E-Z-GO 4X4, Owner'S Manual

Page 1: ...4x4 owner s manual 4x4 4x4 owner s manual owner s manual...

Page 2: ...UTV OEM 00 indd 2 2011 03 21 1 14 04...

Page 3: ...vide the best quality products It is strongly recommended for all customers and operators to read this owner s manual thoroughly before using this vehicle as the manual contains a lot of valuable info...

Page 4: ...UTV OEM 00 indd 2 2011 03 21 1 14 04...

Page 5: ...CLE IDENTIFICATIONS SPECIFICATIONS CONTROLS AND FEATURES OPERATION REPLACEMENT PARTS MAINTENANCE STORAGE AND DISPOSAL TROUBLESHOOTING INDEX SECTION 1 2 3 4 5 6 7 8 9 10 TABLE OF CONTENTS UTV OEM 00 in...

Page 6: ...NTING LOCATION 1 19 DECALS 1 20 CAUTIONS FOR DECAL MAINTENANCE 1 26 PRECAUTIONS BEFORE OPERATION 2 1 VEHICLE IDENTIFICATION NUMBER 2 2 VEHICLE SERIAL NUMBER 2 2 ENGINE SERIAL NUMBER 2 2 SPECIFICATIONS...

Page 7: ...CUP HOLDERS AND STORAGE BOXES 4 30 CARGO BED 4 30 CARGO BED CONTROL LEVER 4 30 REFLEX REFLECTOR 4 7 SAFETY LAMP KIT OPTIONAL 4 8 SWITCHES 4 9 KEY SWITCH 4 9 COMBINATION SWITCH 4 11 HAZARD LAMP SWITCH...

Page 8: ...ERATING THE ENGINE 5 2 STARTING THE ENGINE 5 2 CHECKING WARNING LAMPS AFTER STARTING ENGINE 5 5 OPERATING PRINCIPLE OF PREHEAT SYSTEM 5 6 STOPPING THE ENGINE 5 6 OPERATING THE VEHICLE 5 7 HOW TO DRIVE...

Page 9: ...NING INSPECTION SHIELD A 7 7 OPENING SEAT CUSHION B 7 8 RAISING CARGO BED C 7 8 APPLYING GREASE D 7 9 CHECKING ENGINE OIL LEVEL E 7 10 CHANGING ENGINE OIL AND FILTER F 7 11 DUST VALVE G 7 12 REPLACING...

Page 10: ...ECKING SUSPENSION SHOCK ABSORBER AC 7 35 BATTERY SEALED AD 7 35 REPLACING HEADLAMP BULB AE 7 37 CHECKING AND REPLACING FUSE AF 7 38 MAIN FUSE SLOW BLOW FUSE AG 7 39 ALIGNING WHEELAND CHECKING WHEELNUT...

Page 11: ...in harm serious in jury or death to you or other persons if the warning is not hee ded Follow the advice provided with the warning CAUTION This indicates that a condition may result in damage to your...

Page 12: ...gs UNIVERSAL SYMBOLS Fuel Level low Parking Brake Battery Charging Condition Engine Oil Pressure Turn Signal Differential Lock Hazard Warning Lights Headlight Low Beam Headlight High Beam Four Wheel D...

Page 13: ...ON 1 4 WHEN STARTING THE ENGINE 1 4 WHEN DRIVING THE VEHICLE 1 6 WHEN PARKING THE VEHICLE 1 13 SAFETY PRECAUTIONS DURING SERVICING 1 14 SAFETY PRECAUTIONS WHEN USING THE ROPS 1 18 SAFETY DECAL 1 19 MO...

Page 14: ...T66O101A PRECAUTIONS BEFORE OPERATION GENERAL PRECAUTIONS A careful operator is the best oper ator Most accidents can be avoid ed by observing certain precautions To help prevent accidents use these...

Page 15: ...ni cate your intentions 8 This vehicle should be driven only by a driver with a valid driver s li cense driver s license UUVO114A 9 Never let anyone under 5 years of age ride in the vehicle If it is u...

Page 16: ...whenever driving this vehi cle in an aggressive manner Eye protection is recommended at all times UUVO123A PRECAUTIONS DURING OP ERATION WHEN STARTING THE ENGINE 1 Do not operate your vehicle in an e...

Page 17: ...that wheel nuts have been tightened to the specified torque 8 Always check the tire pressure be fore start engine For more infor mation about tire pressure see chapter 4 9 Make sure that all pressure...

Page 18: ...park brake UUVO133A WHEN DRIVING THE VEHICLE KUVO158A 2 While turning the headlights on dim them when meeting another vehicle T66O127A 1 This is an off road vehicle only it is illegal to drive a UTV o...

Page 19: ...ling at road speeds in a normal road con dition 7 Avoid sudden movements of the steering wheel as this can cause a loss of control of the vehicle This risk is especially great when trav eling at road...

