Cushman SHUTTLE 4X User manual

TECHNICIAN’S REPAIR AND SERVICE MANUAL
ELECTRIC POWERED UTILITY VEHICLES
625615
REVISED AUGUST 2012ISSUED MARCH 2012

SAFETY
WASH HANDS
AFTER HANDLING!
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
WAS H HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
CONTAIN LEAD
AND RELATED PARTS
BATTERY WARNING
BATTERIES
!
<
˚
25
DO NOT
DRIVE ACROSS
SLOPES IN
EXCESS OF 14˚
( NOTICES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER )
A NOTICE indicates a condition that should be observed.
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.
Engine exhaust from this product contains
chemicals known, in certain quantities, to
cause cancer, birth defects, or other reproduc-
tive harm.
Battery posts, terminals and related accesso-
ries contain lead and lead compounds. Wash
hands after handling.
NOTICE
NOTICE
NOTICE
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
prevent 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”.
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 NOTICES, CAUTION and WARNING and will be used.
Observe these NOTICES, 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.
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
manufacture.Significant fines could result from modifications or
tampering with the engine, fuel, ignition or air intake systems.
This spark ignition system meets all requirements of the
Canadian Interference-Causing Equipment Regulations.
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleur
du Canada.

Page i
Repair and Service Manual
SERVICE AND REPAIR MANUAL
ELECTRIC POWERED
UTILITY VECHICLE
SHUTTLE 4X
STARTING MODEL YEAR 2012
DISCLAIMER: 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 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
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]

Page ii Repair and Service Manual
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 batteries may void the warranty.
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).
For winter storage, the batteries must be clean, fully charged and disconnected from any
source of electrical drain. The battery charger and the controller are both sources of
electrical drain. Unplug the battery charger DC plug from the vehicle receptacle.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
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
Repair and Service Manual
TITLE PAGE
TABLE OF CONTENTS
SAFETY .................................................................................................................INSIDE COVERS
GENERAL INFORMATION.............................................................................................................. II
SAFETY INFORMATION .................................................................................................................V
TITLE SECTION
GENERAL INFORMATION & ROUTINE MAINTENANCE ..............................................................A
SAFETY ...........................................................................................................................................B
BODY...............................................................................................................................................C
WHEELS AND TIRES......................................................................................................................D
FRONT SUSPENSION AND STEERING ........................................................................................E
SPEED CONTROL...........................................................................................................................F
MOTOR........................................................................................................................................... G
BATTERIES & CHARGING..............................................................................................................H
ELECTRICAL SYSTEM ................................................................................................................... J
BRAKES...........................................................................................................................................K
BATTERY CHARGER......................................................................................................................L
REAR SUSPENSION......................................................................................................................M
REAR AXLE.....................................................................................................................................N
WEATHER PROTECTION...............................................................................................................P
HANDHELD DIAGNOSTICS........................................................................................................... Q
TROUBLESHOOTING.....................................................................................................................R
LIGHTNING PROTECTION & GROUNDING ..................................................................................S
GENERAL SPECIFICATIONS .........................................................................................................T

Page iv Repair and Service Manual
NOTES:
TABLE OF CONTENTS
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Page v
Repair and Service Manual
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
This manual has been designed to assist the owner-operator 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 and/or property damage, the
following instructions must be carefully observed:
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 the owner-operator read this entire manual
paying particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that
employees and other operators be encouraged to do the same.
If you have any questions, contact your closest representative or write to the address on the back cover of this
publication, Attention: Customer Care Department.
E-Z-GO Division of Textron 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 Division of Textron 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.
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 Motor Vehicle
Safety Standards 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.
With electric powered vehicles, be sure that all electrical accessories are grounded directly to the battery (-) post.
Never use the chassis or body as a ground connection.
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, increase the speed or extend the stopping distance beyond the factory specification.
Such modifications can result in 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 dis-
claims 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.

Page vi Repair and Service Manual
B
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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 your vehicle in accordance with the manufacturer’s periodic service schedule.
ensure that mechanics performing repairs are trained and qualified to do so.
follow the manufacturer’s directions if you do any maintenance on your 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 batteries 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 safety stands. Never get under a vehicle that is supported by a jack. Lift
the vehicle in accordance with the manufacturer’s instructions.
Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking.
be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated.
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.

Page vii
Repair and Service Manual
B
B
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
ALWAYS:
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.
VENTILATION
Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4%.
Because hydrogen gas is lighter than air, it will collect in the ceiling of buildings necessitating proper ventilation. Five
air exchanges per hour is considered the minimum requirement.
Never charge a vehicle in an area that is subject to flame or spark. Pay particular attention to natural gas or propane
gas water heaters and furnaces.
use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the receptacle
when the charger is in operation.
Chargers must be installed and operated in accordance with charger manufacturers recommendations or applicable
electrical code (whichever is more restrictive).

