Bad Boy 617816, Owner'S Manual

Page 1: ...HD LTO GAS OWNER S MANUAL 617816 ISSUED JANUARY 2011 REVISED AUGUST 2012...

Page 2: ...s and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm BATTERIES CONTAIN LEAD AND RELATED PARTS 14 25 DO NOT DRIVE ACROSS SLOPES IN EXCESS OF 1...

Page 3: ...o change without notice E Z GO DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL and E Z GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUEN TIAL DAMAGES RESULTING FROM THE USE OF THE INFORMAT...

Page 4: ...ntain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self...

Page 5: ...ch Mounted to Vehicle 4 Winch Remote Control 4 Winch Clutch Knob 4 WINCH APPLICATIONS 4 Never Operate Winch with Less Than Five Turns Around Drum 5 Use a Nylon Sling and Install a Damper when Winching...

Page 6: ...TRAL LOCK 16 Neutral Lock 16 SERVICE AND MAINTENANCE 16 SERIAL NUMBER LABEL LOCATION 17 Serial Number Label Location 17 PERIODIC SERVICE SCHEDULE 18 Periodic Service Schedule 18 TIRE INSPECTION 20 FOU...

Page 7: ...APACITIES AND REPLACEMENT PARTS 27 Capacities and Replacement Parts 27 HARDWARE 28 Torque Specifications and Bolt Grades 28 GENERAL SPECIFICATIONS 35 Vehicle Dimensions 40 Vehicle Dimensions Continued...

Page 8: ...Page vi TABLE OF CONTENTS NOTES...

Page 9: ...ecting that E Z GO Branch personnel Distributors and Dealers advise all customers to adhere to this SAFETY RESTRICTION in connection with the use of all products new and used the Distributor or Dealer...

Page 10: ...when approaching sharp or blind turns Use extreme caution when driving over loose terrain Use extreme caution in areas where pedestrians are present MAINTENANCE ALWAYS Maintain the vehicle in accordan...

Page 11: ...ge to the vehicle Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic VENTILATION Always store gasoline vehicles in a well ventilat...

Page 12: ...Page viii SAFETY INFORMATION Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS NOTES...

Page 13: ...Page ix LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS...

Page 14: ...ssible and secure Top heavy loads may cause vehicle instability or tip over Drive slowly straight up and down slopes and in turns Do not permit anyone to ride on the platform when used as a load bed F...

Page 15: ...NOT STAND BEHIND DUMP BED 14 READ MANUAL 2 WARNING USE CAUTION IN INCLEMENT WEATHER 3 WARNING DO NOT OPERATE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL 4 MAX 14 25 MAXIMUM CROSS HILL RAMP ANGLE AS SPECI...

Page 16: ...UND BATTERY 20 DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND 21 SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION 22 NO TAMPERING KEEP HANDS OUT 23 WARNING CORROSIVE 24 WARNING EXPLOSIVE 25 WARNING...

Page 17: ...ELECTOR TO REVERSE AN AUDIBLE DEVICE WILL SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTO...

Page 18: ...TCH TO RAISE LOAD BED PUSH BOTTOM PART OF SWITCH TO LOWER LOAD BED 61 54 WARNING READ OWNER S MANUAL BEFORE OPERATING VEHICLE IN FORWARD OR REVERSE WARNING READ OWNER S MANUAL BEFORE ENGAGING TWO OR F...

Page 19: ...Page xv LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS NOTES...

Page 20: ...Page xvi LABELS AND PICTOGRAMS Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS NOTES...

Page 21: ...us Plan carefully before using the vehicle to go significant distances over questionable terrain Remember that a one hour drive may take many hours to walk out should you run out of fuel or be strande...

Page 22: ...lever per mits the selection of either F forward or R reverse The vehicle should be left in F when unattended Fig 3 Direction Selector CHOKE The choke is used to aid cold starting Ref Fig 4 on page 2...

Page 23: ...until it locks in place The park brake will release when the service brake pedal is depressed Use the lower section of the brake pedal to operate the service brake system Fig 5 Accelerator Brake and H...

Page 24: ...nd evenly onto the drum leaving no gaps that could cause premature wear to the cable When using winch under a load operate the remote control from as far to the side of the vehicle as possible Do not...

Page 25: ...and allow the motor to cool Always wear thick leather gloves when han dling the wire cable Replace frayed wire cable with a direct fac tory replacement only Never operate the winch with less than five...

Page 26: ...esigned for the job Do not apply shock loads to the winch Do not attempt to modify or weld the winch COMMON SENSE OPERATION To prevent severe injury or death observe the following Never transport load...

Page 27: ...the driver and passengers plus any options or accessories must be deducted from the total payload rating to deter mine the cargo capacity Never exceed the rated capac ity of the load bed MODIFICATION...

Page 28: ...ve the toggle switch lever up to raise the load bed and down to lower Before operating load bed check to ensure no one is behind the vehicle Fig 16 Electric Lift Switch TAIL GATE OPERATION To open the...

Page 29: ...ics REAR STORAGE COMPARTMENT The rear storage compartment is not weather tight The rear storage compartment can be accessed with the rear seat folded down by reaching under the central portion of the...

Page 30: ...he first hours of operation As internal moving parts are run in oil consumption should gradually decrease until the rate of consumption stabilizes Check the oil level per the Periodic Service Schedule...

Page 31: ...foot and release the service brake by lifting left foot COASTING To reduce the possibility of severe injury or death from coasting at above recommended speeds limit speed with service brake On steep h...