Page 20: ...ees and around other obstructions UUVO109A 10 Watch where you are going at all times so that you are able to avoid obstacles that can cause injury or damage to your vehicle 11 Before making reverse mo...

Page 21: ...of a rollover crash be especially careful when obstacles and slopes are ahead and when braking on hills or dur ing turns UUVO121A 16 Never drive the vehicle at ex cessive speeds Always travel at speed...

Page 22: ...e during operation 19 Always keep arms and legs in side the cab frame while the ve hicle is in motion UUVO126A 20 Never drive in excessively rough slippery or loose terrain 21 Never operate on excessi...

Page 23: ...go over the top of any hill at high speed UUVO129A 23 When driving on a road inclined vertically or sideward make sure to drive at a low speed Other wise the vehicle can roll over leading to a seriou...

Page 24: ...out the pads UUVO130A 27 Never exceed the stated load capacity for this vehicle Car go should be properly distributed and securely attached Reduce speed and follow the instructions in this manual for...

Page 25: ...or acci dental starting 3 Never leave the vehicle without setting the parking brake and shut ting off the vehicle 4 Never park on a slope with only the transmission engaged The ve hicle may roll down...

Page 26: ...e while working around the battery or when refuel ing your vehicle Keep all sparks and flames away from the battery and fuel tank The battery pres ents an explosive hazard because it gives off hydroge...

Page 27: ...icle is equipped with a coolant recovery tank add coolant there rather than to the radiator 6 Allow the vehicle time to cool off before servicing any part that may have become hot while the vehicle wa...

Page 28: ...he vehicle when changing wheels UUVO135A 13 Fluid escaping from pinholes may be invisible Do not use hands to search for suspected leaks Use a piece of cardboard or wood instead Use of safety goggles...

Page 29: ...llution in mind When replacing coolant or oil dispose of it the right way Be sure to observe all relevant regulations when you dispose of the engine oil transmission oil fuel coolant filters and batte...

Page 30: ...cture It never can protect the riders against falling objects Aviod driving the vehicle into a dangerous area such as falling rocks zone IMPORTANT UUVO143A A ROPS should never be modified by welding g...

Page 31: ...SAFETY PRECAUTIONS 1 19 1 SAFETY DECAL MOUNTING LOCATION UUVO142C UTV OEM 01 indd 19 2011 03 21 5 29 46...

Page 32: ...uld lead to impaired visibility or the loss of vehicle control Turn engine off and apply parking brake before exiting the vehicle 4 Part No U3215 85681 1 The owner s manual and warning labels contain...

Page 33: ...t reduced speeds Apply brakes when going down slopes to prevent the vehicle from accelerating suddenly freewheeling Reduce speeds on rough or uneven terrain Turn engine off and apply parking brake bef...

Page 34: ...85161 NOTICE THIS ROPS IS TESTED IN ACCORDANCE WITH SAE J2194 METHOD MAXIMUM VEHICLE MASS INCLUDING CARGO DECK AND PERMANENT ATTACHMENTS IS 850kg 1874 lbs MEC2200 U3215 2610 ROPS P Number Trade Name...

Page 35: ...he dump If equipped with hydraulic dump only operate while sitting in the seat Do not place hands behind the seat or underneath the bed when lowering or raising the cargo bed Never work underneath a r...

Page 36: ...or bypassing the safety start switch The vehicle may start in gear and move if normal starting circuitry is bypassed 2 Only Start the engine from the operator s seat with range shift lever in neutral...

Page 37: ...ng navigate turns and rough or uneven terrain at reduced speeds DO NOT haul or tow unsecured loads or cargo U3215 85191 19 Part No U3215 85201 U3215 85201 20 Part No U3215 85711 1 The selective contro...

Page 38: ...olvent such as thinner or acetone since it can ruin the decals Do not spray high pressure water directly onto the decal The decal may fall off the vehi cle If a decal is damaged or lost contact your l...

Page 39: ...2 PRECAUTIONS BEFORE OPERATION 2 VEHICLE IDENTIFICATION NUMBER 2 2 VEHICLE SERIAL NUMBER 2 2 ENGINE SERIAL NUMBER 2 2 UTV OEM 02 indd 1 2011 03 21 4 57 54...

Page 40: ...N NUMBER VEHICLE SERIAL NUMBER ENGINE SERIAL NUMBER UUVO202A UUVO201A Have the vehicle serial number and engine serial number with you when ordering parts or asking for service information Fill in the...

Page 41: ...SPECIFICATIONS SPECIFICATION 3 2 EXTERIOR DIMENSIONS 3 2 GENERAL SPECIFICATIONS 3 3 OPTION LIST AND FEATURES 3 5 3 3 UTV OEM 03 indd 1 2011 03 21 4 59 50...

