Bad Boy HD G User manual

HD & LTO GAS
OWNER'S MANUAL
617 816
ISSUED JANUARY 2011 REVISED AUGUST 2012

SAFETY
(NOTES, CAUTIONS, WARNINGS and DANGERS CONTINUED ON INSIDE OF BACK COVER)
For any questions on material contained in this manual, contact an authorized representative for clarification.
Read and understand all labels located on the vehicle. Always replace any damaged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre-
vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed
on level ground. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.
Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.
If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of
situation that could result in an unsafe condition.
Be sure that this manual remains as part of the permanent service record should the vehicle be sold.
WASH HANDS
AFTER HANDLING!
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
BATTERY WARNING
WASH HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals 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 14˚
Throughout this guide NOTE, CAUTION, WARNING
and DANGER will be used.
Address practices not related to personal injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if
not avoided, will result in death or serious
injury.
Please observe these NOTES, CAUTIONS, WARN-
INGS and DANGERS; be aware that servicing a vehicle
requires mechanical skill and a regard for conditions
that could be hazardous. Improper service or repair may
damage the vehicle or render it unsafe.
Engine exhaust from this product contains
chemicals known, in certain quantities, to
cause cancer, birth defects, or other reproduc-
tive harm.
The exhaust emissions of this vehicles’ engine complies with
regulations set forth by the Environemntal Protection Agency
(EPA) of the United States of America (USA) at time of manu-
facture. Significant fines could result from modifications or
tampering with the engine, fuel, ignition or air intake systems.
Battery posts, terminals and related accesso-
ries contain lead and lead compounds. Wash
hands after handling.
This spark ignition system meets all requirements of the Cana-
dian Interference-Causing Equipment Regulations.
NOTICE
NOTICE
NOTICE
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleur
du Canada.

Page i
OWNER’S GUIDE
GASOLINE POWERED
UTILITY VEHICLE
HD G
LTO G
Starting Model Year 2011
The E-Z-GO Division of Textron Inc. (e-z-go) reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to
include these changes on units leased/sold previously.
The information contained in this Manual may be revised periodically by E-Z-GO and therefore is subject to 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 INFORMATION AND MATERIALS IN THIS MANUAL.
These are the original instructions as defined by 2006/42 EC.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: [phone]
INTERNATIONAL: PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Page ii
GENERAL INFORMATION
This vehicle has been designed and manufactured in the United States of America (USA) as
a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in
the USA unless otherwise indicated.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Overfilling battery may 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 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
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
Afullychargedbatterywillnot freeze in wintertemperaturesunless the temperature falls
below -75° F (-60° C).
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer
or lead smelter for recycling. For neutralized spills, place residue in acid-resistant
containers with absorbent material, sand or earth and dispose of in accordance with local,
state and federal regulations for acid and lead compounds. Contact local and/or state
environmental officials regarding disposal information.

Page iii
TABLE OF CONTENTS
SAFETY ................................................................................................................inside covers
GENERAL INFORMATION ........................................................................................................ii
SAFETY INFORMATION ...........................................................................................................v
LABELS AND PICTOGRAMS...................................................................................................ix
WELCOME .................................................................................................................................1
BEFORE INITIAL USE ...............................................................................................................1
Initial Service Chart ................................................................................................................... 1
CONTROLS AND INDICATORS ...............................................................................................1
KEY/LIGHT SWITCH.......................................................................................................................................... 2
Key/Light Switch and Fuel Gauge ............................................................................................. 2
DIRECTION SELECTOR..................................................................................................................................... 2
Direction Selector ...................................................................................................................... 2
CHOKE ................................................................................................................................................................ 2
Choke ........................................................................................................................................ 2
FUEL GAUGE...................................................................................................................................................... 2
LOW OIL PRESSURE INDICATOR LIGHT......................................................................................................... 2
ACCELERATOR PEDAL ..................................................................................................................................... 3
COMBINATION SERVICE AND PARK BRAKE PEDAL...................................................................................... 3
Accelerator, Brake and Horn ..................................................................................................... 3
HORN................................................................................................................................................................... 3
12 VOLT POWER OUTLET................................................................................................................................. 3
12 Volt Power Outlet ................................................................................................................. 3
TERRAIN.....................................................................................................................................3
WINCH................................................................................................................................................................. 3
OPERATION OF THE WINCH............................................................................................................................. 3
Winch 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 .......................................................... 5
Do Not Hook Cable to Itself ....................................................................................................... 6
Do Not Pull at Angle .................................................................................................................. 6
COMMON SENSE OPERATION ................................................................................................6
ENVIRONMENTAL CONCERNS................................................................................................7
VEHICLE CAPACITY..................................................................................................................7
MODIFICATIONS TO VEHICLE ................................................................................................. 7
LOAD BED..................................................................................................................................7
Load Bed Configurations and Capacities .................................................................................. 8
MANUAL LIFT BED ............................................................................................................................................. 8
Manual Bed Latch ..................................................................................................................... 8
ELECTRIC LIFT BED OPERATION .................................................................................................................... 8
Electric Lift Switch ..................................................................................................................... 8
TAIL GATE OPERATION..................................................................................................................................... 8
SEATING.....................................................................................................................................8
VEHICLES EQUIPPED WITH CONVERTIBLE CARRIER.................................................................................. 8
STORAGE...................................................................................................................................9
Cargo Platform........................................................................................................................................ 9
Cargo Platform and Rear Compartment ................................................................................... 9
REAR STORAGE COMPARTMENT ................................................................................................................... 9
GLOVE COMPARTMENTS................................................................................................................................. 9
OPERATING THE VEHICLE ......................................................................................................9
RUN-IN............................................................................................................................................................... 10
Check Oil Level on Dipstick .....................................................................................................10

Page iv
TABLE OF CONTENTS
Clean Entire Dipstick ...............................................................................................................10
COLD STARTING.............................................................................................................................................. 10
STARTING AND DRIVING................................................................................................................................. 11
STARTING THE VEHICLE ON A HILL..............................................................................................................11
COASTING.........................................................................................................................................................11
FUEL..................................................................................................................................................................11
Fuel Tank Location ..................................................................................................................12
BATTERY...........................................................................................................................................................12
LABELS AND PICTOGRAMS............................................................................................................................12
SUN TOP & WINDSHIELD (If Equipped) ..........................................................................................................12
VEHICLE CLEANING AND CARE........................................................................................... 12
VEHICLE CLEANING.........................................................................................................................................12
REPAIR..................................................................................................................................... 13
LIFTING THE VEHICLE.....................................................................................................................................13
Lifting the Vehicle ....................................................................................................................13
WHEELS AND TIRES........................................................................................................................................13
Tire Repair.............................................................................................................................................13
Wheel Installation..................................................................................................................................14
Wheel Installation ....................................................................................................................14
LIGHT BULB REPLACEMENT ..........................................................................................................................14
Headlight Replacement............................................................................................................15
Tail and Brake Light Bulb Replacement ..................................................................................15
FUSE REPLACEMENT......................................................................................................................................15
VEHICLE WITH A DISCHARGED BATTERY....................................................................................................15
TRANSPORTING VEHICLE..................................................................................................... 15
TOWING.............................................................................................................................................................15
HAULING ...........................................................................................................................................................15
NEUTRAL 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
FOUR CYCLE ENGINE............................................................................................................ 20
ENGINE SPECIFICATIONS...............................................................................................................................20
ENGINE DESCRIPTION....................................................................................................................................20
CHECKING OIL LEVEL .....................................................................................................................................20
Clean Entire Dipstick................................................................................................................20
Check Oil Level on Dipstick...................................................................................................... 20
CHANGING THE OIL......................................................................................................................................... 21
Oil Viscosity Chart....................................................................................................................21
Cleaning Top of Engine............................................................................................................21
Remove Oil Filter......................................................................................................................21
Inspect Oil Filter .......................................................................................................................21
Oil Drain Plug ...........................................................................................................................22
Add Engine Oil .........................................................................................................................22
STARTER/GENERATOR BELT TENSION........................................................................................................ 22
Check Belt Tension with Guage...............................................................................................22
Check Belt Tension Manually...................................................................................................23
Adjust Belt Tension ..................................................................................................................23
ADJUSTING THE BELT..................................................................................................................................... 23
BATTERY CLEANING .......................................................................................................................................23
Preparing Acid Neutralizing Solution........................................................................................23
BRAKES.............................................................................................................................................................24
PERIODIC BRAKE TEST FOR MECHANICAL BRAKES..................................................................................24
Typical Brake Performance Test..............................................................................................24
LUBRICATION...................................................................................................................................................25
Lubrication Points.....................................................................................................................25