Page 32: ...m tree limbs or flying objects The top and windshield provide some protection from the elements however they will not keep the operator and passengers dry in a downpour For complete pro tection from t...

Page 33: ...or death from a vehicle falling from a jack Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is sup ported by a jack Use jack stands and test the stability of the...

Page 34: ...tires should have the same pressure for optimum handling characteristics Be sure to install the valve dust cap after checking or inflating The vehicle is fitted with low pressure tubeless tires mount...

Page 35: ...or is not designed to charge a discharged battery When engine starts the clutches engage and cause vehicle to move making jump starting both dangerous and impractical If the vehicle battery has become...

Page 36: ...ngine is running must be made with both drive wheels raised and vehicle properly support ed on jack stands To reduce the possibility of engine damage never operate vehicle at full throttle for more th...

Page 37: ...hassis between the seat back supports Fig 26 Serial Number Label Location Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the manufacture date code...

Page 38: ...NOT OVERFILL COOLING FAN Check for build up of debris inside blower housing clean if required STARTER GENERATOR BELT Check for tension wear cracks MONTHLY 20 HOURS includes items listed in previous t...

Page 39: ...rease Check bellows and pinion seal for damage or grease leakage RACK END BALL JOINT Lubricate use wheel bearing grease REAR AXLE Check for unusual noise and loose or missing mounting hardware AIR FIL...

Page 40: ...moking or allow oil to enter the air filter enclosure The oil should be checked with the engine warm The vehicle should be on a level surface with the parking PARK brake engaged Allow adequate time fo...

Page 41: ...d oil left in engine The oil should be changed as part of spring maintenance This will remove any moisture that has accumulated during storage Be aware that engine fluids may be hot and contact to the...

Page 42: ...left in engine The oil must be high quality oil that meets or exceeds API SF SG CC standards Ref Fig 35 on page 22 Check oil level on dipstick Oil should be slightly below H to allow for expansion If...

Page 43: ...age to vehicle or floor neutralize acid before rinsing battery To reduce the possibility of damage to electrical compo nents while cleaning do not use a pressure washer Cleaning should take place per...

Page 44: ...est should be per formed regularly as an evaluation of braking system performance It is useful as a method of identifying sub tle loss of performance over time Periodic Brake Test For Mechanical Brake...

Page 45: ...ting more than three pumps of grease in a grease fit ting could damage grease seals and cause premature bearing failure Fig 41 Lubrication Points AIR INTAKE AND COOLING FINS To prevent possible burns...

Page 46: ...e 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...

Page 47: ...ngine 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 corro sion in the engine Raise the rear of the vehicle...

Page 48: ...Ref Fig 47 on page 28 Fig 47 Torque Specifications and Bolt Grades BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 4 5 8 11 15 20 24 33 35 47 55 75 75 102 130 176 125 169 190 258 Grade 5 G...

Page 49: ...OPERATION AND SERVICE INFORMATION Page 29 Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS NOTES...

Page 50: ...OPERATION AND SERVICE INFORMATION Page 30 Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS NOTES...

Page 51: ...GENERAL SPECIFICATIONS Page 27 Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS GENERAL SPECIFICATIONS...

Page 52: ...l e e h W r a e R h p k 8 0 h p k 4 7 2 h p m 5 0 h p m 7 1 d n u o r G l e v e L d e e p S m c 5 1 n i 3 5 l a i t n e r e f f i D e c n a r a e l C d n G d a o l x a m g k 5 2 2 b l 0 0 5 y t i c a...

Page 53: ...c n a r a e l C e l s i A g n i t c e s r e t n I m c 7 9 n i 5 8 3 k c a r T l e e h W r a e R Gnd Clearance Differential 6 0 in 15 cm Load Bed Width 40 0 in 102 cm A N y t i c a p a C g n i w o T m...

Page 54: ...CES CAUTIONS WARNINGS and DANGERS 107 in 272 cm 65 5 in 166 cm Rear 38 in 96 cm Front 38 5 97 cm 46 5 in 118 cm 76 in 193 cm 50 in 127 cm 5 in 12 7 cm LTO VEHICLE DIMENSIONS 103 in 262 cm Rear 38 in 9...

Page 55: ...manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX TURNING CLEARANCE DI...

Page 56: ...GENERAL SPECIFICATIONS Page 32 Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS NOTES...

Page 57: ...VEHICLE WARRANTIES Page 33 Read all of manual to become familiar with vehicle Pay attention to all NOTICES CAUTIONS WARNINGS and DANGERS VEHICLE WARRANTIES...

Page 58: ...ention to all NOTICES CAUTIONS WARNINGS and DANGERS DOMESTIC WARRANTY U S AND CANADA To obtain a copy of the limited warranty applicable to the vehicle call or write a local Distributor authorized Bra...

Page 59: ...enance or unapproved modifications You are responsible for presenting your vehicle to E Z GO Division of Textron Inc distribution center or service center as soon as the problem exists The warranty re...

Page 60: ...fficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner Such u...

Page 61: ...enrichment system if applicable Air Induction System Intake manifold if applicable Air filter Ignition System Spark plugs Magneto or electronic ignition system Spark advance retard system if applicabl...

Page 62: ...y warranty coverage if the engine has not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records...

Page 63: ...ed with the utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools listed i...

Page 64: ...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 2011 E Z GO Division of Textron Inc This manual m...