Page 42: ...all height C Wheel base D Front wheel tread E Rear wheel tread F Ground clearance G 112 3 2 852 60 7 1 543 76 4 1 940 76 4 1 940 49 7 1 262 48 3 1 228 12 304 D A E F B C G C UUVO301A Notes The specifi...

Page 43: ...ential case oil U S Gal L 0 16 0 6 Rear differential case oil U S Gal L 0 21 0 8 Coolant U S Gal L 1 66 6 3 Driving unit Main shift CVT Continuous Variable Transmission with belt Range shift High Low...

Page 44: ...ty lbs kg 1 600 726 Others Seat Bench for 3 persons Cargo dumping Manual Hydraulic optional Brush guard Standard ROPS Standard Instrument cluster Standard Tachometer fuel gauge odometer Winch mount St...

Page 45: ...protect CV joints Muffler Spark Arrester Kit To prevent wild fire by collecting exhaust sparks Install at the end of exhaust pipe Soft Cabin Black To protect driver and passenger from outside somethi...

Page 46: ...MEMO MEMO UTV OEM 03 indd 6 2011 03 21 4 59 51...

Page 47: ...SPEEDOMETER HOURMETER 4 15 FUEL GAUGE 4 16 COOLANT TEMPERATURE GAUGE 4 16 ENGINE OIL PRESSURE WARNING LAMP 4 17 BATTERY CHARGING LAMP 4 18 HEAD LIGHT HIGH BEAM LAMP 4 18 TURN SIGNAL LAMP 4 18 GLOW PL...

Page 48: ...BOXES 4 30 CARGO BED 4 30 CARGO BED CONTROL LEVER 4 30 CARGO BED CONTROL LEVER OPTIONAL 4 31 REMOTE HYDRAULIC LEVER OPTIONAL 4 32 HAND THROTTLE LEVER OPTIONAL 4 33 CARGO BED EXTENSION OPTIONAL 4 33 W...

Page 49: ...Seat 3 Dumping Handle 4 Dumping Latch 5 Fuel Tank Cap 6 ROPS 7 Steering Handle 8 Hood 9 Headlamp 10 Brush Guard 11 Rear Reflex Reflector 12 Cargo Bed 13 Rear Hitch Receiver 14 Rear Wheel Mudguard UUVO...

Page 50: ...ont Working Lamp 2 Sun Canopy 3 Head Rest 4 Rear View Mirror 5 Front Turn Signal Lamp 6 Windshield 7 Cargo Bed Extension UUVO461A FULL OPTION MODEL 8 Tail Lamp 9 Fog Lamp 10 Rear Screen UTV OEM 04 ind...

Page 51: ...g the hood CAUTION UUVO402A UUVO452A 1 Hood Support ELECTRIC COOLING FAN MOTOR The fan motor runs when the cool ant temperature raises over 80 and stops when the coolant temperature drops below 75 The...

Page 52: ...s vehicle is equipped with the rear hitch receiver as standard The rear hitch receiver is a 2 inch square boss type and is used to in stall a trailer or 3 point hitch imple ment Make sure to observe t...

Page 53: ...ler including cargo weight does not exceed 590 kg 1 300 lbs When connecting a trailer at tach it only to the trailer hitch bracket Never connect a trailer to any point other than the specified Otherwi...

Page 54: ...quently UUVO409A There is no separate switches for the turn signal lamps and horn as these can be operated by the combination switch standard NOTE always check that the reflex reflector are clean befo...

Page 55: ...ON D Heat E Start a When the key switch is in position A the engine and all electrical devices in the vehicle stop except horn hazard lamps and turn sig nal There are five positions for the ig nition...

Page 56: ...ce the preheat system s life e The position E indicates the Start In order to start the engine the shift lever should be in the neutral position As soon as the engine is started release the key then t...

Page 57: ...UVO412A The combination switch consists of the head light turn signal light and horn switches HEADLAMP SWITCH The headlamp switch can be operat ed while the key switch is in the ON position then head...

Page 58: ...gnal lamp switch is to op erate the turn signal lamps which is included in the Safety lamp kit as an option Check if the safety lamp kit is installed before using this switch UUVO414A The turn signal...

Page 59: ...cles when malfunction occurs in the vehicle while driving Pressing this switch up blinks the hazard lamp and returning it turns off the lamp The turn signal lights cannot be oper ated while this switc...

Page 60: ...WITCH PANEL 1 Spare Switch Panel The spare switch panel is prepared in case that the owner wants to in stall the switches for the option al hazard warning lamp working lamps wiper and other implements...

Page 61: ...Turn Signal Indicator RH The speedmeter operates correctly when the specified tires with the cor rect inflation pressure are installed Refer to the chapter Maintenance for the correct tire inflation...

Page 62: ...the ON position C Coolant is cold H Coolant is hot The range marked 2 in the figure indicates the normal engine temper ature normal driving range If the needle is in the H zone dur ing driving it indi...