Page viii Repair and Service Manual
Notes:
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TABLE OF CONTENTS FOR SECTION ‘A’
SECTION TITLE PAGE NO.
Page A-i
Repair and Service Manual
GENERAL INFORMATION & ROUTINE MAINTANENCE
SERIAL NUMBER LOCATION.................................................................................A - 1
TRANSPORTING VEHICLE .....................................................................................A - 1
Towing .............................................................................................................A - 1
Hauling.............................................................................................................A - 1
SERVICING THE ELECTRIC VEHICLE....................................................................A - 1
ROUTINE MAINTENANCE...................................................................................... A - 2
REAR AXLE..............................................................................................................A - 2
BRAKES...................................................................................................................A - 2
TIRES........................................................................................................................A - 2
LIGHT BULB REPLACEMENT.................................................................................A - 2
VEHICLE CLEANING AND CARE............................................................................A - 2
VEHICLE CARE PRODUCTS...................................................................................A - 3
SUN TOP AND WINDSHIELD ..................................................................................A - 3
HARDWARE.............................................................................................................A - 4
TORQUE SPECIFICATIONS ....................................................................................A - 4
PERIODIC SERVICE SCHEDULE............................................................................A - 5
LIST OF ILLUSTRATIONS
Fig. 1 Initial Service Chart .....................................................................................A - 2
Fig. 2 Lubrication Points........................................................................................A - 2
Fig. 3 Torque Specifications..................................................................................A - 4
Fig. 4 Periodic Service Schedule...........................................................................A - 5

Page A-ii Repair and Service Manual
Notes:
GENERAL INFORMATION & ROUTINE MAINTANENCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

Page A-1
Repair and Service Manual
GENERAL INFORMATION & ROUTINE MAINTANENCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
SERIAL NUMBER LABEL
LOCATION
Two serial number and manufacture date code label are
on the vehicle. One is placed on the body below the
front, driver side of the seat. The other is located on the
chassis under the seat.
Design changes take place on an ongoing basis. In
order to obtain correct components for the vehicle, the
manufacture date code, serial number and vehicle
model must be provided when ordering service parts.
TRANSPORTING VEHICLE
Towing
This vehicle is not designed to be towed.
It is recommended that the vehicle be moved by placing
the entire vehicle on a trailer, flatbed truck or other
suitable transport.
Hauling
To reduce the possibility of severe injury or
death while transporting vehicle:
Secure the vehicle and contents.
Never ride on vehicle being transported.
Always remove windshield before
transporting.
Maximum speed with sun top installed is
50 mph (80 kph).
If the vehicle is to be transported at highway speeds,
the sun top must be removed and the seat bottom
secured. When transporting vehicle below highway
speeds, check for tightness of hardware and cracks in
sun top at mounting points. Always remove windshield
when transporting. Always check that the vehicle and
contents are adequately secured before transporting.
The rated capacity of the trailer or truck must exceed
the weight of the vehicle (see GENERAL SPECIFICA-
TIONS for vehicle weight) and load plus 1000 lbs. (454
kg). Lock the park brake and secure the vehicle using
ratchet tie downs.
SERVICING THE ELECTRIC
VEHICLE
To prevent severe injury or death, resulting
from improper servicing techniques, observe
the following Warnings:
Do not attempt any type of servicing opera-
tions before reading and understanding all
notes, cautions and warnings in
this manual.
Any servicing requiring adjustments to be
made to the powertrain while the motor is
running must be made with both drive
wheels raised.
Wear eye protection when work-
ing on the vehicle. In particular,
use care when working around
batteries, or using solvents or
compressed air.
To reduce the possibility of causing an
electrical arc, which could result in a bat-
tery explosion, turn off all electrical loads
from the batteries before removing any
heavy gauge battery wires.
To prevent the possibility of motor
disintegration, never operate vehicle at full
throttle for more than 4 - 5 seconds while
vehicle is in a “no load” condition.
It is in the best interest of both vehicle owner and ser-
vicing dealer to carefully follow the procedures recom-
mended in this manual. Adequate preventive
maintenance, applied at regular intervals, is the best
guarantee for keeping the vehicle both dependable and
economical.
Before a new vehicle is put into operation, it is recom-
mended that the items shown in the INITIAL SERVICE
CHART be performed (Ref. Fig. 1).
Vehicle batteries must be fully charged before initial
use.