Page v
TABLE OF CONTENTS
AIR INTAKE AND COOLING FINS ....................................................................................................................25
Cleaning Cooling System with Air.............................................................................................25
REAR AXLE........................................................................................................................................................25
CHECKING THE LUBRICANT LEVEL...............................................................................................................25
Add, Check and Drain Rear Axle Lubricant..............................................................................26
AIR CLEANER INSPECTION AND REPLACEMENT........................................................................................26
Air Cleaner................................................................................................................................26
SPARK PLUG.....................................................................................................................................................26
Gapping the Spark Plug............................................................................................................27
PROLONGED STORAGE..................................................................................................................................27
CAPACITIES 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) ..............................................................................................41
Vehicle Incline Specifications and Turning Clearance Diameter ..............................................42
LABELS AND PICTOGRAMS................................................................................................ A-1
Label Location ........................................................................................................................A-3
VEHICLE WARRANTIES........................................................................................................ B-1
DOMESTIC WARRANTY.................................................................................................................................B-2
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT...................................................................B-3
FEDERAL EMISSION COMPONENT DEFECT WARRANTY.........................................................................B-5
DECLARATION OF CONFORMITY (EUROPE ONLY).......................................................... C-1

Page vi
TABLE OF CONTENTS
NOTES:

Page v
SAFETY INFORMATION
Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.
This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the
manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the
product. To reduce the chance of personal injury or property damage, the following must be carefully observed:
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 20mph. 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 strictures
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 Identification 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 modifications converting E-Z-GO products into LSV’s.
The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE
OPERATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE
STATE REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On
behalf of E-Z-GO, I am directing 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 has reason to believe may be operated in personal transportation applications.
Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or
through the Internet at the web site for the U.S. Department of Transportation - at Dockets and Regulation, then to
Title 49 of the Code of Federal Regulations (Transportation).
GENERAL
All vehicles can be used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impos-
sible to anticipate and warn against every possible combination of circumstances that may occur. No warning can
take the place of good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. E-Z-GO strongly suggests that all users and maintenance personnel read this entire
manual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.
If you have any questions regarding this vehicle, contact your E-Z-GO Dealer or write to the address on the back
cover of this publication, Attention: Customer Care Department.
E-Z-GO reserves the right to make design changes without obligation to make these changes on units previously
sold and 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 CON-
SEQUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL.
This vehicle conforms to the current applicable standard(s) for safety and performance requirements.
These vehicles are designed and manufactured for off-road use. They DO NOT conform to Federal 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 on a limited basis and in accordance with
local ordinances.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.

Page vi
SAFETY INFORMATION
Read all of manual to become familiar with vehicle. Pay attention to all NOTICES, CAUTIONS, WARNINGS and DANGERS.
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 specification. Such modifications can cause serious personal
injury or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance
and may reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer pro-
hibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the
safety of the vehicle.
Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when
used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions,
terrain and common sense.
Operation of the vehicle is limited to persons above the height of 59 inches (150 cm).
GENERAL OPERATION
ALWAYS:
• Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition.
• Read and observe all warnings and operation instruction labels affixed to the vehicle.
• Follow all safety rules established in the area where the vehicle is being operated.
• Leave the vehicle when there is a risk of lightning.
• Reduce speed to compensate for poor terrain or conditions.
• Apply service brake to control speed on steep grades.
• Maintain adequate distance between vehicles.
• Reduce speed in wet areas.
• Use extreme caution 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 accordance with the manufacturer’s periodic service schedule.
• Ensure that repairs are performed by those that are trained and qualified to do so.
• Follow the manufacturer’s maintenance procedures for the vehicle. Be sure to disable the vehicle before performing
any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire.
• Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the
battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material.
• Check the polarity of each battery terminal and be sure to rewire the batteries correctly.
• Use specified replacement parts. Never use replacement parts of lesser quality.
• Use recommended tools.
• Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the
safety of personnel nor jeopardize the safe operation of the vehicle.
• 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 vehicle in an area away from exposed flame or persons who are smoking.
• Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
• Test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both
vehicular and pedestrian traffic.
• Replace damaged or missing warning, caution or information labels.
• Keep complete records of the maintenance history of the vehicle.