Cushman BELLHOP 2 User manual

A Textron Company
OWNER’S MANUAL
AND SERVICE GUIDE
ISSUED OCTOBER 2007 REVISED JUNE 2012
GASOLINE POWERED
PERSONNEL CARRIERS
AND GOLF CAR
606893

SAFETY
(NOTES, CAUTIONS AND WARNINGS 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 moving/transporting vehicle, refer to “TRANSPORTING VEHICLE”.
Signs similar to the ones illustrated should be used to warn of situations 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. Throughout this
guide NOTE, CAUTION and WARNING will be used.
Observe these NOTES, CAUTIONS and WARNINGS; 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.
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˚
A NOTE indicates a condition that should be observed.
A CAUTION indicates a condition that may result in
damage to the vehicle.
A WARNING indicates a hazardous condition
that could result in severe injury or death.
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 Environmental Protection Agency
(EPA) of the United States of America (USA) at time of manu-
facture. Significant fines could result from modifications or tam-
pering 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.
C
e système d'allumage par étincelle de véhicule respecte
t
outes les exigences du Règlement sur le matériel brouilleu
r
d
u Canada.

Page i
Owner’s Manual and Service Guide
OWNER’S MANUAL AND
SERVICE GUIDE
GASOLINE POWERED
CARGO, PERSONNEL CARRIER
AND GOLF CAR
VEHICLES
BELLHOP 2
BELLHOP 4
BELLHOP 6
Starting Model Year 2008
The E-Z-GO Division of Textron Inc. 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 the E-Z-GO Division, and therefore is subject to change without notice.
The E-Z-GO Division DISCLAIMS LIABLITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCI-
DENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
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 Owner’s Manual and Service Guide
NOTES
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.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75° F (-60° C).

Owner’s Manual and Service Guide Page iii
TABLE OF CONTENTS
SAFETY............................................................................................................ INSIDE COVERS
NOTES.........................................................................................................................................II
SAFETY INFORMATION............................................................................................................V
BEFORE INITIAL USE ................................................................................................................1
Fig. 1 Initial Service Chart ................................................................................................................... 1
CONTROLS AND INDICATORS ................................................................................................1
KEY/LIGHT SWITCH .......................................................................................................................................... 1
Fig. 2 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge ....................................................... 2
DIRECTION SELECTOR .................................................................................................................................... 2
Fig. 3 Direction Selector ...................................................................................................................... 2
CHOKE ............................................................................................................................................................... 2
Fig. 4 Choke ........................................................................................................................................ 2
FUEL GAUGE ..................................................................................................................................................... 2
LOW OIL PRESSURE INDICATOR LIGHT ........................................................................................................ 2
ACCELERATOR PEDAL .................................................................................................................................... 3
Fig. 5 Accelerator and Brake Controls ................................................................................................ 3
HORN .................................................................................................................................................................. 3
Fig. 6 Horn Button ............................................................................................................................... 3
OPERATING THE VEHICLE ......................................................................................................3
RUN-IN ................................................................................................................................................................ 4
Fig. 7 Check Oil Level on Dipstick ....................................................................................................... 4
COLD STARTING .............................................................................................................................................. 4
STARTING AND DRIVING ................................................................................................................................. 5
STARTING THE VEHICLE ON A HILL ............................................................................................................... 5
COASTING ......................................................................................................................................................... 5
FUEL ................................................................................................................................................................... 6
Fig. 8 Fueling ...................................................................................................................................... 6
BATTERY ............................................................................................................................................................ 6
LABELS AND PICTOGRAMS ............................................................................................................................. 6
SUN TOP AND WINDSHIELD ............................................................................................................................ 7
VEHICLE CLEANING AND CARE ..............................................................................................7
VEHICLE CLEANING ......................................................................................................................................... 7
REPAIR .......................................................................................................................................7
LIFTING THE VEHICLE ...................................................................................................................................... 7
Fig. 9 Lifting the Vehicle ...................................................................................................................... 8
WHEELS AND TIRES ......................................................................................................................................... 8
WHEEL INSTALLATION...................................................................................................................................... 9
Fig. 10 Wheel Installation ...................................................................................................................... 9
LIGHT BULB REPLACEMENT .......................................................................................................................... 10
FUSE REPLACEMENT ..................................................................................................................................... 10
Fig. 11 Headlight, Turn Signal & Marker Light Bulb Replacement ...................................................... 10
VEHICLE WITH A DISCHARGED BATTERY ................................................................................................... 10
Fig. 12 Tail and Brake Light Bulb Replacement .................................................................................. 10
TRANSPORTING VEHICLE .....................................................................................................10
TOWING ........................................................................................................................................................... 10
NEUTRAL LOCK ............................................................................................................................................... 11
Fig. 13 Neutral Lock ............................................................................................................................ 11
HAULING .......................................................................................................................................................... 11
SERVICE AND MAINTENANCE ..............................................................................................11
SERIAL NUMBER PLATE LOCATION ............................................................................................................. 12
Fig. 14 Serial Number Plate Location................................................................................................... 12
PERIODIC SERVICE SCHEDULE .................................................................................................................. 13
Fig. 15 Periodic Service Schedule ...................................................................................................... 13