Page A-2 Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTANENCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Fig. 1 Initial Service Chart
ROUTINE MAINTENANCE
Some maintenance items must be serviced more frequently on
vehicles used under severe driving conditions.
This vehicle will give years of satisfactory service
provided it receives regular maintenance. Refer to the
Periodic Service Schedule for appropriate service inter-
vals (Ref. Fig. 4). Refer to Lubrication Point for
appropriate lubrication location (Ref. Fig. 2).
Fig. 2 Lubrication Points
Do not use more than three pumps of grease for each
grease fitting at any one time- Excess grease may
cause grease seals to fail or grease migration into
areas that could damage components.
Putting more than three pumps of grease in a grease fit-
ting could damage grease seals and cause premature
bearing failure.
REAR AXLE
The only maintenance required for the first five years is
the periodic inspection of the lubricant level. The rear
axle is provided with a lubricant level check/fill plug
located on the bottom of the differential. Unless leakage
is evident, the lubricant need to be only replaced after
five years. The procedure to follow for checking the rear
axle lubricant level is in the REAR AXLE section.
BRAKES
After the vehicle has been put into service, it is recom-
mended that the brakes be checked daily by performing
a brake test.
To prevent severe injury or death resulting
from operating a vehicle with improperly oper-
ating brake system, the braking system must
be properly maintained. All driving brake tests
must be done in a safe location with regard for
the safety of all personnel.
For information on conducting a brake test, refer to
BRAKES section.
TIRES
Tire condition should be inspected per the Periodic
Service Schedule. Inflation pressures should be
checked when the tires are cool. Be sure to reinstall
valve dust cap after checking or inflating. For additional
information, refer to WHEELS AND TIRES section.
LIGHT BULB REPLACEMENT
Refer to ELECTRICAL SYSTEM for information regard-
ing light bulb replacement.
VEHICLE CLEANING AND CARE
When pressure washing vehicle, do not use pressure in
excess of 700 psi (4826 kPa). To prevent cosmetic
damage, do not use any abrasive or reactive solvents
to clean plastic parts.
It is important that proper techniques and cleaning
materials be used. Using excessive water pressure may
ITEM SERVICE OPERATION
Batteries Charge batteries
Seats Remove protective plastic covering
Brakes Check operation and adjust if necessary
Establish acceptable stopping distance
Check hydraulic brake fluid level
Tires Check air pressure (see SPECIFICATIONS)
Portable
Charger
Remove from vehicle and properly mount
NOTICE
View From Underside Of Vehicle
Rack Ball Joint
Ref Lub 1

Page A-3
Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTANENCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
cause damage to seals, plastics, the electrical system,
body finish or seat material. Do not use pressure in
excess of 700 psi (4826 kPa) to wash vehicle.
Normal cleaning of vinyl seats and plastic or rubber trim
require the use of a mild soap solution applied with a
sponge or soft brush and wipe with a damp cloth.
Removal of oil, tar, asphalt, shoe polish, etc. will require
the use of a commercially available vinyl/rubber cleaner.
The painted surfaces of the vehicle provide attractive
appearance and durable protection. Frequent washing
with lukewarm or cold water is the best method of
preserving those painted surfaces.
Do not use hot water, strong soap or harsh chemical
detergents.
Rubber parts should be cleaned with non-abrasive
household cleaner.
Occasional cleaning and waxing with non-abrasive
products designed for ‘clear coat’ automotive finishes
will enhance the appearance and durability of the
painted surfaces.
Corrosive materials used as fertilizers or for dust control
can collect on the underbody of the vehicle. These
materials will accelerate corrosion of underbody parts. It
is recommended that the underbody be flushed occa-
sionally with plain water. Thoroughly clean any areas
where mud or other debris can collect. Sediment packed
in closed areas should be loosened to ease its removal,
taking care not to chip or otherwise damage paint.
VEHICLE CARE PRODUCTS
To help maintain the vehicle, there are several products
available through local Distributors, authorized
Branches, or the Service Parts Department.
• Touch-up paint specially formulated to match
vehicle colors for use on TPE (plastic) bodies
(P/N 28140-G** and 28432-G**).
• Multi-purpose Battery Protectant formulated to
form a long-term, flexible, non-tacky, dry coating
that will not crack, peel or flake over a wide
temperature range (P/N 606312).
• Multi-purpose Hand Cleaner is an industrial
strength cleaner containing no harsh solvents, yet
gently lifts grease off hands. May be used with or
without water (P/N 607636).
• Battery Maintenance Kit for complete battery
cleaning and watering, with battery maintenance
instructions (P/N 25587-G01).
• Plexus plastic cleaner and polish removes minor
scratches from windshield (P/N 606314).
SUN TOP AND WINDSHIELD
The sun top does not provide protection from
roll over or falling objects.
The windshield does not provide Complete
protection from tree limbs or flying objects.
The sun top and windshield are designed for weather
protection only.
Clean with lots of water and a clean cloth. Minor
scratches may be removed using a commercial plastic
polish or Plexus plastic cleaner available from Service
Parts Department.

