Ezgo 622021-GB, Owner'S Manual

Page 1: ...622021 GB Owner s Guide ISSUED JULY 2011 REVISED NOVEMBER 2011...

Page 2: ...es in controls will be illustrated Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service representative on servicing the vehicle in a...

Page 3: ...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 p...

Page 4: ...void the warranty Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and repla...

Page 5: ...thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers SECTION PAGE NO SAFETY 1 1 GENERAL SPECIFICATIONS 2 1 INTRODUCTION 3 1 OPERATING PROCEDURES...

Page 6: ...Page iv TABLE OF CONTENTS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

Page 7: ...amiliar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 1 TITLE PAGE NO SAFETY 1 3 NOTICES CAUTIONS WARNINGS AND DANGERS 1 3 GENERAL 1 5 GENERAL OPERATION 1 5 M...

Page 8: ...1 2 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1...

Page 9: ...ated under the pas senger seat in the Tow position If the vehicle is to be used in a commercial environment signs similar to the ones illustrated should be used to warn of situations that could result...

Page 10: ...ERAL LAW the modified product will be a Low Speed Vehicle LSV subject to the strictures and requirements of Federal Motor Vehicle Safety Standard 571 500 In these instances pursuant to Federal law the...

Page 11: ...eral Motor Vehicle Safety Standards of the United States of America USA and are not equipped for operation on public streets Some communities may permit these vehicles to be operated on their streets...

Page 12: ...icle support the vehicle using wheel chocks and jack stands NEVER get under a vehicle that is supported by a jack lift the vehicle in accordance with the manufacturer s instructions maintain the vehic...

Page 13: ...g MAX 4 in 10cm MAX 35980G01 PLASTIC 74821G01 ALLUMINIUM 35980G02 WARNING Windshields do not provide protection from golf balls or other ying objects EGWHL14 35493G01 Pb35493 G01 71489G01 R F P F 3596...

Page 14: ...ITY COULD RESULT IN TIP OVER LOAD CENTER OF GRAVITY MAXIMUM HEIGHT 14 25 WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY MAXIMUM RAMP HILL SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAP...

Page 15: ...BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION DO NOT EXPOSE TO FLAME WARNING CORROSIVE WARNING LETHAL VOLTAGE WARNING EXPLOSIVE DO NOT DISP...

Page 16: ...SELECTOR 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 SELECT...

Page 17: ...TCH TO LOCK DIFFERENTIAL PUSH BOTTOM OF SWITCH TO UNLOCK DIFFERENTIAL 58 REAR DIFFERENTIAL LOCK SWITCH 59 PUSH TOP PART OF SWITCH TO RAISE LOAD BED PUSH BOTTOM PART OF SWITCH TO LOWER LOAD BED 61 54 W...

Page 18: ...1 12 SAFETY Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 1...

Page 19: ...manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TITLE PAGE NO Vehicle Specifications 2 3 Vehicle Dimensions 2 4 Vehicle I...

Page 20: ...2 2 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2...

Page 21: ...capacity 800 lb 360 kg Cargo Box Width inside 44 0 in 112 0 cm Outside Clearance Circle 23 5 ft 7 2 m Cargo Box Length inside 36 0 in 91 0 cm Intersecting Aisle Clearance N A Cargo Box Depth inside 10...

Page 22: ...ings and Dangers 2 4 2 34 in 86 0 cm 10 5 in 27 0 cm 18 in 46 0 cm 6 in 15 cm Ground Clearance 110 5 in 281 0 cm 49 0 in 125 0 cm 78 5 in 199 0 cm 15 in 38 cm 44 0 in 122 0 cc 36 0 in 91 0 cm Rear 38...

Page 23: ...RAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers 2 TURNINGCLEARANCEDIAMETER Approx 23 5...

Page 24: ...2 6 GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 2...

Page 25: ...General Information 3 3 Key Switch Headlight Switch 3 3 Low Oil Pressure Indicator Light 3 4 Fuel Gauge 3 4 Direction Selector 3 4 Accelerator Pedal 3 4 Park Brake 3 4 Differential Lock 3 5 Horn 3 5 1...

Page 26: ...3 2 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3...