Owner’s Manual and Service Guide
Page iv
TABLE OF CONTENTS
TIRE INSPECTION ............................................................................................................................................15
FOUR CYCLE ENGINE ............................................................................................................15
ENGINE SPECIFICATIONS...............................................................................................................................15
ENGINE DESCRIPTION ....................................................................................................................................15
CHECKING OIL LEVEL......................................................................................................................................15
Fig. 16 Clean Entire Dipstick.................................................................................................................15
Fig. 17 Check Oil Level on Dipstick......................................................................................................15
CHANGING THE OIL .........................................................................................................................................15
Fig. 18 Oil Viscosity Chart.....................................................................................................................16
Fig. 19 Cleaning Top of Engine ............................................................................................................16
Fig. 20 Remove Oil Filter......................................................................................................................16
Fig. 21 Inspect Oil Filter........................................................................................................................16
Fig. 22 Oil Drain Plug............................................................................................................................17
Fig. 23 Add Engine Oil.............................................................................................................17
STARTER/GENERATOR BELT TENSION ........................................................................................................17
Fig. 24 Check Belt Tension with Guage................................................................................................18
Fig. 25 Check Belt Tension Manually ...................................................................................................18
Fig. 26 Adjust Belt Tension...................................................................................................................18
ADJUSTING THE BELT .....................................................................................................................................18
BATTERY CLEANING........................................................................................................................................18
Fig. 27 Preparing Acid Neutralizing Solution ........................................................................................19
Fig. 28 Typical Brake Performance Test...............................................................................................19
BRAKES .............................................................................................................................................................19
PERIODIC BRAKE TEST FOR MECHANICAL BRAKES ..................................................................................19
AIR INTAKE AND COOLING FINS ....................................................................................................................20
Fig. 29 Cleaning Cooling System with Air.............................................................................................20
REAR AXLE........................................................................................................................................................20
CHECKING THE LUBRICANT LEVEL...............................................................................................................20
AIR CLEANER INSPECTION AND REPLACEMENT ........................................................................................20
Fig. 30 Add, Check and Drain Rear Axle Lubricant..............................................................................21
Fig. 31 Air Cleaner................................................................................................................................21
LUBRICATION....................................................................................................................................................23
Fig. 32 Lubrication Points .....................................................................................................................21
SPARK PLUGS ..................................................................................................................................................22
Fig. 33 Gapping the Spark Plug...............................................................................................22
DIRECTION SELECTOR....................................................................................................................................22
PROLONGED STORAGE ..................................................................................................................................22
HARDWARE.......................................................................................................................................................23
Fig. 34 Torque Specifications and Bolt Grades ....................................................................................23
CAPACITIES AND REPLACEMENT PARTS.....................................................................................................24
Fig. 35 Capacities and Replacement Parts...........................................................................................24
GENERAL SPECIFICATIONS.................................................................................................. 27
BELLHOP 2 GASOLINE POWERED CARGO CARRIER .................................................................................28
BELLHOP 4 GASOLINE POWERED PERSONNEL / CARGO CARRIER ........................................................29
BELLHOP 6 GASOLINE POWERED PERSONNEL CARRIER ........................................................................30
Fig. 36 Vehicle Dimensions .................................................................................................................31
Fig. 37 Vehicle Dimensions Continued.................................................................................................32
Fig. 38 Vehicle Dimensions and Incline Specifications.........................................................................33
Fig. 39 Turning Clearance Diameter & Intersecting Isle Clearance......................................................34
VEHICLE WARRANTIES.......................................................................................................... 37
(U.S. AND CANADA) .........................................................................................................................................38
VEHICLE WARRANTIES FEDERAL 2006 ........................................................................................................39
VEHICLE WARRANTIES CALIFORNIA 2006....................................................................................................41
DECLARATION OF CONFORMITY .........................................................................................43
LABELS AND PICTOGRAMS .................................................................................APPENDIX A

Owner’s Manual and Service Guide Page v
SAFETY INFORMATION
SAFETY
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 FED-
ERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of Fed-
eral 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 OPER-
ATED 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 rea-
son 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 website for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
GENERAL
Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore, it is impossible
to anticipate and warn against every possible combination of circumstances that may occur. No warnings 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. The manufacturer strongly suggests that all users and maintenance personnel read this
entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein.
If you have any questions regarding this vehicle, contact your closest representative or write to the address on the back
cover of this publication, Attention: Product Service Department.
The manufacturer reserves the right to make design changes without obligation to make these changes on units previ-
ously sold and the information contained in this manual is subject to change without notice.
The manufacturer is not liable for errors in this manual or for incidental or consequential damages that result from the
use of the material in this manual.

Owner’s Manual and Service Guide
Page vi
SAFETY INFORMATION
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 commu-
nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi-
nances.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
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 prohibits 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.
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.
• 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

Owner’s Manual and Service Guide Page vii
SAFETY INFORMATION
battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material.
• 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.
• Empty the fuel tank or plug fuel hoses to prevent fuel leakage.
• 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.
The manufacturer cannot anticipate all situations, therefore people attempting to maintain or repair the vehicle must
have the skill and experience to recognize and protect themselves from potential situations that could result in severe
personal injury or death and damage to the vehicle. Use extreme caution and, if unsure as to the potential for injury,
refer the repair or maintenance to a qualified mechanic.
VENTILATION
Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating.
Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane water
heaters and furnaces.
Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Carbon
monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

Owner’s Manual and Service Guide
Page viii
SAFETY INFORMATION
NOTES: