E-Z-GO ST 480, Owner'S And Service Manual

Page 1: ...A Textron Company...

Page 2: ...hat should be observed A CAUTION indicates a condition that may result in damage to the vehicle A WARNING indicates a hazard ous condition which could result in severe injury or death Please observe t...

Page 3: ...anual is subject to change without notice E Z GO Division of Textron Inc is not liable for errors in this manual or for incidental or consequential damage that result from the use of material in this...

Page 4: ...tory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components mustbe per original vehicle specifications in order to maintain the United States o...

Page 5: ...FUEL GAUGE 3 9 LOW OIL PRESSURE INDICATOR LIGHT 3 9 ACCELERATOR PEDAL 3 9 Fig 11 Accelerator Brake and Horn 3 10 SERVICE BRAKE PEDAL 3 10 PARK BRAKE 3 10 HORN 3 10 DIFFERENTIAL LOCK 3 10 LOAD BED 3 11...

Page 6: ...ervice 3 33 Cartridge Service 3 33 Fig 30 Air Cleaner 3 33 REAR AXLE 3 34 Checking the Lubricant Level 3 34 Fig 31 Add Check and Drain Rear Axle Lubricant 3 34 STARTER GENERATOR BELT TENSION 3 34 Fig...

Page 7: ...t notice This vehicle conforms to the current applicable standard for safety and performance requirements These vehicles are designed and manufactured for off road use They do not conform to Federal M...

Page 8: ...er get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions Never attempt to perform vehicle maintenance in an area where exposed flame is pr...

Page 9: ...stributor an autho rized Branch or the Service Parts Department When ordering parts or requesting information for your vehicle provide vehicle model serial number and manufacture date code BEFORE INIT...

Page 10: ...n terrain that is free from stumps large rocks or holes The vehicle should not be used to cross water VEHICLE CAPACITY Due to the variety of ways the vehi cle may be used it is important that the oper...

Page 11: ...ded it will take longer to stop than with no load When operating vehicle in wet weather conditions remember that the brakes may need to be lightly applied in order to provide enough friction to dry th...

Page 12: ...r mance of the vehicle To prevent severe injury or death while driving be aware of the follow ing Environmental hazards such as steep slopes overhanging limbs etc Danger of fire when vehicle is operat...

Page 13: ...winds tightly and evenly onto the drum leaving no gaps that could cause pre mature wear to the cable When using winch under a load operate the remote control from as far to the side of the vehicle as...

Page 14: ...load capacity of the winch decreases with the steepness of the slope The winch is designed for intermittent duty only The elec tric motor should not be allowed to become excessively hot If the motor b...

Page 15: ...the winch drum or the winch cable while it is under tension Unplug the winch switch before working on the winch drum in order to prevent inadvertent operation When operating winch take up slack slowl...

Page 16: ...ght accelerator pedal brake pedal park brake horn differential lock KEY LIGHT SWITCH Located on the dash panel this switch enables the basic electrical sys tem of the vehicle to be turned on and off b...

Page 17: ...page 3 9 LOW OIL PRESSURE INDICATOR LIGHT A low oil pressure indicator light is located on the dash panel Ref Fig 9 on page 3 9 If oil pressure drops below 1 4 psi 1 2 kg cm2 the oil pressure switch...

Page 18: ...the front seats Ref Fig 10 on page 3 9 The brake is engaged when the handle is raised and disengaged when the handle is in the full down position When leaving the vehicle unattended engage the park br...

Page 19: ...mum load The load must be posi tioned in the bed as far forward as possible distributed in such a way that its center of gravity must not be higher than height noted on label and secured Failure to fo...

Page 20: ...ervice brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of control Slow down before and during turns All turns should be made at reduced sp...

Page 21: ...helmet and protective clothing are recom mended for operator and passenger at all times Do not permit anyone in the load bed while vehicle is in motion Use caution when operating the electric dump Do...

Page 22: ...ce brake place the key in the key switch and turn it to the ON position Move the direction selector to the direction desired Release the park brake by pressing the release button in the end of the han...

Page 23: ...dequate space for the expansion of gaso line Leave at least 1 2 5 cm space below bottom of filler neck Inspect fuel cap tank and other components for leaks or deterioration that could cause a hazardou...

Page 24: ...of conveying information or warnings Appendix A illustrates and explains picto grams that may appear on the vehicle Not all pictograms shown in Appendix A will be found on your vehicle SUN TOP AND WIN...

Page 25: ...eat material body finish or elec trical system Do not use pressure in excess of 700 psi to wash exterior of vehicle Clean windshield with lots of water and a clean cloth Minor scratches may be removed...

Page 26: ...cleaner con taining no harsh solvents yet gently lifts grease off hands May be used with or without water P N 75505 G01 Battery Cleaner that neutralizes battery acids and dissolves termi nal corrosion...

Page 27: ...is vehicle are uni directional and should never be moved from one side of vehi cle to the other This vehicle comes standard with uni directional tires Left side tires should always remain on the left...

Page 28: ...signated on tire sidewall All four tires should have the same pres sure for optimum handling characteristics Be sure to install the valve dust cap after checking or inflating The vehicle is fitted wit...

Page 29: ...previ ously removed To replace the turn signal light bulb support turn signal housing from backside of cowl while removing two screws securing lens Ref Fig 18 on page 3 21 Install new bulb and replac...

Page 30: ...vehicle be moved by placing the entire vehi cle on a trailer flatbed truck or other suitable transport NEUTRAL LOCK To prevent the driven clutch from turning the rear wheels during service operations...

Page 31: ...ENANCE To reduce the possibility of severe injury or death from improper servic ing techniques Do not attempt any type of servicing operations before reading and understanding all notes cautions and w...

Page 32: ...roviding it receives regular maintenance Refer to the Periodic Service Schedule for appro priate service intervals Ref Fig 22 on page 3 26 Refer to Lubrication Points for appropriate lubrication locat...

Page 33: ...ERIAL NUMBER PLATE LOCATION The serial number and manufacturing date code are located on a plate on the passenger side of the dash housing of the vehicle Ref Fig 21 on page 3 25 Design changes take pl...

Page 34: ...KLY TIRES Examine for cuts excessive wear and pressure see GENERAL SPECIFICATIONS WHEELS Check for bent rims missing or loose lug nuts FUEL GAUGE Check for proper operation at fueling and fuel cap ven...

Page 35: ...heck for binding cables Check for damage or wear Lubricate as required use light oil DO NOT LUBRICATE CABLES REAR SHOCK ABSORBERS Check for oil leakage loose mounting hardware ENGINE ELECTRICAL SYSTEM...

Page 36: ...page 3 29 RACK END BALL JOINT Lubricate use wheel bearing grease REAR AXLE Check for unusual noise and loose or missing mounting hardware DRIVE BELT Check for cracks fraying and excessive wear 250 300...

Page 37: ...W arrow on the side of filter Install new fuel filter and reposition the clamps over the inlet and outlet CHECKING THE OIL LEVEL Tool List Qty Required Clean cloth 2 Never overfill the engine with oil...

Page 38: ...ng the engine Failure to install the dipstick and fill cap will result in oil becoming contaminated and or oil being discharged into the engine com partment CHANGING THE OIL Tool List Qty Required Pli...

Page 39: ...frequently SAE 30 oil if used below 40 F 4 C will result in hard starting and possible engine bore damage due to inadequate lubrication To reduce the possibility of severe injury wear rubber gloves to...

Page 40: ...mount with a clean lint free cloth Lightly oil the seal on the new filter with fresh clean oil Screw fil ter on by hand until the seal contacts the filter mount Tighten 1 2 to 3 4 turn more Refill en...

Page 41: ...s Access the filters by unsnapping the spring clip on each side of the air cleaner and removing the air cleaner cover Ref Fig 30 on page 3 33 If necessary vacuum or wipe out any loose dirt or trash fr...

Page 42: ...R AXLE The rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing Ref Fig 31 on page 3 34 Unless leakage is evident an annual lubricant check is...

Page 43: ...ection of 3 8 1 cm is acceptable for a new belt Ref Fig 33 on page 3 35 Tighten an existing belt to 75 80 lbs 34 36 kg tension using the same technique and inspect for cracking or wear A maximum defle...

Page 44: ...d result in severe injury or death do not use metallic spray wand to clean battery and keep all smoking materials open flame or sparks away from the battery The correct cleaning technique is to spray...

Page 45: ...ze compound and tighten to 15 ft lbs 20 Nm torque Fouled spark plugs are indicated by a wet black appearance This could be caused by a dirty air filter element or other restrictions in the air intake...

Page 46: ...r 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...

Page 47: ...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 inst...

Page 48: ...Tank Fuel Engine Oil Oil Filter Air Cleaner Filter Pre Cleaner Filter Spark Plugs Starter Generator Belt Clutch Belt Rear Axle Oil Fuse Headlight Bulb Turn Signal Bulb Tail Light Bulb 6 0 gal 22 5 lit...

Page 49: ...ator 1 Passenger TOTAL LOAD CAPACITY 800 lbs 365 kg Including Operator Passenger Accessories Cargo 500 lbs 230 kg Maximum Bed Load SPEED 16 5 mph 26 5 kph Max CHASSIS Powder Coated DuraShield Welded T...

Page 50: ...ensions 42 5 in 108 cm 50 in 127 cc 34 in 86 cm 6 in 15 cm Ground Clearance 110 5 in 281 cm 15 in 38 cm 49 in 125 cm 77 in 196 cm Rear 38 in 96 cm Front 38 5 in 97 cm 78 in 198 cm or 75 in 191 cm with...

Page 51: ...4 3 GENERAL SPECIFICATIONS Fig 2 Vehicle Incline Specifications Maximum Recommended Side Tilt 25 or 14 Max Maximum Recommended Ramp Grade 25 or 14 Max...

Page 52: ...4 4 GENERAL SPECIFICATIONS Fig 3 Vehicle Turning Clearance Diameter TURNING CLEARANCE DIAMETER Approx 23 5 ft 7 2 m...

Page 53: ...nd Obligations Refer to the Briggs Stratton Operating Maintenance Instructions provided with vehicle for Emission Control System Warranty information ENGINE OWNER WARRANTY POLICY Refer to the Briggs S...

Page 54: ...5 2 LIMITED WARRANTY Notes...

Page 55: ...6 1 DECLARATION OF CONFORMITY NOT AVAILABLE AT TIME OF PUBLICATION...

Page 56: ...6 2 DECLARATION OF CONFORMITY Notes...

Page 57: ...808 G01 H O 2 1 2 3 P P P P P P 74093 G01 74093G01 See Following Pages For Explanation Of These Pictograms 1 23 27 18 20 22 17 15 See Following Pages For Explanation Of These Pictograms 1 2 46 47 48 7...

Page 58: ...cm MAX 14o 25 35980G01 35980G02 See Following Pages For Explanation Of These Pictograms 1 2 12 10 8 7 5 11 WARNING Windshields do not provide protection from golf balls or other flying objects EGWHL14...

Page 59: ...INCLEMENT WEATHER WARNING DO NOT OPERATE IF USING ALCOHOL OR DRUGS MAX 14 25 MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED 14 25 WARNING MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED LOAD WITH HIGH CENTER...

Page 60: ...AR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAPACITY DO NOT RIDE IN LOAD BED P P DANGER OF EXPLOSION DO NOT FILL GAS CAN IN LOAD BED x in x in xx cm xx cm MAX LOAD MAX LOAD XXX LBS XXX LBS XXX KG XXX KG W...

Page 61: ...D GASOLINE P P GROUND FUEL PUMP P P DO NOT SPILL FUEL ON A HOT ENGINE NO TAMPERING KEEP HANDS OUT NEGATIVE GROUND BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS...

Page 62: ...NOT DISPOSE OF BATTERIES IN LANDFILL DO NOT DRIVE ON HIGHWAY WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS BATTERIES ARE HEAVY USE CARE LIFTING USE INSULATED TOOLS WEAR EYE PROTECTION NO S...

Page 63: ...HAND OR FINGERS CAN BE TRAPPED 37 38 42 P F R TO OPERATE VEHICLE IN REVERSE TURN KEY TO ON MOVE DIRECTION SELECTOR TO REVERSE AN AUDIBLE DEVICE WILL SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMO...

Page 64: ...ndix A 8 LABELS AND PICTOGRAMS Fig 8 Pictogram Definitions Continued ON OFF ON POSITION OFF POSITION HEADLIGHTS UNLOCKED 43 44 45 46 LOCKED DIFFERENTIAL LOCKED 47 48 49 WARNING KEEP ENTIRE BODY INSIDE...

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Page 66: ...00 448 8124 Outside USA Phone 010 1 706 798 4311 FAX 010 1 706 771 4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E Z GO Division of...