted acceleration less than 2.5 m/s²

Owner’s Guide

GENERAL SPECIFICATIONS

35.5”

(90 cm)

38”

(97 cm)

45.7”

(116 cm)

68.50”

(174 cm)

47”

(119 cm)

68.50

(

)

65.7”

(167 cm)

94.5”

(240 cm)

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

APPROXIMATE VEHICLE DIMENSIONS

”

174 cm

Figure 1 Fleet & Freedom Vehicle Dimensions

Owner’s Guide

GENERAL SPECIFICATIONS

65.7”

(167 cm)

105.5”

(268 cm)

47”

(119 cm)

35.5”

(90 cm)

38”

(97 cm)

45.7”

(116 cm)

74”

(188 cm)

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Figure 2 Shuttle 2 + 2 Vehicle Dimensions

Owner’s Guide

GENERAL SPECIFICATIONS

19’ 2”

(5.8m)

RECOMMENDED MAX SIDE TILT

25% GRADE OR 14° MAX

RECOMMENDED MAX RAMP

25% GRADE OR 14° MAX

TIL

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TURNING DIAMETER AND INCLINE INFORMATION

Figure 3 Vehicle Incline Specifications and Turning Diameter

Owner’s Guide

GENERAL SPECIFICATIONS

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Owner’s Guide

INTRODUCTION

Front of Vehicle

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INTRODUCTION

CONTROLS AND INDICATORS

Vehicle controls and indicators consists of:

1. Key Switch

2. Fuel Gauge (if equipped)

3. Head Light Switch (if equipped)

4. Turn Signal Switch (if equipped)

5. Horn Button (if equipped)

6. Center Compartment

7. Power Outlet, 12V (if equipped)

8. USB Port (if equipped)

9. Accelerator Pedal

10. Brake Pedal

11. Parking Brake

12. Hour Meter (if equipped)

13. Direction Selector

14. Choke

Owner’s Manual

INTRODUCTION

Figure 1

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

FEATURES

General Information

Key Switch

To decrease the risk of component damage, stop the vehicle before you move the key switch or the direction

The key switch (1) is located on the dash panel. The switch controls the basic electrical system of the vehicle to be turned on and off by turning the key. To prevent accidental operation of an unattended vehicle, turn the key to the OFF position and remove from the switch (Figure 1).

If the vehicle has accessories that were installed at the factory, some accessories continue to operate with the key

switch in the OFF position.

selector.

Headlight Switch (if equipped)

If the vehicle is equipped with lights, the headlight ON/OFF switch (3) is located on the instrument panel to the left of the key switch (1) (Figure 1).

Turn Signal Switch (if equipped)

The turn signal switch (4) is on the steering column and controls the operation of the right and left turn signal lights (Figure 1).

Horn (if equipped)

The horn button (5) is located on the driver side of the floorboard. Press the button to activate the horn (Figure 1).

Fuel Gauge with Low Oil Pressure Indicator (if equipped)

The Fuel gauge (6) is located on the dash panel to the left of the key switch (1). The fuel gauge indicates the amount of fuel remaining in the fuel tank. The fuel gauge operates only when the key is in the ON position and the accelerator is pressed (Figure 1).

The fuel gauge has a low oil pressure indicator. A low engine oil pressure condition is shown with an indicator light.

The indicator light illuminates when the oil pressure is low. Check oil level. If the light is on and the oil level is between the ADD and FULL mark on the dipstick, the engine has a mechanical problem and you must not operate the vehicle. Contact a vehicle distributor or authorized branch.

To prevent engine damage DO NOT operate the vehicle until the oil pressure is corrected. DO NOT over fill

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

Owner’s Manual

INTRODUCTION

Figure 2

Forward

Reverse

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

12-Volt Power Outlet (if equipped)

A 12-Volt power outlet (7) is located to the left of the center compartment. The outlet supplies continuous power for any accessories that have a 12-Volt plug (Figure 2).

USB Port (if equipped)

A USB port (9) is located to the right of the center compartment (Figure 2).

Direction Selector

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

direction selector.

The direction selector is located on the seat panel and allows the operator to select F (forward) or R (reverse). The vehicle should be left in F when unattended.

When you leave the vehicle, put the direction selector in the F position, engage the parking brake, turn the key to OFF position and remove the key.

When the direction selector is moved to the R position, a reverse warning buzzer activates.

Choke

The choke (15) is located on the seat panel below the driver seat. The choke helps start the vehicle when the engine is cold.

Owner’s Manual

INTRODUCTION

Parking

Brake

Figure 3

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Accelerator Pedal

Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause

severe injury or death.

With the key switch in the ON position, press the accelerator pedal (12) to start the engine. When the pedal is released, the engine will stop. To stop the vehicle immediately, press the brake pedal (13) (Figure 3).

When you press the accelerator pedal (12), the parking brake will be released if it is engaged. This is a feature to assure the vehicle is not driven with the parking brake engaged. This is not the preferred method of releasing the parking brake (Figure 3).

Brake and Parking Brake Pedal

The foot operated parking brake is the top part of the brake pedal (13). To engage the parking brake, press on the upper section of the pedal until it locks in position. Press the lower part of the brake pedal to release the parking brake (Figure

3).

Pressing the bottom of the brake pedal is the preferred method of releasing the park brake to assure the longest

A parking brake that is engaged releases when you press the accelerator pedal. This is a feature to make sure the vehicle is not driven with the parking brake engaged. Pressing the accelerator pedal is not the recommended method to release the parking brake.

service life of the brake components.

Front Seat

The front seat (14) is for two people, one person on each side of the seat (Figure 4).

Front Hip Restraint

The front hip restraints (15) help people stay in position while the vehicle is in motion (Figure 4).

Cup Holder

The vehicle has a cup holder (16) for the benefit of both the driver and passenger (Figure 4).

Owner’s Manual

INTRODUCTION

Figure 4

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Steering Wheel

The steering wheel (17) controls the direction of vehicle travel (Figure 4).

Rear Seat and Cargo Platform (if equipped)

Rear passengers must stay in the seat and hold both the hand rail and rear handle while the

vehicle is in motion.

Do not allow passengers to ride on the cargo platform. A sudden move or stop can cause severe

injury or death to passengers on the cargo platform.

The vehicle has a feature that functions as a rear seat (18) or a cargo platform (Figure 4).

When in the upright position, it is a rear seat for two passengers. Fold the seat flat for a cargo platform.

Rear Hand Rail

There is a hand rail (19), one on each side of the rear seat to help passengers stay in position when the vehicle is in motion. The passengers must hold the rear hand rail whenever the vehicle is in motion (Figure 4).

Rear Handle

The rear handle (20) is located at the far end of the vehicle in the center of the rear footrest. The handle helps the passengers stay in position when the vehicle is in motion. The passengers must hold the handle when the vehicle is in motion (Figure 4).

Weather Enclosure (if equipped)

A weather enclosure provides protection from strong weather conditions.

Rear View Mirror (if equipped)

The rear view mirror is adjustable for use during the day or night.

Owner’s Manual

INTRODUCTION

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Owner’s Manual

OPERATING PROCEDURES

Serial Number

Serial Number Location on Front Frame

Serial Number

Serial Number Location on Rear Frame

Serial Number

Serial Number Location on Steering Column

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OPERATING PROCEDURES

SERIAL NUMBER LOCATION

Three serial number and manufacture date code labels are on the vehicle. One of the labels is found on the steering column, the second label is found on the frame member under the front splash shied on the driver side, and the third is found on the passenger side frame rail at the rear of the vehicle (Figure 1).

Design changes occur continuously. When you order service parts, the PIN number, manufacture date code or serial number must be available.

Figure 1 Serial Number Locations

Owner’s Manual

OPERATING PROCEDURES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BEFORE INITIAL USE

Read, understand and follow the safety label on the cup holder. Make sure you understand how to safely operate the vehicle and its equipment.

Reckless use of this vehicle can cause severe injury or death. This vehicle is a light-duty vehicle,

NOT an All Terrain Vehicle (ATV).

Do not engage in rough or reckless operation of this vehicle.

If you do not know the terrain, make sure you prepare for unexpected occurrences. If the vehicle

does not move or the battery is out of charge, an one-hour drive can take many hours to return on

foot.

To prevent battery explosion, keep all flammable materials, open flame or sparks away from the

battery.

Never charge a battery near flammable materials, open flame or sparks. Never charge a battery near gas water heaters and furnaces.

Before a new vehicle is put into operation, do the items shown in the INITIAL SERVICE CHART.

INITIAL SERVICE CHART

Item Service Operation

Seats Remove the protective plastic cover.

Brakes Check the operation.

Calculate the distance necessary to stop the vehicle for the brake performance test.

Tires Check air pressure (18 - 22 psi).

Fuel Fill tank with correct fuel.

Engine Check oil level.

General Check for possible fluid leaks that may have developed during shipment.

HOW TO OPERATE THE VEHICLE

Incorrect use of the vehicle or the lack of proper maintenance can cause damage or decreased

performance.

Read the following warnings before you operate the vehicle.

Make sure you know the terrain and traffic conditions. Make sure you know environmental condi-

tions that change the terrain and your ability to control the vehicle. Drive the vehicle only as fast

as terrain and conditions allow.

Owner’s Manual

OPERATING PROCEDURES

Forward

Reverse

Direction Selector

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

When possible, stay in approved areas. Do not drive on steep slopes.

Do not drive fast downhill. Sudden stops or change of direction can cause a loss of control. Use

the brake to control the speed of the vehicle when you drive down a slope.

To prevent loss of control, do not move the direction selector while the vehicle is in motion. If you

move the selector, the speed will immediately decrease and a warning device will activate.

Decrease speed before and during turns.

Do not drive the vehicle up, down, or across a slope that is more than 14° (25% grade).

See GENERAL SPECIFICATIONS for the vehicle load and seat capacity.

When the accelerator pedal is pressed, the foot-operated parking brake releases and can cause

accidental or sudden vehicle movement. When the vehicle is parked, make sure the key is in the

OFF position.

When you leave the vehicle, turn the key to the OFF position and remove from the switch to pre-

vent accidental operation.

Make sure the direction selector is in the correct position before you press the accelerator pedal.

Make sure you completely stop the vehicle before you move the direction selector to a different

position.

Do not take vehicle out of gear while in motion.

Before you drive in the reverse direction, make sure the area behind the vehicle is clear.

Driver and passengers must stay in their seats while the vehicle is in motion.

Always keep feet, legs, hands and arms inside vehicle while in motion.

Direction Selector Operation

To prevent loss of control, do not move the direction

selector to a different position while the vehicle is in

motion. If you move the selector, the speed will immedi-

ately decrease and a warning device will activate.

Move the direction selector to F (Forward) to move in the forward direction.

Move the direction selector to R (Reverse) to move in the reverse direction. A reverse warning buzzer activates when the direction selector is moved to the R position.

The position between F and R is the neutral position.

When you leave the vehicle, put the direction selector in the forward position, engage the parking brake and remove the key from the switch.

Owner’s Manual

OPERATING PROCEDURES

Horn

Accelerator

Pedal

Brake Pedal

Parking

Brake Pedal

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Accelerator Pedal Operation

Accidental movement of the accelerator pedal can cause the vehicle to suddenly move and cause

severe injury or death.

An engaged parking brake will release when the accelerator pedal is pressed and cause the vehi-

cle to move suddenly. When the vehicle is parked, make sure the key is in the OFF position so

that the electrical system is disabled.

When the key switch is in the ON position, press the accelerator pedal to start the engine and move the vehicle. Release the pedal to stop the engine.

Press the brake pedal to stop the vehicle quickly.

If the key switch is in the ON position and the parking brake is engaged, the brake releases when you press the accelerator pedal and can cause the vehicle to move suddenly. This is a feature to make sure the vehicle is not driven with the parking brake engaged. Pressing the accelerator pedal is not the recommended method of to release the parking brake.

Brake and Parking Brake Operation

The function of the lower part of the brake pedal is to control speed. Press the lower part of the pedal to decrease speed or stop the vehicle.

To engage the parking brake, press the upper section of the pedal until it locks into position. Press the lower part of the pedal to release the parking brake.

Horn (if equipped)

If the vehicle is equipped with a horn, the horn button is located on the driver's side of the floorboard. Pressing the button will sound the vehicle's horn.

Rear Seat and Cargo Platform Operation

To prevent damage to the rear seat, move any accessories that are installed on the hand rail, when you fold

the seat.

Fold the seat to the flat position to access the cargo platform.

Secure the loads on the platform to prevent movement.

Put the load on the platform as far forward as possible.

Owner’s Manual

OPERATING PROCEDURES

Power Outlet

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

The center of gravity of the load must be less than 4 inches (10 cm) above the platform.

Do not put more than the specified capacity on the platform.

Increased loads can change the driving properties of the vehicle.

Do not allow passengers to ride on the cargo platform.

When you put cargo on the platform, make sure you follow the information below to decrease the risk of injury, damage to the vehicle or cause the vehicle to tilt over.

• Put the load on the platform as far forward as possible.

• Secure the loads on the platform to prevent movement.

• The center of gravity of the load must be less than 4 inches (10 cm) above the platform.

• The load capacity of the cargo platform is a maximum of 250 lbs. (115 kg). Do not put more than the specified capacity on the platform.

Increased loads can change the drive properties of the vehicle.

12-Volt Power Outlet

Overuse of accessories can drain the battery and leave insuffi-

Excessive use of accessories that are connected to the outlet

Lift the cover and insert the 12-Volt accessory plug.

cient charge to start the vehicle.

can drain the battery.

STARTING AND DRIVING

To operate the vehicle:

• Apply the brake, put the key in the key switch and turn to the ON position.

• Move the direction selector to the desired direction.

• Press the brake to release the parking brake.

• Slowly press the accelerator pedal to start the engine. Release brake when the engine starts.

• When the accelerator pedal is released, the ignition circuit is de-energizes and the engine stops. To stop the vehicle quickly, press the brake pedal.

When the direction selector is in the reverse position, a warning signal activates to indicate that the vehicle is ready to

run in the reverse direction.

Owner’s Manual

OPERATING PROCEDURES

Maximum Oil Level For Hot Engine Do Not Overfill

Fill Cold Engine To This Point

Safe

Operating Range

Hot Engine

Add Oil

Front of Vehicle

Choke

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Run-In

Avoid full throttle starts and fast acceleration until the engine has reached operating temperature.

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

Check the oil level according to the Periodic Service Schedule. Add oil if the level on the dipstick indicates that oil is in the add oil range.

Do not overfill engine. Too much oil can cause engine to smoke

or cause spark plug fouling.

The oil dipstick and fill cap must be in position before starting the engine. Failure to install the dipstick and fill cap will

cause oil contamination and/or oil discharge into the engine compartment.

Oil dipsticks are unique to this model vehicle. Do not use a dipstick from another engine.

Dipstick must be installed with the lip towards the front of the vehicle.

Change the oil according to the Periodic Service Schedule while the engine is warm.

See the Repair and Service Manual for procedures to check the oil level and change the oil.

Cold-Start

The use of a choke may be necessary to start a cold engine.

Press the accelerator 1 inch (2.5 cm) or until the starter begins to operate. Pull the choke out if needed. Press the accelerator slowly and push the choke in completely when the engine is running smoothly.

Do not allow the starter to operate continuously

for more than 10 seconds. Allow 30 seconds

between starting tries. If the vehicle does not

start on the third try, turn the key to the OFF posi-

tion, set the parking brake and find the cause of

the problem.

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

Owner’s Manual

OPERATING PROCEDURES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Starting Vehicle On A Hill

To decrease the risk of roll-back, do not release the brake until the engine has started.

Do not use the accelerator and engine to hold the vehicle on a hill. Doing so will cause early and excessive

To decrease the risk of permanent damage to the drive train, do not allow roll-back when you start the vehicle

Put left foot on brake and release the parking brake. Press the accelerator with right foot and release the brake.

Coasting

Do not allow the vehicle to coast at above recommended speeds. Control vehicle speed with the

Steep hills allow the vehicle to move at faster speeds than speeds on a flat surface. To prevent the loss of vehicle control and possible injury, speeds must be controlled to the maximum level ground speed indicated in the GENERAL SPECIFICATIONS section. Apply the brake to control the speed.

wear to the drive train components.

on a hill.

brake.

FUEL

To decrease the risk of severe injury or death from improper fuel handling:

Do not smoke near the fuel tank.

Do not add fuel near open flame or electrical items that can cause a spark.

Always handle gasoline in a well ventilated area.

Always wear eye protection to protect against splashed fuel and fuel vapors.

Inspect the fuel cap, tank and other components for leaks or damage that can cause a hazardous

condition.

Oxygenated or reformulated gasoline, is mixed with alcohols or ethers. Excessive amounts of these blends

can damage the fuel system or cause performance problems. If any operating problems occur, use gasoline

with a lower percentage of alcohol or ether.

Use clean regular grade unleaded fuel. The Ethanol blend fuel up to 10% is permitted.

Owner’s Manual

OPERATING PROCEDURES

FUEL

Leave 1” Min. (2.5 cm) airspace for ventilation

Late Production Fuel Tank

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Do not use gasoline that contains methanol.

High altitude or heavy use/load applications can benefit from higher octane gasoline.

FUEL TANK

The fuel tank is found below the seat on the passenger side of the vehicle. Fill the tank with clean, automotive grade gasoline.

Early Production Fuel Tank

Always allow enough space for the expansion of gasoline. Leave at least 1-inch (2.5 cm) of space

below bottom of filler neck.

Early production fuel tanks can be identified by the location of the fuel cap which is located in the middle of the top of the tank as shown.

Early production fuel tanks require enough space for the expansion of the gasoline. Leave at least 1-inch (2.5 cm) of space below the bottom of the filler neck.

Late Production Fuel Tank

Late production fuel tanks can be identified by the location of the fuel cap which is located in the rear of the top of the tank as shown.

Late production fuel tanks are designed to allow for fuel expansion and do NOT require space below bottom of filler neck.

Owner’s Manual

OPERATING PROCEDURES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BATTERY

Heavy use of accessories drains the battery which can leave insufficient reserve to start the vehicle.

The vehicle uses a starter/generator to start the engine and charge the battery. The engine will not idle. The battery does not charge while the vehicle is stopped. Do not operate lights and other accessory items excessively while the vehicle is stopped.

The generator can supply 35 amps. Operation of all accessories can cause the discharge of the battery even if the engine is running and the generator is operating. Discharging the battery is known as deep cycling. The battery is not a deep cycle model. It is a starting battery. Multiple deep cycling causes early failure of the battery.

If the battery has discharged, charge it with a 12-volt charger that is rated at 10 amps or less and according to instructions supplied by the manufacturer of the charger.

LABELS AND PICTOGRAMS

The vehicle can have labels with pictograms to provide information or warnings. Refer to the SAFETY section of this manual for the description of the labels.

SUN TOP AND WINDSHIELD (IF EQUIPPED)

The sun top does not provide protection from roll-over or falling objects.

The windshield does not provide protection from tree limbs or flying objects.

The sun top and windshield provide some protection from the elements; however, they will not keep the operator and passenger dry in heavy rain. This vehicle is not equipped with seat belts and the sun top has not been designed to provide roll-over protection. In addition, the sun top does not protect against falling objects nor does the windshield protect against flying objects and tree limbs. Keep arms and legs inside whenever the vehicle is in motion.

Owner’s Manual

OPERATING PROCEDURES

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Owner’s Manual

MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

MAINTENANCE

VEHICLE CLEANING AND CARE

Read and understand all instructions supplied by the manufacturer of the pressure washer before

use.

When you clean the outside of the vehicle with a pressure washer, do not use more than 700 psi pressure.

Keep a minimum distance of 12 inches from the spray nozzle to the painted surface. Do not clean the plastic

parts with abrasive solvents.

Make sure you use correct methods and cleaning materials to prevent risk of damage to the outside of the vehicle. The use of more than 700 psi water pressure can cause injury to anyone in the area or damage to vehicle.

Clean the windshield with water and a clean cloth. Remove small scratches with a plastic polish or Plexus® plastic cleaner, available from the service parts department.

Apply a soap and water solution with a sponge or soft brush to clean the vinyl seats and plastic or rubber trim. Dry with a cloth.

Use a commercially available vinyl and rubber cleaner to remove oil, tar, asphalt, shoe polish, etc.

Wash the vehicle frequently with cool water and mild detergent to protect the painted surfaces.

Apply wax that is for clear coat automotive finishes to improve the appearance and protection of the painted surfaces. Do not apply wax to matte finish surfaces.

Materials used as fertilizers or for dust control can collect on the bottom of the vehicle. These materials will cause corrosion of components, unless cleaned with water. Clean areas where mud or dirt can collect. Loosen the sediment that is packed in closed areas to help with removal. Be careful not to damage the paint.

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.

Always be respectful of the environment.

Make sure you are permitted by property owners to operate the vehicle on their property.

There is a risk of fire when the vehicle is operated near combustible material.

Be careful of environmental hazards like steep slopes, tree branches, etc.

Owner’s Manual

MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Battery Disposal

Return used batteries to the manufacturer or lead smelter for recycling. For neutralized spills, put residue in acid-resistant containers with absorbent material, sand or earth and discard according to state and federal regulations for acid and lead compounds. Contact authorized environmental authorities for information about disposal.

LIFTING THE VEHICLE

You must lift the front, the rear or the entire vehicle for some service and maintenance operations.

The vehicle is not stable during the lifting process.

Make sure the vehicle is on a hard and level surface.

Never get below a vehicle that is supported by a jack only.

Make sure a vehicle that is supported on jack stands is stable before you get below the vehicle.

Put wheel chocks in front and behind the wheels that remain on the ground.

Do not allow any person in or on the vehicle being lifted.

When you lift the vehicle, put the jacks and jack stands at the areas indicated only.

Tool List Qty. Tool List Qty.

Floor Jack.................................................................... 1 Jack Stands................................................................. 4

Wheel Chocks ............................................................. 4

Remove payload from vehicle before lifting. No person(s) should be in or on the vehicle while lifting.

How to Lift the Entire Vehicle:

1. Install wheel chocks in front and behind each front wheel.

2. Center the jack under the bagwell.

3. Lift the vehicle enough to place two jack stands under the frame where the leaf spring mounting brackets are welded to the frame.

4. Lower the jack and test the stability of the vehicle on the two jack stands.

5. Place the jack under the center front just behind the bumper.

6. Lift the vehicle and place two jack stands under the frame where the instrument panel support is attached to the frame.

7. Lower the jack and test the stability of the vehicle on the jack stands.

Owner’s Manual

MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

How to Lift the Rear of the Vehicle Only:

1. Install wheel chocks in front and behind each front wheel.

2. Center the jack under the bagwell.

3. Lift the vehicle enough to place two jack stands under the frame where the leaf spring mounting brackets are welded to the frame.

4. Lower the jack and test the stability of the vehicle on the two jack stands.

How to Lift the Front of the Vehicle Only:

1. Install wheel chocks in front and behind each rear wheel.

2. Place the jack under the center front just behind the bumper.

3. Lift the vehicle and place two jack stands under the frame where the instrument panel support is attached to the frame.

4. Lower the jack and test the stability of the vehicle on the two jack stands.

Lower the Vehicle:

1. Lift the vehicle enough to remove the jack stands.

2. Carefully lower the vehicle to the ground with the jack.

WHEELS AND TIRES

To decrease the risk of tire explosion, add small amounts of air to the tire at intervals to seat the

tire beads. Over inflation of small tires can occur in a few seconds.

Do not over inflate the tires. Excess pressure can cause the tire to separate from the wheel or

explode.

Owner’s Manual

MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Protect face and eyes when removing a tire valve core.

Use only sockets made for use with impact wrenches to decrease the risk of injury caused by a

broken socket.

Do not use tires that have a recommended tire inflation pressure less than the tire pressure

recommended.

Tire Repair

Tool List Qty. Tool List Qty.

Lug Wrench, 3/4”......................................................... 1 Impact Socket, 3/4” ..................................................... 1

Impact Wrench ............................................................ 1 Torque Wrench, ft. lbs. ................................................ 1

Use caution when you inflate the tires. Because of the low volume of the small tires, over inflation can occur in seconds. Over inflation can cause the tire to separate from the wheel or cause a tire explosion.

The general recommended tire inflation pressure is 18-22 psi. Tire inflation pressure can be adjusted for the condition of the terrain.

For outdoor applications with primary use on areas with grass, consider the following:

• Slightly higher tire inflation pressure is suitable on hard turf

• A lower pressure decreases the risk of tires cutting into a soft turf

For hard surfaces or pavement, tire inflation pressure must be in the higher allowed range, but not more than recommended on the tire sidewall.

All four tires must have the same pressure for best control qualities. Always install the valve stem cap after you check or inflate the tires.

The vehicle has low-pressure tubeless tires, installed on one-piece rims.

Use a tire plug to repair small holes in the tread part of the tire. For large holes and cuts, replace the tire.

Tire plug tools and plugs are available at automotive outlets. The tires do not have to be removed from the wheel to

install the tire plugs.

If the tire is flat, remove the wheel and inflate the tire to the recommended maximum pressure for the tire. Submerge the tire in water to find the leak and mark with chalk. Install the tire plug according to manufacturers instructions.

Wheel Installation

To decrease the risk of component damage, do not tighten lug nuts to more than 63 - 77 ft. lbs. (85 - 105 Nm)

torque.

Always follow the cross-sequence pattern when you install the lug nuts to make sure the wheel is evenly seated

against the hub.

Owner’s Manual

MAINTENANCE

Valve Stem Cap

Cross Sequence

Tire style may vary

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

With the valve stem to the outside of the wheel, install the wheel on the hub with lug nuts.

Tighten the lug nuts (1) with your fingers in the cross-sequence pattern shown.

Tighten the lug nuts to 63 - 77 ft. lbs. (85 - 105 Nm) torque in 20 ft. lbs. (27 Nm) increments.

Continue to follow the cross-sequence pattern until the correct torque is reached.

LIGHT BULB REPLACEMENT

To decrease the risk of premature bulb failure, do not allow your fingers to contact new bulbs. Use clean, dry

paper or paper towels to touch the glass part of the bulb.

Headlight (if equipped)

Make sure that the vehicle key switch is in the OFF position and the key has been removed.

• Disconnect the accessory harness (5) from the light bulb.

• Turn the headlight bulb (3) clockwise and pull to remove.

• Align the new bulb with the opening in the back of the headlight assembly.

• Turn the bulb (3) counter clockwise until it stops.

• Connect the accessory harness (5) to the light bulb (3).

Turn Signal (if equipped)

Make sure that the vehicle key switch is in the OFF position and the key has been removed.

• Remove the phillips head screw (7) and turn the retaining collar (8) to align with the turn signal bulb housing (9).

• Grip the turn signal bulb housing (9) and pull backward to remove housing from the headlight assembly.

• Remove the bulb from the housing and replace with a new one.

• Push turn signal housing (9) into headlight assembly firmly, making sure that it is seated completely.

• Turn the retaining collar (8) to secure the bulb housing and install the phillips head screw (7) to secure in place.

Taillight (if equipped)

Make sure that the vehicle key switch is in the OFF position and the key has been removed.

• Remove the two phillips head screws (10) that secure the lens (11) to the taillight assembly.

• Remove the light bulb.

• Install the new light bulb.

• Install the lens (11) and secure in place with the two phillips head screws (10).

Replacement bulbs are available from a local Distributor, an authorized Branch or the Service Parts Department.

Owner’s Manual

MAINTENANCE

Unlocked

Hole in Direction Selector Cam

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

VEHICLE WITH A DISCHARGED BATTERY

To decrease the risk of severe injury or death from accidental movement, do not use jumper

cables to start the vehicle.

The vehicle has a starter/generator and does not idle. When you start the engine, the starter/generator functions as a starter and with the engine running, it functions as a generator.

The generator can keep the battery charged with the short run times with this type of vehicle. The generator will not charge a discharged battery.

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

If the battery has discharged, charge it with a 12-volt charger that is rated at 10 amps or less and according to instructions supplied by the manufacturer of the charger.

TRANSPORTING VEHICLE

Towin g

Do not ride or allow other people on the vehicle being towed.

DO NOT try to tow the vehicle with ropes, chains or any device other than a tow bar approved by

the factory.

DO NOT tow a single vehicle at speeds in excess of 12 mph (19 kph).

DO NOT exceed 5 mph (8 kph) while towing multiple vehicles.

DO NOT tow more than three vehicles at a time.

Do not tow the vehicle on highways.

Neutral Lock

To prevent the driven clutch from turning the rear wheels during service operations, a neutral lock is located on the direction selector.

To operate: Turn key switch to OFF and lift the seat. Pull out and rotate the neutral lock pin handle so that the pointed portion of the handle is to the side of the direction selector cam. Move the direction selector 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.

When in this position, the direction selector remains locked in the neutral position. To unlock the direction selector, pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole in the direction selector cam.

Owner’s Manual

MAINTENANCE

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Hauling

Make sure you secure the vehicle and all items before you transport a vehicle on a trailer.

DO NOT allow any people on a vehicle being transported on a trailer.

Remove the windshield before you transport vehicle on a trailer.

Maximum speed with sun top installed is 50 mph (80 kph).

If you transport the vehicle on a trailer at highway speeds, the sun top must be removed and the seat bottom secured.

When you transport the vehicle on a trailer below highway speeds, check for tight hardware and cracks in the sun top at the mounting points.

The rated capacity of the trailer or truck must be more than the weight of the vehicle and load plus 1000 lbs. (454 kg). See GENERAL SPECIFICATIONS for the weight of the vehicle.

Secure the vehicle to the trailer with ratchet tie downs.

SERVICE AND MAINTENANCE

Read all notices, cautions and warnings before any type of service operations.

The drive wheels must be lifted and supported on jack stands before you do any service to the

powertrain when the engine is in operation.

To decrease the risk of engine damage, do not operate the vehicle at full throttle for more than 5

seconds with the drive wheels lifted off the ground.

Disconnect the negative (-) battery cable before you service the vehicle to prevent accidental

operation.

Wear eye protection when you service the vehicle. Be careful when you do

work around batteries, use solvents or compressed air.

To decrease the risk of an electrical arc, which can cause a battery explosion,

disable all electrical loads from the battery before you remove the battery

wires.

Use insulated wrenches to decrease the risk of a wrench falling on a battery to cause a short-cir-

cuit. A battery short-circuit can cause an explosion.

The electrolyte in a battery is an acid solution which can cause burns to the skin and eyes. Com-

pletely clean all electrolyte spills that contact the body and eyes with clear water. Contact a physi-

cian immediately.

Neutralize electrolyte spills with a solution of 2 teaspoons (10 ml) sodium bicarbonate (baking

soda) mixed in 1 quart (1 liter) of water. Rinse with water.

Owner’s Manual

MAINTENANCE

Front of Vehicle

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 SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Be careful when you use aerosol containers near battery terminals. Insulate metal containers to

decrease the risk of a short-circuit or explosion if the container is dropped across the battery ter-

minals.

The vehicle owner and service technician must carefully follow the procedures recommended in this manual. The preventative maintenance, applied at recommended intervals, keeps the vehicle dependable and decreases the costs for the repairs. Refer to the Periodic Service Schedule for service and intervals. Refer to LUBRICATION POINTS for correct lubrication locations.

ROUTINE MAINTENANCE

To increase the life of a vehicle that is used in harsh conditions, some maintenance must be done more often

than recommended in the Periodic Service Schedule. Harsh condition include high or low temperatures, high

To access the powertrain for normal maintenance, lift or remove the seat and remove the rear access panel. For major repairs, refer to the applicable Technician’s Repair and Service Manual.

Some service procedures make it necessary to lift the vehicle. Refer to LIFTING THE VEHICLE for the correct lift procedure and safety information.

dust and dirt conditions, high use with maximum load.

Engine Specifications

Engine Model ....................................................FJ400D Oil Filter......................... Cartridge Type Full Flow Filter

Type..................................................... Four cycle, OHV Oil Pump ..........................Positive Displacement Pump

Number of Cylinders.................................................... 1 Cooling ..............................................Forced Air Cooled

Displacement.......................................................401 cc Spark Plug Gap.................. .028" - .031" (.70 - .80 mm)

Rated Horsepower ............................................... 13 hp Spark Plug Type..................................... NGK BPR2ES

Checking the Oil Level

Do not overfill engine. Too much oil may cause engine

to smoke or cause spark plug fouling.

The oil should be checked with the engine warm. The vehicle should be on a level surface with the parking 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.

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

Owner’s Manual

MAINTENANCE

-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

Oil Dipstick & Cap

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

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.

Changing the Oil

Tool List Qty. Tool List Qty.

Socket, 19 mm ............................................................ 1 Oil Filter Wrench ......................................................... 1

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

Extension, 8” ............................................................... 1 Funnel ......................................................................... 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 require 10W-40 oil after a break-in period of 100 hours.

Be aware that engine fluids are carcinogenic and

may be hot. 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 the engine warm. Park the vehicle on a level surface, engage the parking brake and remove the key.

Place a drain pan under the engine. Wipe the engine with a clean cloth. Remove the oil fill cap.

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

burn you severely.

Place an oil drain pan under the oil drain plug (1) located at the rear of the engine base. Remove the drain plug (1) and allow the oil to drain into the pan. At the first oil change, small metal chips and lint may be found. This is normal and a result of the engine break-in period. Inspect the filter at every oil change. The presence of large metal chips could indicate possible damage to the engine. Before installing the drain plug, clean the area around the drain hole with a lint free cloth and inspect the drain plug (1) for damage. Replace if necessary. If the O-ring (2) on the drain plug is damaged, replace it with a new one. Tighten the drain plug to 62 in. lbs. (7 Nm) torque.

Owner’s Manual

MAINTENANCE

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Clean the area around the oil filter. Use a filter wrench (3) to remove the oil filter (4) from the engine and allow the oil to drain.

The O-ring (5) may have remained on the engine (6) or the filter (7). If the O-ring (5) is on the engine surface (6), remove it and discard with the filter (7).

Inspect the new oil filter for any defects. Apply clean engine oil to the oil filter O-ring (5) and install the oil filter onto the engine until the seal contacts the mounting surface. Turn the filter 2/3 to 3/4 turn by HAND. Pour in the specified type and amount of oil. See CAPACITIES AND REPLACEMENT PARTS.

The 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 the engine. The oil must be high quality and meet or exceed API SF, SG, CC standards. Check the oil level on the dipstick. Oil should be slightly below H to allow for expansion. If necessary, continue to add oil slowly and allow time for the oil to flow down into the engine. Check the oil level on the dipstick. Do not overfill.

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 oper-

ating the engine. Failure to install the dipstick and fill cap will

result in oil being discharged into the engine compartment.

Start the vehicle. Allow the engine to run for a few minutes to fill up the oil filter. Stop the vehicle on a level surface, set the parking brake and remove the key. Check for oil leaks at the drain plug and oil filter. Tighten the drain plug or oil filter if a leak is found. Check the oil level on the dipstick. Add oil if necessary.

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 indi- cated on the dipstick.

Owner’s Manual

MAINTENANCE

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

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

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Starter Generator Belt Tension

Tool List Qty. 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).

At no time during installation of belt, should the belt tension exceed 160 lbs (73 kg).

During installation, the belt must not be rolled over the edges of the starter/generator or drive clutch pulleys.

Tighten a new starter/generator belt to 110 - 130 lbs. (50 - 59 kg) tension when a gauge is applied half way between the two pulleys. A new belt may be checked manually. A maximum deflection of 3/8" (10 mm) is acceptable.

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.

Excessive stretch in belt may cause cord failure.

A loose belt can cause audible vibration and squeal.

Owner’s Manual

MAINTENANCE

1 quart (1 liter)

Clear Water

Plastic

Spray

Bottle

2 Teaspoons

(10 ml)

Sodium

Bicarbonate

(Baking Soda)

Preparing Acid Neutralizing Solution

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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 the 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.

Battery Cleaning

To decrease the risk of damage to vehicle or floor, neutralize acid before you spray the battery with water.

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

Clean the battery according to the Periodic Service Schedule.

When you clean the battery cases and terminals, do not use a water hose without neutralizing any acid deposits first. The water hose moves the acid from the top of the battery to another area of the vehicle or storage facility, where it can cause damage. Conductive residue on the battery will contribute to the discharge of the battery.

The correct cleaning method is to spray the top and sides of the battery with a solution of baking soda and water. Apply this solution with a plastic spray bottle. The solution is 2 teaspoons (10 ml) sodium bicarbonate (baking soda) mixed with 1 quart (1 liter) of water. Spray the solution on all metal components near the battery also.

Allow the solution to set a minimum of three minutes. Use a soft bristle brush or cloth to clean the top of the battery to remove residue that can cause the discharge of the battery. Clean the area with low pressure clear water.

Be careful when you use the aerosol containers near battery terminals. Insulate metal containers

to decrease the risk of a short-circuit or explosion if the container is dropped across the battery

terminals.

Clean once a month, or more often in harsh conditions. After the battery is clean and dry, apply a commercially available protectant to the terminals.

TIRE INSPECTION

Inspect the tire condition according to the Periodic Service Schedule. Tire inflation pressures must be checked when the tires are cool. Always install the valve dust cap after you check or inflate the tires.

Owner’s Manual

MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

BRAKES

Always inspect the pedal travel before you operate a vehicle to confirm brake function.

Make sure you do all brake tests in a safe location with regard to the safety of all personnel.

A subtle loss of performance can occur over time; therefore, it is important to establish the standard with a new

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.

vehicle.

LUBRICATION

Do not use more than three 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.

CAPACITIES AND REPLACEMENT PARTS

CAPACITIES

Engine Oil 1.25 L (1.3 qt.)

Fuel Tank (early production)

Fuel Tank (late production)

5.1 gal (19.3 liters) 87 Octane minimum

5.2 gal (19.8 liters) 87 Octane minimum

Rear Axle Lubricant Oil 1.5 L (51 oz.)

REPLACEMENT PARTS

Oil Filter E-Z-GO P/N 607454

Air Filter E-Z-GO P/N 28463G01

Spark Plug NGK BPR2ES (E-Z-GO P/N 607462)

Starter/Gen. Belt E-Z-GO P/N 16548G1

Clutch Belt E-Z-GO P/N 606136

Fuse ATC 10A (E-Z-GO P/N 35212G07)

Headlight Bulb #894 (E-Z-GO P/N 74004G01)

Turn Signal Bulb #912-NA (E-Z-GO P/N 74005G01)

Taillight Bulb 2057 (E-Z-GO P/N 604311)

Owner’s Manual

MAINTENANCE

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

BOLT SIZE

Grade 2

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

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.

(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

Torque Specifications and Bolt Grades

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

HARDWARE

Normally, three classes of standard hardware and three classes of metric hardware are used in the vehicle. Grade 5 hardware is identified by the three marks on the hexagonal head; grade 8 hardware is identified by six marks on the head; grade 2 hardware is not marked. The class specification is marked on metric hardware.

Inspect the vehicle for loose fasteners periodically. The fasteners must be tightened carefully and according to the Torque Specifications table or as specified in the Repair and Service Manual.

AIR INTAKE AND COOLING FINS

Engine parts should be kept clean to reduce the

risk of overheating and ignition of accumulated

debris. After every off road use, allow engine 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.

Keep linkages, springs and controls clean. Keep

area around muffler free of any combustible mate-

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.

Operation in wet or damp weather or over freshly cut grass may result in debris accumulating and adhering to the internal shroud and fins of the cooling system.

rial.

Owner’s Manual

MAINTENANCE

Drain Plug

Fill / Check Plug

Dust Collector

Air Cleaner Cover

Air Cleaner

Air Filter Element

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REAR AXLE

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

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 and the fill plug. In the event that the lubricant is to be replaced, a drain plug is provided at the bottom of the differential housing.

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.

Cleaning the Air Filter Element

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. 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.

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.

Owner’s Manual

MAINTENANCE

Battery (+)

Battery

Tie Down

Tie Down Screw

Battery (-)

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

SPARK PLUGS

Tool List Qty. Tool List Qty.

Spark Plug Socket, 13/16”........................................... 1 Anti-Seize Compound .............................................. AR

Ratchet ........................................................................ 1 Torque Wrench, ft. lbs. ............................................... 1

Plug Gauge, Wire Type ............................................... 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. Spark plug should

be properly gapped. Tighten to 16 ft. lbs. (22 Nm) torque.

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

A fouled spark plug is indicated by an electrode with a wet, black appearance. A fouled plug can be caused by:

• Dirty air filter element.

• Restrictions in the air intake system.

• Incorrect valve adjustment.

• Spark plug wire in poor condition.

• Poor quality fuel.

BATTERY REMOVAL AND INSTALLATION

Tool List Qty. Tool List Qty.

Insulated Wrench, 1/2" ................................................ 1 Ratchet........................................................................ 1

Socket, 1/2" ................................................................. 1 Torque Wrench, ft. lbs. ............................................... 1

Extension, 12" ............................................................. 1

Hardware that is removed must be installed in its original position unless otherwise specified. If the torque values are

not specified, refer to the Torque Specifications table in the GENRAL INFORMATION AND ROUTINE MAINTE-

NANCE section.

At the battery, remove the negative (-) cable before removing the positive (+) cable. Remove the bolt from the battery hold down and remove the battery.

Installation of the battery is in reverse order of removal.

Connect the positive (+) battery cable first and then connect the negative (-) battery cable.

Be sure to remove all corrosion from the terminals and hardware. After installing the battery, coat terminals with a commercially available terminal protectant.

Be careful when you use aerosol containers near battery

terminals. Use a metal container that has insulation to pre-

vent an explosion.

Owner’s Manual

MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

PROLONGED STORAGE

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 gaso-

line 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.

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.

• Turn the Key Switch to the OFF position, and leave the Forward/Reverse switch in the NEUTRAL position during storage.

• Perform all required routine maintenance per the Periodic Service Schedule.

• Properly inflate the tires to the recommended pressure (psi) stated on sidewall of tires.

• Place the Forward/Reverse handle in the NEUTRAL position engage the neutral lock.

• Turn the fuel shut-off valve to the closed (OFF) position.

• With proper ventilation, run the engine until the remaining fuel in the carburetor and fuel lines is depleted and the engine stalls.

• Return the neutral lock to the OPERATE position.

• Loosen, but do not remove the carburetor drain screw. Drain any fuel remaining in the bowl into an approved container and pour the fuel collected into the vehicle fuel tank. Add fuel stabilizer to stabilize fuel and install the tank cap securely (Follow manufacturer's instructions).

• Tighten the carburetor drain screw.

• Remove the spark plug and pour 1/2 oz. (15 ml) of SAE 10 - 30 weight oil or fogging oil into the cylinder. Rotate the crankshaft by hand several times, then install the spark plug.

• Do not engage the parking brake, but secure the car from rolling.

• While the engine is still warm, change the oil.

• Clean the body, chassis and engine of debris, mud, chaff or grass.

Owner’s Manual

MAINTENANCE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Owner’s Manual

PERIODIC SERVICE SCHEDULE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

PERIODIC SERVICE SCHEDULE



- CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE

REMARKS

20 rnds/20 hrs

100 miles/160 kms

MONTHLY

60 rnds/60 hrs

300 miles/500 kms

QUARTERLY

125 rnds/125 hrs

600miles/1000 kms

SEMI-ANNUAL

250 rnds/250 hrs

1200miles/2000 kms

ANNUAL

5 YEARS

Tires - pressure, condition of tires and rims

before each use

DAILY

WEEKLY



Hardware - loose or missing

Reverse Warning Indicator

Overall Vehicle Condition

Battery - charge condition, loose terminals, corrosion,

hold down and hardware

Brake (Mechanical) - smooth operation

Brakes - aggressive stop test C&A C&A C&A C&A

Parking Brake - operation, does it hold on a hill

Accelerator - smooth operation

Starter/Generator Belt - tension, wear, cracks

Wiring - loose connections, broken or missing insula-

tion

Carburetor Linkage - attachment C&A C&A C&A C&A

Carburetor CL

Direction Selector - attachment and mechanism C&A C&A C&A C&A

Cooling Fan - build up of debris on blower housing

screen

Engine Oil ** - oil level C&A C&A C&A C&A C&A C&A

Engine Oil ** and Filter - drain and change R R

Engine - noise, vibration, acceleration, oil leaks C&A C&A C&A C&A

Valves - check cold - Ref: Repair and Service Manual C&A

Cylinder Head and Piston - remove carbon CL

Choke Cable - smooth movement and adjustment C&A C&A C&A C&A

Cooling Fan - buildup of foreign matter inside housing

and fins

  



CL CL CL CL





C&A C&A C&A C&A







CL CL CL CL CL CL

CL CL CL CL

**Initial oil change after 8 hours of run time.

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

Owner’s Manual

PERIODIC SERVICE SCHEDULE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

REMARKS

20 rnds/20 hrs

100 miles/160 kms

before each use

DAILY

WEEKLY

Steering Assembly - excessive play, loose or missing

hardware

Tie Rods - excessive play, bent rods, loose or missing

hardware

Rear Axle - fluid level, oil leakage, noise, loose or

missing hardware

Rear Axle - replace fluid R

Rear Suspension - shock oil leakage, worn bushings,

loose or missing hardware

Front Suspension - strut oil leakage, excessive play in

hubs or kingpins, worn bushings, loose or missing hardware

Front Wheel Alignment - unusual tire wear C&A C&A C&A

MONTHLY

60 rnds/60 hrs

300 miles/500 kms

QUARTERLY

125 rnds/125 hrs

600miles/1000 kms

SEMI-ANNUAL

250 rnds/250 hrs

1200miles/2000 kms

ANNUAL







5 YEARS

Fuel Level

Fuel System - leaks at tank, cap, system lines for

cracks/deterioration, filters, pump

Fuel Filter R

Spark Plug R

Throttle/Governor Linkage - operation and governed

speed

Air Filter Element - check and replace as necessary

Drive Belt - cracks, frayed, excessive wear

**Initial oil change after 8 hours of run time.

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





 

Owner’s Manual

PERIODIC SERVICE SCHEDULE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Owner’s Manual

PERIODIC SERVICE SCHEDULE

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Owner’s Manual

APPENDIX A

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

APPENDIX A

DECLARATION OF CONFORMITY

Owner’s Guide

APPENDIX A

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

APPENDIX A

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Owner’s Guide

APPENDIX A

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Notes:

Owner’s Guide

Read the following the warnings before you operate

the vehicle:

When you leave the vehicle, turn the key to

the OFF position and remove the key from

the vehicle.

Drive the vehicle only as fast as terrain and

conditions allow. Consider the terrain and traffic conditions. Consider environmental

conditions that change the terrain and your

ability to control the vehicle.

Do not drive fast downhill. Sudden stops or

change of direction can cause a loss of con-

trol. Use the brake to control the speed of the

vehicle when you drive down a slope.

When possible, stay in approved areas and

do not drive on steep slopes.

Always keep feet, legs, hands and arms

inside vehicle.

Normal use, age, wear or abuse can cause some components on the vehicle to fail. The manufacturer can not know all possible component failures or the methods that failures can occur. A vehicle in need of repair does not operate correctly and can be dangerous.

Be careful when you service the vehicle. Be aware of your safety and the safety of other people in the area.

Always use the correct tools shown in the tool list and wear safety equipment.

Remove all jewelry before you service the

vehicle.

Do not allow loose clothing or hair to contact

the moving parts.

Do not touch hot objects.

The drive wheels must be lifted and sup-

ported on jack stands before you do any ser-

vice to the powertrain when the motor is in

operation.

Do not drive on rough terrain.

Before you drive in the reverse direction, make sure the area behind the vehicle is

clear.

Make sure the direction selector is in the cor-

rect position before you press the accelerator

pedal.

Decrease speed before and during turns.

Make sure you completely stop the vehicle

before you move the direction selector.

See GENERAL SPECIFICATIONS for the

vehicle load and seat capacity.

Read the following information and warnings before

you operate the vehicle:

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

When you service the

vehicle, always wear eye

protection. Be careful

when you do work

around batteries or you

use solvents com-

pressed air.

Use wrenches with insulation to decrease the

risk of a short-circuit if a wrench falls across

the battery terminals. A battery short-circuit

can cause an explosion.

To prevent the risk of battery explosion, keep

all flammable materials, open flames or

sparks away from the batteries.

Hydrogen gas is made as batteries are

charged. Do not charge batteries without

good ventilation

E-Z-GO Textron, Inc.

1451 Marvin Griffin Road Augusta, Georgia 30906-3852 USA

North America:

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

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

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

Service Parts Manuals, as well as Repair and Service Manuals are available from a local Distributor, an authorized Branch, Genuine E-Z-GO Parts & Accessories Department or at www.shopezgo.com.

Copyrighted Material

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

Textron E-z-go RXV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

OWNER’S GUIDE

GASOLINE POWERED VEHICLES

RXV SHUTTLE 2+2

STARTING MODEL YEAR 2016

Use Original Equipment Manufacturer (OEM) approved parts to keep the warranty effective.

Overfilling the battery can void the warranty.

BATTERY PROLONGED STORAGE

BATTERY DISPOSAL

ALWAYS:

ALWAYS:

Figure 1 Fleet & Freedom Vehicle Dimensions

Figure 2 Shuttle 2 + 2 Vehicle Dimensions

Figure 3 Vehicle Incline Specifications and Turning Diameter

1. Key Switch

2. Fuel Gauge (if equipped)

3. Head Light Switch (if equipped)

4. Turn Signal Switch (if equipped)

5. Horn Button (if equipped)

6. Center Compartment

7. Power Outlet, 12V (if equipped)

8. USB Port (if equipped)

9. Accelerator Pedal

10. Brake Pedal

11. Parking Brake

12. Hour Meter (if equipped)

13. Direction Selector

14. Choke

Figure 1

General Information

Key Switch

Headlight Switch (if equipped)

Turn Signal Switch (if equipped)

Horn (if equipped)

Fuel Gauge with Low Oil Pressure Indicator (if equipped)

Figure 2

12-Volt Power Outlet (if equipped)

USB Port (if equipped)

Direction Selector

Choke

Figure 3

Accelerator Pedal

Brake and Parking Brake Pedal

Front Seat

Front Hip Restraint

Cup Holder

Figure 4

Steering Wheel

Rear Seat and Cargo Platform (if equipped)

Rear Hand Rail

Rear Handle

Weather Enclosure (if equipped)

Rear View Mirror (if equipped)

Figure 1 Serial Number Locations

Direction Selector Operation

Accelerator Pedal Operation

Brake and Parking Brake Operation

Horn (if equipped)

Rear Seat and Cargo Platform Operation

12-Volt Power Outlet

Run-In

Cold-Start

Starting Vehicle On A Hill

Coasting

Late Production Fuel Tank

Early Production Fuel Tank

Battery Disposal

How to Lift the Entire Vehicle:

1. Install wheel chocks in front and behind each front wheel.

2. Center the jack under the bagwell.

3. Lift the vehicle enough to place two jack stands under the frame where the leaf spring mounting brackets are welded to the frame.

4. Lower the jack and test the stability of the vehicle on the two jack stands.

5. Place the jack under the center front just behind the bumper.

6. Lift the vehicle and place two jack stands under the frame where the instrument panel support is attached to the frame.

7. Lower the jack and test the stability of the vehicle on the jack stands.

How to Lift the Rear of the Vehicle Only:

1. Install wheel chocks in front and behind each front wheel.