Page 63: ...the radi ator fan is operating If the fan is not operating stop the engine and have your vehicle checked by your dealer This lamp comes on when the en gine oil pressure or oil level is low This lamp c...

Page 64: ...ur local dealer or work shop as soon as possible CAUTION UUVO420A HEAD LIGHT HIGH BEAM LAMP This lamp comes on in blue when the high beam head light is switched on Driving with high beam head light di...

Page 65: ...he engine is warm In this case the engine can be started without the preheat operation GLOW PLUG INDICATOR UUVO423A paRKINg BRaKe INDIcatOR This lamp comes on in red when the parking brake is engaged...

Page 66: ...lamp on or with the fuel level be low E can cause the engine to mis fire and damage the engine parts If the air enters into the fuel system refer to maintenance chapter page 7 18 for Bleeding fuel lin...

Page 67: ...R po sition Shifting during driving can damage parts in the gear box Shift the lever into the l low speed position when driv ing on a hill or a bumpy area so that the vehicle can utilize more power an...

Page 68: ...the steering wheel in the straight ahead po sition and drive at a low speed while the differential lock lever is in the lock position Oth erwise you can lose control of the vehicle or damage the dif...

Page 69: ...stressed and steerability can be de teriorated if using the 4WD unneces sarily UUVO430A BRaKe peDal The brake pedal is located on the left of the accelerator pedal Depress the brake pedal slowly to st...

Page 70: ...his vehicle is equipped with the cVt continuous Variable transmission therefore the vehicle may roll down a slope if the parking brake is not en gaged even though the shift le ver is in the h l or R p...

Page 71: ...g a driver The seat cushion and seatback can be separated Re moving the seat cushion can access to the engine compartment SEAT 1 Seat Cushion 2 Seat Back UUVO434A The seat belts for a driver and pas s...

Page 72: ...e to fasten the seat belt during driving the ROpS cannot protect you if not wear ing the seat belt WARNING as the safety belt can reduce or prevent injuries in an acci dent make sure to wear the seat...

Page 73: ...e rearview mirror on the driver and passenger sides as an option 1 Outside Rearview Mirror OUTSIDE REARVIEW MIRROR OptIONal Objects seen in the convex mirror are closer than they ap pear therefore avo...

Page 74: ...e sure that the vehicle does not hit the ceiling or entrance of the garage CAUTION UUVO403A The transparent optional acrylic windshield is to block wind from the front 1 Windshield WINDShIelD OptIONal...

Page 75: ...of abrupt braking Make sure to secure cargo with ropes even though the ve hicle is equipped with the rear screen Wearing helmet for a riders is highly recommended especial ly when there is no rear scr...

Page 76: ...A Turn B Pull Up To raise the cargo bed pull up the handle with one hand while turning the dumping latch lever with the oth er hand Take your hand off the han dle after the support rod is set into th...

Page 77: ...n and en gage the latch before driving WARNING UUVO454A 1 Cargo Bed Support 1 Hydraulic Lever 2 Lever Lock Bracket A Up B Down C Floating 1 Hydraulic Cylinder UUVO463A UUVO446A CARGO BED CONTROL LEVER...

Page 78: ...cargo bed raised Make sure to lower the cargo bed to its original position and en gage the latch before driving When raising or lowering the cargo bed be careful not to let any part of your body such...

Page 79: ...er lock bracket and pull the lever up to operate the implement or hydrau lic motor Return the lever to stop op erating implement or hydraulic mo tor As the valve is ON OFF style the cylinder of implem...

Page 80: ...in condi tions Make sure to stop the en gine and remove the key before fueling 4 Never smoke while fueling Add fuel in a well ventilated area and keep away from spark and flame 5 Do not fill the tank...

Page 81: ...is recommended to use diesel fuel with high cetane number in order to enhance power and starting of the engine in a cold weather FUEL REQUIREMENTS ENGINE INSPECTION 1 Inspection Shield UUVO450A UUVO4...

Page 82: ...IN RecReatIONal UUVO460A TIRE TREAD PATTERNS WORKSIte cOOlaNt BRaKe flUID aND ELECTRICAL DEVICES The coolant radiator cooling fan and brake fluid can be checked by open ing the hood Also various relay...

Page 83: ...nd tighten them as necessary before driving Driving with loose wheel nuts can lead to a serious accident UUVO458A UUVO457A TURF Do not use tires larger or smaller than specified Do not disassemble or...

Page 84: ...0 4 6 kgf m 28 9 33 3 lb ft All terrain 25x10 12 12 PSI 4 0 4 6 kgf m 28 9 33 3 lb ft Turf 25x10 12 12 PSI 4 0 4 6 kgf m 28 9 33 3 lb ft Rear wheel Work site 25x 12 18 PSI 4 0 4 6 kgf m 28 9 33 3 lb f...

Page 85: ...G UP 5 10 JUMP START 5 11 STOPPING 5 12 PARKING 5 12 SHIFTING 5 13 DRIVING ON SLIPPERY SURFACES 5 14 TURNING 5 15 DRIVING ON SLOPE 5 15 DRIVING IN FOREST 5 17 DRIVING THROUGH WATER 5 17 DRIVING BACKWA...

Page 86: ...amps Check the fuel level Visually check the tire inflation pressure and wheel nut tightness For more information refer to the chapter Maintenance PRE OPERATION DAILY INSPECTION OPERATING THE ENGINE S...

Page 87: ...e shift lever without releas ing the parking brake Make sure to release the parking brake be fore starting off Failure to do so could reduce the life of the park ing brake disk NOTE 1 Shift Lever 3 Ch...

Page 88: ...If the engine cannot be started within 10 seconds wait for 30 seconds and try again When trying to start the engine again make sure that the fly wheel is stopped in advance Do not turn the key switch...

Page 89: ...stop the engine immediate ly and check the engine oil level If the engine oil level is within safe operating limits contact your local dealer 9 Check to see that all the warning lamps on the instrumen...

Page 90: ...the ignition key If the vehicle is operated for an extended period of time idle the engine at low speed for 2 to 3 minutes in order to cool down the engine before shut down IMPORTANT OPERATING PRINCIP...

Page 91: ...MPORTANT Fasten the seat belt firmly when you are seated in the ve hicle The seat belt can reduce or prevent injuries in an accident Make sure to wear the seat belt during driving Also be sure the sea...

Page 92: ...elease 3 Release the parking brake UUVO503A UUVO505A 4 Place the shift lever to the H High speed or L Low speed 5 Depress the accelerator pedal gradually to start off the vehicle 6 The 4WD system can...

Page 93: ...g used to these controls Place the shift lever into the L position when driving on a soft or bumpy surface or car rying a heavy load CAUTION Do not shift the gear when the vehicle is moving or the en...

Page 94: ...ming up the engine exces sively increases fuel consump tion and affects the durability of the vehicle negatively Never warm up the engine and leave the vehicle for an extend ed period of time It can c...

Page 95: ...les Remove the bat tery terminal cover as necessary 4 Connect the alligator clips on both ends of the red positive cable to the positive terminals of both bat teries 5 Connect one clip of the black ne...

Page 96: ...ed with the parking brake system and main brake system separately for safe ty The parking brake should be used in an emergency such as brake pedal failure Never depress the accelerator and brake pedal...

Page 97: ...n and the shifting operation is au tomatic according to the accelerator pedal operation and outer load con dition Make sure to move the shift lever to the H L or R position when the vehicle is station...

Page 98: ...this circumstance observe the fol lowing 1 Slow down before you enter a slip pery area 2 Before entering a slippery area move the shift lever to the L po sition and 2WD 4WD lever to the 4WD position...

Page 99: ...belts If the dif ferential lock system is used during turning on a normal road with suffi cient friction the durability of the in ternal gears related to the differential system can be damaged Also th...

Page 100: ...n a road in clined vertically or sideward make sure to drive at a low speed Otherwise the vehicle can roll over leading to a seri ous accident Driving with excessive load on a slope can lead to overtu...

Page 101: ...observe the spec ified water depth limit Never drive through swift water flow even though its depth is below the height of the vehicle floor 1 Drive at a low speed when driving in a mountainous area o...

Page 102: ...CAUTION Consider the following when driving backward 1 Drive backward at a low speed To stop the vehicle depress the brake pedal gently 2 Avoid abrupt turning and driving down the slope backward 3 Ne...

Page 103: ...kit there will be no brake lamps turn signal lamps and tail lamps on the vehicle In this condition it is very dan gerous to drive on a path WARNING TRANSPORTING CARGO 1 Distribute cargo evenly onto t...

Page 104: ...load when driving on a slope with excessive cargo Therefore load only up to half of the specified load limit when driving on a slope 6 When loading heavy material such as sand and earth distribute it...

Page 105: ...ain UNLOADING 4 After raising the cargo bed make sure support is latched in the groove A firmly 5 Never drive the vehicle with the cargo bed raised If the support rod comes off the groove by vibra tio...

Page 106: ...ack to lower down the cargo bed 1 Hydraulic Lever 2 Lever Lock Bracket A Up B Down C Floating 1 Hydraulic Cylinder UUVO463A UUVO446A Make sure to check the ground condition before driving back wards t...

Page 107: ...pecification is not met the vehicle can turn over backward 3 It is very hard to drive backward with a trailer connected Keep the speed low A part of your body may get between the vehicle body and carg...

Page 108: ...ting vehicle or trailer 2 Set ramps to the transporting vehi cle firmly 3 It is recommended to drive back ward onto the transporting vehicle to drive out of it more easily later 4 Make sure to set the...

Page 109: ...ll the wheels are driven in the 4WD mode Keep the following instructions to use the 4WD correctly 1 It is recommended to use the 4WD when driving on a slippery muddy or icy road driving through water...

Page 110: ...oving or the engine is running at a high speed The power transfer sys tem can be severely damaged and an accident can occur 5 In some cases it may be hard to move the 2WD 4WD shift lever out of the 4W...

Page 111: ...or bumpy road for better traction 2 Keep your feet as far as possible as any object can fall off the car go bed when the tailgate opens abruptly H11O585A UUVO523A 1 Gate TAILGATE BACK DOOR 1 Latch Le...

Page 112: ...MEMO MEMO UTV OEM 05 indd 28 2011 03 21 5 30 34...

Page 113: ...REPLACEMENT PARTS 6 ESSENTIAL REPLACEMENT PART 6 2 OIL AND FLUID 6 2 FILTERS 6 2 BELTS AND RUBBER PARTS 6 3 ELECTRIC PARTS 6 3 6 UTV OEM 06 indd 1 2011 03 21 5 05 30...

Page 114: ...maintenance intervals Refer to chapter 7 Maintenance ESSENTIAL REPLACEMENT PART OIL AND FLUID NO ITEM SPECIFICATION CAPACITY 1 Engine Oil SAE 15W40 8 45 3 0 2 Gear Box DAEDONG UTF55 Exxonmobil Mobilf...

Page 115: ...BELTS AND RUBBER PARTS N0 PART NO DESCRIPTION QTY 1 E5205 32091 Engine Oil Filter 1 2 84612 4316 0 Fuel Filter Element 1 3 T2350 11641 Air Filter 1 N0 PART NO DESCRIPTION QTY 1 E5760 72532 Fan Belt 1...

Page 116: ...MEMO MEMO UTV OEM 06 indd 4 2011 03 21 5 05 32...

Page 117: ...FILTER L 7 17 BLEEDING FUEL LINE M 7 19 CHECKING INJECTION NOZZLE AND FUEL INJECTION PUMP N 7 20 CLEANING RADIATOR CORE O 7 20 CHECKING COOLANT IN AUXILIARY COOLANT TANK P 7 21 CHANGING COOLANT Q 7 2...

Page 118: ...38 MAIN FUSE SLOW BLOW FUSE AG 7 39 ALIGNING WHEEL AND CHECKING WHEEL NUT AH 7 39 CHECKING DIFFERENTIAL LOCK CABLE AI 7 40 CHECKING SHIFTAND 4WD CABLES AJ 7 41 USING BIODIESEL AK 7 41 ADJUSTING BELT...

Page 119: ...tank O P Q Seat Belt Check the condition of seat belt and mounting hardware Tires Check for wear damaged tires and air pressure Check wheel hub nuts are tightened Parking Brake condition Check operat...

Page 120: ...5 Air cleaner filter Check H Replace 6 Air intake hose connection and filter body anti dust valve Check I 7 Valve clearance Check 8 Injection nozzle Check N 9 Spark arrester Check R 10 Coolant Replac...

Page 121: ...ont rear wheel and parking brake pads Check AA AC 19 Suspension mounting bushing play and mounting rubber Check AC 20 Leakage from shock absorber Check AC 21 Wheel hub bearing clearance Check 22 Wheel...

Page 122: ...Antifreezing solution Ethylene glycol Pure water 50 50 3 Engine oil 0 9 3 2 SAE 15W40 4 Gear Box Oil 0 24 0 9 Exxonmobil Mobilfluid 424 Exxonmobil Hydraulic 560 Shell Donax TD 5 Front differential ca...

Page 123: ...the inspection shield This vehicle is designed so that it is easy to access the inspection points for service Most of regular services can be performed by opening the in spection shield under the sea...

Page 124: ...align the pins under the cushion with the holes and then push down the cushion gently Most of the engine services includ ing engine oil change and head cover repair can be performed by opening the se...

Page 125: ...greasing points Two of them are located on both ends of the universal joint which connects the gearbox and rear axle Raise the cargo bed and then apply grease to the greasing points It is recommend ed...

Page 126: ...firmly 2 Stop the engine and wait at least for 5 minutes 3 Unscrew the mounting bolts of the inspection shield from under the seat cushion 4 Pull out the engine oil dipstick and wipe it clean 5 Inser...

Page 127: ...drain plug to drain the oil to the container Be careful as the engine oil may be hot CHANGING ENGINE OILAND FILTER F 1 Warm up the engine oil by operat ing the engine for approx 10 min utes or driving...

Page 128: ...erfill the oil Over filled oil applies excessive stress to the crankshaft lead ing to serious malfunction Trying to drain the oil while it is hot may cause serious skin burn IMPORTANT DUST VALVE G 1 P...

Page 129: ...ace the filter 4 Make sure to fit the filter to the center of the canister 5 Install the canister cover after checking that the anti dust valve is facing downward without any gap 1 Filter 2 Cap 3 Evac...

Page 130: ...bber hose and re place it if necessary UUVO714A It is not easy to inspect the CVT on your own It is recommended to have it inspected by your dealer 1 Park the vehicle on level ground and apply the par...

Page 131: ...at shield cover 1 2 Heat shield cover 2 UUVO717A 5 Remove the exhaust pipe but leave the muffler in place 1 Exhaust pipe 2 Muffler UUVO718A 6 Remove the air hoses 1 and 2 from the CVT cover 1 Air hose...

Page 132: ...ratio is 0 68 As suming that its width is reduced to 1 in due to wear the speed reduction ratio would be 3 22 and 0 76 respectively There fore the maximum speed would be reduced by 10 and the max tor...

Page 133: ...ground and apply the parking brake firmly 2 Stop the engine and raise the car go bed making sure support is latched In case the hydraulic dumping kit is installed raise the cargo bed before stopping...

Page 134: ...can bleed more easily by assembling the filter cup after filling clean fuel to two thirds of its level 7 Turn the fuel cock to the AIR side and crank for several seconds un til the filter cup is fill...

Page 135: ...o protect the start motor and battery It is recommended to start servic ing after filling the fuel tank to its top for easy bleeding as it might be needed to bleed the fuel line after servicing the fu...

Page 136: ...NG INJECTION NOZZLE AND FUEL INJECTION PUMP N The injection nozzle and injection pump can be inspected only by a qual ified service personnel For detailed in formation contact your dealer CLEANING RAD...

Page 137: ...LIARY COOLANT TANK P When the coolant in the radiator ex pands by heat it overflows into the auxiliary coolant tank On the other hand when the coolant temperature in the radiator decreases the radi at...

Page 138: ...the auxil iary coolant tank flows to the radi ator 4 When the coolant is cooled down sufficiently add water an anti freeze mix to the auxiliary cool ant tank so that the coolant level is between the M...

Page 139: ...rush guard upper 2 Brush guard middle 3 Brush guard lower 6 Remove the lowest grille from the brush guard 1 Coolant Drain Plug Of Radiator 7 Place a container with wide open ing under the vehicle and...

Page 140: ...t the hose to the auxil iary coolant tank 1 Air Bleeder Bolt 13 Make sure to install the drain plugs for radiator and engine be fore filling new coolant 14 Fill the tank with water and an ti freeze Et...

Page 141: ...spark arrester with a new one 1 Filler plug 4 Clean around filler plug then re move the filler plug 5 Check that the gearbox surface is not hot Then check the oil lev el and condition with a finger be...

Page 142: ...sufficiently 3 Raise the hood and support it with the support rod CHECKING AND CHANGING FRONT AXLE OIL T 1 Filler Plug 4 Clean around filler plug then re move the filler plug 5 Check that the differe...

Page 143: ...o spill out of filler plug hole UUVO762A 1 Funnel 11 Wipe the differential case and its surrounding with a rag thorough ly 12 Test drive the vehicle for 5 to 10 minutes to check for leakage Oil Capaci...

Page 144: ...lor or viscosity of the oil is not normal or it is at the oil change interval change the oil 6 To change oil place a container with wide opening under the drain plug Then remove the drain plug 7 After...

Page 145: ...oots Rear Wheel 4 Check if the CV boots of the drive shaft for the rear wheels are torn or have a sign of leakage 5 If the CV boots should be re placed contact your dealer UUVO740A UUVO741A You can ge...

Page 146: ...ie Rod End 5 Turn steering wheel fully to the right and inspect the boots of the tie rod end and nut then turn wheel fully to the left and inspect boot of the tie rod end and nut 6 If the above compon...

Page 147: ...fluid is severely con taminated or insufficient contact your dealer CHECKING BRAKE PEDAL FREE PLAY Y The master cylinder rod of the vehi cle is adjusted so that the brake ped al free play is 0 59 0 7...

Page 148: ...side of the disc is too thin close to 0 04 in 1 mm both pads for that disc as well as the pads for the wheel on the other side should be replaced 6 Check the brake pads on the oth er axle using the s...

Page 149: ...e cargo bed and support it with the support rod In case the hydraulic dumping kit is installed raise the cargo bed before stopping the engine 3 Adjust the length of the parking brake cable Test the ca...

Page 150: ...the hydraulic jack so that the vehi cle chassis sits on the stand 1 Wheel Nut The rear suspension equipped on this vehicle is adjustable to allow for ride quality and weight hauling To adjust the sus...

Page 151: ...ck absorber is malfunc tioning your riding comfort can be harmed In this case check the shock absorber as follows 1 Park the vehicle on level ground and apply the parking brake firmly 2 Stop the engin...

Page 152: ...ct the positive battery ca ble 6 Remove the battery mounting bracket 7 When connecting cables connect the positive cable first and then the negative cable The battery discharges natu rally if the vehi...

Page 153: ...n Do not smoke near the battery Do not leave the battery near flame or spark Do not touch the both termi nals of the battery with a metal object simultaneously When disconnecting the bat tery disconne...

Page 154: ...r A Pull Out CHECKING AND REPLACING FUSE AF 1 Park the vehicle on level ground and apply the parking brake firmly 2 Stop the engine open the hood and support the hood 1 Fuse Box 3 Open the fuse box co...

Page 155: ...fter replacement Make sure that the inspection shield is visible 5 If this fuse is repeatedly blown contact your dealer ALIGNING WHEEL AND CHECKING WHEEL NUT AH 1 Wheel nut 2 Unscrew the nuts on the w...

Page 156: ...ected daily Driving with loose wheel nuts is very dangerous and can lead to overturn and collision Make sure that they are firmly tightened WARNING IMPORTANT WARNING 3 Unscrew the nut and adjust the c...

Page 157: ...e engine and move the 2WD 4WD lever to 4WD and 2WD positions to check rotation of each wheel USING BIODIESEL AK 1 It is allowed to use 5 biodiesel fuel If biodiesel fuel of higher ratio is used the en...

Page 158: ...the engine inspection shield and seat cushion 1 Adjusting Bolt A Belt Tension NOTE 3 Loosen the adjusting bolt on the top of the alternator as well as the hinge bolt on the bottom of the al ternator 4...

Page 159: ...It is recommended to wash your ve hicle with water of moderate pres sure and with or without soap When washing your vehicle in a car wash make sure high pressure water is not directly sprayed to the f...

Page 160: ...MEMO MEMO UTV OEM 07 indd 44 2011 03 21 5 06 17...

Page 161: ...UTV OEM 08 indd 1 2011 03 21 5 07 14...

Page 162: ...4 Inflate the tires to a pressure a lit 9 Apply grease to every grease fit necessary drain and flush it and UTV OEM 08 indd 2 2011 03 21 5 07 15...

Page 163: ...te the tires if they are low 4 Check all fluid levels including the and brake fluid points and grease fitting as need leading to a fire diesel and fill the standard diesel UTV OEM 08 indd 3 2011 03 21...

Page 164: ...UTV OEM 08 indd 4 2011 03 21 5 07 15...

Page 165: ...UTV OEM 09 indd 1 2011 03 21 5 07 32...

Page 166: ...l Clogged fuel filter or fuel hose blocked fuel filter valve This troubleshooting chart summarizes simple service items for users who are familiar with mechanical systems For more detailed service ite...

Page 167: ...il Improper valve clearance 3 Engine power is insufficient knocking vibration smoke Excessive engine oil overfilling water or hydraulic oil mixed with engi Overheated engine Restricted fuel supply clo...

Page 168: ...e power is insufficient knocking vibration smoke Improper valve clearance 4 Engine is overheated Insufficient or leaking coolant loose hose connection Broken cooling fan UTV OEM 09 indd 4 2011 03 21 5...

Page 169: ...erheated Insufficient engine oil Insufficient fuel or clogged filter and hose Seizure due to overheated engine Engine oil leakage Coolant leakage 6 Electrical device is malfunc UTV OEM 09 indd 5 2011...

Page 170: ...engine start and stop lack of time to charge Excessive electricity use from external device additionally attached device such as implement Prolonged cranking in severe condition 8 Vehicle cannot be d...

Page 171: ...nsufficient to drive Shift lever not in L position 13 Braking force is insufficient Wet brake Insufficient brake fluid Air in brake line Excessively worn brake pad when braking Wet brake pads on one s...

Page 172: ...lation pressure of front tires Insufficient lubrication and contamination due to torn steering rack boots Faulty steering knuckle Excessive steering wheel play kit or auxiliary hydraulic kit Lack of H...

Page 173: ...UTV OEM 10 indd 1 2011 03 21 5 07 47...

Page 174: ...UTV OEM 10 indd 2 2011 03 21 5 07 47...

Page 175: ...INDEX UTV OEM 10 indd 3 2011 03 21 5 07 47...

Page 176: ...UTV OEM 10 indd 4 2011 03 21 5 07 47...

Page 177: ...INDEX UTV OEM 10 indd 5 2011 03 21 5 07 47...

Page 178: ...UTV OEM 10 indd 6 2011 03 21 5 07 48...

Page 179: ...UTV OEM 00 indd 2 2011 03 21 1 14 04...

Page 180: ...06 796 4540 I www ezgo com e mail ezgo textron com I 2011 E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta GA 30906 1451 Marvin Griffin Road Augusta GA 30906 1451 Marvin Griffin Road Au...