Page A-4 Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTANENCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
HARDWARE
Periodically the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref. Fig. 3).
Use care when tightening fasteners and refer to the
Technician’s Repair and Service Manual for specific
torque values.
Generally, two grades of hardware are used in the
vehicle.
• Grade 5 hardware can be identified by the three
marks on the hexagonal head.
• Unmarked hardware is Grade 2.
TORQUE SPECIFICATIONS
Fig. 3 Torque Specifications
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.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
4
(5)
8
(11)
15
(20)
24
(33)
35
(47)
55
(75)
75
(102)
130
(176)
125
(169)
190
(258)
Grade 5
Grade 8
6
(8)
13
(18)
23
(31)
35
(47)
55
(75)
80
(108)
110
(149)
200
(271)
320
(434)
480
(651)
6
(8)
18
(24)
35
(47)
55
(75)
80
(108)
110
(149)
170
(230)
280
(380)
460
(624)
680
(922)
BOLT SIZE
Class 5.8
(Grade 2)
M4 M5 M6 M8 M10 M12 M14
1
(2)
2
(3)
4
(6)
10
(14)
20
(27)
35
(47)
55
(76.4)
Class 8.8
(Grade 5)
2
(3)
4
(6)
7
(10)
18
(24)
35
(47)
61
(83)
97
(131)
Class 10.9
(Grade 8)
3
(4)
6
(8)
10
(14)
25
(34)
49
(66)
86
(117)
136
(184)
5.8
8.8
10.9
Ref Tsp 1

Page A-5
Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTANENCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
PERIODIC SERVICE SCHEDULE
- CHECK C&A - CHECK & ADJUST CL - CLEAN R- REPLACE
*Use only distilled or purified water that is free of contaminants to fill batteries.
REMARKS
before each use DAILY
20 rnds/20 hrs 100 miles/160 kms MONTHLY
60 rnds/60 hrs 300 miles/500 kms QUARTERLY 125 rnds/125 hrs 600miles/1000 kms SEMI-ANNUAL 250 rnds/250 hrs 1200miles/2000 kms ANNUAL 5 YEARS PAGE
Tires - pressure, condition of tires & rims   
Hardwares and Fasteners - loose or missing   
Reverse Warning Indicator    
Overall Vehicle Condition    
Batteries - state of charge, condition, loose terminals,
corrosion, hold down & hardware CL CL CL CL
Batteries* - check electrolyte level, fill if required C&A C&A C&A C&A
Brakes - smooth operation of pedal, Fluid , stopping
distance    
Brakes - aggressive stop test, does brake hold on a hill 
Accelerator - smooth operation    
Wiring - loose connections, broken or missing insulation 
Charger Receptacle - clean connections CL CL CL CL
Steering Assembly - excessive play, loose or missing
hardware 
Tie Rods - excessive play, bent rods, loose or missing
hardware 
Rear Axle - oil leakage, noise, loose or missing
hardware 
Rear Axle - drain & replace fluid R
Front Suspension - strut oil leakage, excessive play in
hubs or kingpins, worn bushings, loose or missing
hardware 
Front Wheel Alignment - unusual tire wear, missing lug
nuts. C&A C&A C&A
Rear Suspension - shock oil leakage, worn bushings,
loose or missing hardware 
Motor Coupling - Add Anti - Sieze compound
(Apporx 1 tablespoon)
20,000
AMP-
Hrs
Fig. 4 Periodic Service Schedule

Page A-6 Repair and Service Manual
Notes:
GENERAL INFORMATION & ROUTINE MAINTANENCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

TABLE OF CONTENTS FOR SECTION ‘B’
SECTION TITLE PAGE NO.
Page B-i
Repair and Service Manual
SAFETY
NOTICES, CAUTIONS WARNINGS AND DANGERS..............................................B - 1
IMPORTANT SAFETY WARNING ............................................................................B - 1
MODIFICATIONS TO VEHICLE................................................................................B - 1
GENERAL MAINTENANCE......................................................................................B - 1
BEFORE SERVICING THE VEHICLE.......................................................................B - 1
Additional Warnings..........................................................................................B - 2
BATTERY REMOVAL & INSTALLATION.................................................................B - 3
LIFTING THE VEHICLE ............................................................................................B - 4
LIST OF ILLUSTRATIONS
Fig. 1 Battery Connections....................................................................................B - 3
Fig. 2 Lifting the Vehicle .......................................................................................B - 4

Page B-ii Repair and Service Manual
Notes:
SAFETY
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.