Page 27: ...tory installed custom accessories some accessories remain operational with the key switch in the OFF position 1 Key Switch Headlight Switch Located on the dash panel this switch enables the basic elec...

Page 28: ...entional movement of the accelerator pedal will release the park brake and may cause the vehicle to move which could result in severe injury or death With the key switch ON depressing the accelerator...

Page 29: ...lock lever backward towards the green unlocked symbol After unlocking the differential may remain locked if driving is resumed in a straight line This is a normal occurrence caused by pressure remaini...

Page 30: ...s Warnings and Dangers 3 6 3 12 Hip Restraint Front The front hip restraints are designed to help keep the occupants properly positioned in the event of sudden vehicle position changes 13 Brake Light...

Page 31: ...used to steer the vehicle The steering wheel is also installed with scorecard holder assembly 17 Choke Located on the console between the front seats the choke is used to aid cold starting See Cold S...

Page 32: ...3 8 INTRODUCTION Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 3...

Page 33: ...ITLE PAGE NO SERIAL NUMBER LOCATION 4 3 BEFORE INITIAL USE 4 4 OPERATING THE VECHILE 4 5 RUN IN 4 5 COLD STARTING 4 6 STARTING AND DRIVING 4 7 STARTING THE VECHILE WITH DISCHARGED BATTERY 4 7 COASTING...

Page 34: ...4 2 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 4...

Page 35: ...ated on the chassis between the seat back supports To access it raise the seat and lift up the flap on the access panel Design changes take place on an ongoing basis In order to obtain correct compone...

Page 36: ...ely ventilated minimum of 5 air exchanges per hour To reduce the chance of battery explosion that could result in severe injury or death never smoke around or charge batteries in an area that has open...

Page 37: ...eds 14 25 grade To reduce the possibility of severe injury or death resulting from improper vehicle operation the following warnings must be observed Refer to GENERAL SPECIFICATIONS for seating capaci...

Page 38: ...il should be changed in accordance with the Periodic Service Schedule while the engine is warm See SER VICE AND MAINTENANCE for checking oil level and changing oil procedures Clean Entire Dipstick COL...

Page 39: ...icle damage do not release service brake until engine has started Do not hold vehicle on hill by using accelerator and engine This will cause premature and excessive wear to drive train components To...

Page 40: ...el tank Do not refuel near open flame or electrical items which could produce a spark Always handle gasoline in a well ventilated area Always wear eye protection to protect against splashed fuel and f...

Page 41: ...to the vehicle do not hold on to sun top struts and stand on body panels The sun top and windshield provide some protection from the elements however they will not keep the operator and passenger dry...

Page 42: ...ssengers should never be allowed to ride in the dump bed Severe injury or death could result if they should fall out or the vehicle is involved in an accident or sudden maneuver OPTIONAL WINCH This ve...

Page 43: ...pants or bystanders select the object to which the cable is attached with the following considerations Make sure the object cannot be pulled over or otherwise damaged The object the winch cable is att...

Page 44: ...ntinue to activate the winch remote control The wire cable may become overstressed Do not attempt to pull loads exceeding 1500 lbs 680 kg To pull out the cable the free spool clutch knob must be used...

Page 45: ...uired and load attachment Do not pull at an angle This will cause the wire cable to pile up on one end of the winch This may jam the winch causing damage to the cable and or the winch Pulling the vehi...

Page 46: ...4 14 OPERATING PROCEDURES Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 4...

Page 47: ...USE REPLACEMENT 5 8 VEHICLE WITH DISCHARGED BATTERY 5 8 TRANSPORTING VEHICLE 5 9 Towing 5 9 Neutral Lock 5 9 Hauling 5 9 SERVICE AND MAINTENANCE 5 10 ROUTINE MAINTENANCE 5 11 Tire Inspection 5 11 Rear...

Page 48: ...icular attention to all Notices Cautions Warnings and Dangers 5 2 5 Cleaning the Air Filter Element 5 19 Pre Cleaner Service 5 20 Cartridge Service 5 20 LUBRICATION 5 20 SPARK PLUGS 5 21 PROLONGED STO...

Page 49: ...mercial plastic polish or Plexus plastic cleaner available from the service parts department Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied...

Page 50: ...d terrain When driving at full speed on a dirt road loose surfaces or wet grass vehicle stopping distance will increase If the vehicle is fully loaded it will take longer to stop than with no load Whe...

Page 51: ...at the areas indicated only Lifting The Vehicle 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 vehi...

Page 52: ...ld be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for rec ommended tire inflation pressure For outdoor applications with major use on grassy areas the following shoul...

Page 53: ...ve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten the lug nuts 1 in a cross sequence pattern Tighten the lug nuts to 50 to 85 ft lbs 68 to 115 Nm torque in 20 ft lbs 27...

Page 54: ...o replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new automo tive type fuse Headlight and taillight bulbs and fuses are available from a local Distr...

Page 55: ...ion To activate the direc tion selector pull the lock lever out of the slot and rotate counter clockwise until it snaps into the detent position in the direction selector bracket Hauling To reduce the...

Page 56: ...turn off all electrical loads from the battery before removing battery wires Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench shorting out a battery which could result in an...

Page 57: ...t five years is the periodic inspection of the rear axle for lubricant leakage Unless leakage is evident the lubricant need only be replaced after five years Refer to the Service and Repair Man ual fo...

Page 58: ...t gets hot Do not overfill Check that the oil cap is firmly in place When adding oil between oil changes do not mix brands and viscosity grades of oil The oil dipstick fill cap must be in place before...

Page 59: ...isture that has accumulated during storage Be aware that engine fluids may be hot and contact to the skin may cause severe burns Wear rubber gloves to protect skin from exposure to the old oil and deg...

Page 60: ...n lbs 7 0 Nm torque Apply engine oil to the oil filter seal and install oil filter onto the engine until the seal contacts mounting surface of the engine Then turn the filter 2 3 to 3 4 rotations by H...

Page 61: ...ket 3 4 3 8 drive 1 The starter generator belt tension should be checked after the first 15 20 hours and set to 75 80 lbs 34 36 kg A loose belt can cause audible vibration and squeal Tighten a new sta...

Page 62: ...tribute to the discharge of the battery To reduce the possibility of battery explosion that could result in severe injury or death do not use metallic spray wand to clean battery and keep all smoking...

Page 63: ...r known to be good vehicle and recording the stopping location or stopping distance For fleets of vehicles several vehicles should be tested when new and the range of stopping locations or dis tances...

Page 64: ...uld be cleaned Cleaning will assure an adequate supply of air to the cooling fins Compressed air may be used for routine cooling system mainte nance REAR AXLE The rear axle is provided with a lubrican...

Page 65: ...o let debris fall into the carburetor when servicing the air cleaner To prevent water entering air cleaner and causing starting or engine problems replace air clean er cover making sure the entire fla...

Page 66: ...inspect Replace if too dirty to clean or at the first sign of filter paper deterioration Clean cartridge by gently tapping on a flat sur face Do not use petroleum solvents pressurized water or compres...

Page 67: ...sible explosion 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...

Page 68: ...ten the carburetor drain screw Remove spark plug and pour about 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...

Page 69: ...n previous table the following WIRING Check all wiring for loose connections and broken missing insulation ACCELERATOR Check for smooth movement DO NOT LUBRICATE CABLE SERVICE BRAKE MECHANICAL BRAKES...

Page 70: ...rdware AIR FILTER ELEMENT Check filter element clean replace as required OIL FILTER Replace at oil change ENGINE OIL Replace with SAE 10W 30 or 10W 40 that meets or exceeds SF SG CC oil DO NOT OVERFIL...

Page 71: ...d hardware is Grade 2 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 T...

Page 72: ...5 26 MAINTENANCE Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes 5...

Page 73: ...ad all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers TABLE OF CONTENTS FOR APPENDIX A TITLE PAGE NO DECLARATION O...

Page 74: ...A 2 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

Page 75: ...A 3 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers DECLARATION OF CONFORMITY...

Page 76: ...APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers A 4 DECLARATION OF CONFORMITY CONTINUED...

Page 77: ...A 5 Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers APPENDIX A...

Page 78: ...A 6 APPENDIX A Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions Warnings and Dangers Notes...

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Page 80: ...Griffin Road Augusta Georgia 30906 3852 USA 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 De...