Ezgo ST 4X4 User manual

ST 4X4
GASOLINE POWERED 4 WHEEL DRIVE
UTILITY VEHICLE
STARTING MODEL YEAR: 2004
TECHNICIAN’S
REPAIR AND SERVICE MANUAL
600392
Ref Fcv 19

SAFETY
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
NOTES, CAUTIONS AND WARNINGS
Throughout this guide NOTE, CAUTION and WARNING
will be used. ANOTE 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.
Please observe these NOTES, CAUTIONS and WARN-
INGS; 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 chemi-
cals known, in certain
quantities, to cause cancer, birth defects, or other re-
productive harm.
The exhaust emissions of this vehicles’ engine
is regulated by the Federal EPA. Significant
fines could result from modifications or tampering with the
engine, fuel, ignition or air intake systems.
Battery posts, terminals
and related accessories
contain lead and lead
compounds. Wash hands after handling.
This spark ignition system meets all require-
ments of the Canadian Interference-Causing
Equipment Regulations.
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! !
! !
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleu
r
du Canada.
Read and understand all labels located on the vehicle. For any questions on any of the information, contact a represen-
tative for clarification.
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 vehicle specification.) Limit speed by applying the service brake.
Catastrophic damage to the drive train 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.
If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of
situations that could result in an unsafe condition.
Be sure that this manual remains as part of the permanent service record should the vehicle be re-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

Page i
Repair and Service Manual
TECHNICIAN’S
REPAIR AND SERVICE
MANUAL
GASOLINE POWERED
4 WHEEL DRIVE UTILITY VEHICLE
ST 4X4
E-Z-GO Division of Textron Inc., reserves the right to make design changes without obligation to make these changes on units previously sold and the informa-
tion contained in this manual is subject to change without notice.
E-Z-GO Division of Textron Inc., is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this
manual.
CUSTOMER SERVICE DEPARTMENT IN USA PHONE: [phone] FAX: [phone]
OUTSIDE USA PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906-3852

Page ii
NOTES
Repair and Service Manual
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local
distributor, authorized Branch or Warranty Department with vehicle serial number and
manufacturer code.
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 Federal and State emission certification.
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).

Page iii
Repair and Service Manual
TABLE OF CONTENTS
TITLE PAGE
Safety...........................................................................................................................Inside Covers
Notes.................................................................................................................................................ii
Safety Information............................................................................................................................ v
TITLE SECTION
General Information & Routine Maintenance...................................................................................A
Safety...............................................................................................................................................B
Body and Truckbed ..........................................................................................................................C
Brakes..............................................................................................................................................D
Continuously Variable Transmission (CVT)......................................................................................E
Direction and Drive Selector.............................................................................................................F
Electrical.......................................................................................................................................... G
Engine and Transmission.................................................................................................................H
Front Suspension and Steering........................................................................................................ J
Fuel System .....................................................................................................................................K
Paint.................................................................................................................................................L
Rear Axle and Suspension..............................................................................................................M
Speed Control ..................................................................................................................................N
Troubleshooting................................................................................................................................P
Wheels and Tires .............................................................................................................................R
General Specifications .....................................................................................................................S
Limited Warranty..............................................................................................................................T

Page iv Repair and Service Manual
TABLE OF CONTENTS
Notes:

Repair and Service Manual
SAFETY INFORMATION
Page v
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:
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.
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.

Repair and Service Manual
SAFETY INFORMATION
Page vi
• 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.
• 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.

Repair and Service Manual
SAFETY INFORMATION
Page vii
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.

Repair and Service Manual
SAFETY INFORMATION
Page viii
Notes:

TABLE OF CONTENTS FOR SECTION ‘A’
SECTION TITLE PAGE NO.
Page A-i
Repair and Service Manual
A
GENERAL INFORMATION & ROUTINE MAINTENANCE
SERIAL AND MANUFACTURING NUMBER LABEL LOCATIONS.................................................A - 1
SERVICING THE VEHICLE.............................................................................................................A - 1
TOWING...........................................................................................................................................A - 2
JUMP STARTING ............................................................................................................................A - 2
ROUTINE MAINTENANCE..............................................................................................................A - 3
POWERTRAIN MAINTENANCE......................................................................................................A - 3
NEUTRAL POSITION ......................................................................................................................A - 3
BRAKES...........................................................................................................................................A - 4
TIRES...............................................................................................................................................A - 4
CARE AND CLEANING OF THE VEHICLE.....................................................................................A - 4
VEHICLE CARE PRODUCTS..........................................................................................................A - 4
TOP AND WINDSHIELD (IF EQUIPPED)........................................................................................A - 5
TRAILERING....................................................................................................................................A - 5
PROLONGED STORAGE................................................................................................................A - 5
HARDWARE ....................................................................................................................................A - 6
TORQUE SPECIFICATIONS ..........................................................................................................A - 7
CAPACITIES ...................................................................................................................................A - 7
PERIODIC SERVICE SCHEDULE...................................................................................................A - 8
LIST OF ILLUSTRATIONS
Fig. 1 Serial and Manufacturing Number Label Locations ..............................................................A - 1
Fig. 2 Initial Service Chart...............................................................................................................A - 2
Fig. 3 Jump Starting........................................................................................................................A - 3
Fig. 4 Neutral...................................................................................................................................A - 3
Fig. 5 Torque Specifications............................................................................................................A - 7
Fig. 6 Capacities..............................................................................................................................A - 7
Fig. 7 Periodic Service Schedule ....................................................................................................A - 8

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-ii Repair and Service Manual
Notes:

A
Page A-1
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
SERIAL AND MANUFACTURING NUMBER
LABEL LOCATIONS
Supplemental Information Label Location
The supplemental Information label is located on the
driver side of the horizontal frame tube below truck bed
(Ref Fig. 1 on page A-1).
Serial and Manufacturing No. Label Location
The serial and manufacturing number label is located on
the passenger side of the horizontal frame tube below
the truck bed (Ref Fig. 1 on page A-1).
Serial and Manufacturing No. (Stamped)
The serial number and manufacturing number are
stamped on the frame below the truck bed (Ref Fig. 1 on
page A-1).
Serial No. Sticker Location
The serial number is located on the seat support panel
below the choke (Ref Fig. 1 on page A-1).
SERVICING THE VEHICLE
To prevent severe per-
sonal injury or death,
resulting from improper
servicing techniques, observe the following Warn-
ings:
Any servicing requiring adjustments to be made
to the powertrain while the motor is running must
be made with all wheels raised.
Fig. 1 Serial and Manufacturing Number Label Locations
Serial No.
Label
Supplemental Information label
Serial No. & Mfg No.
(Stamped)
Serial No. & Mfg No.
(Label)
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GENERAL INFORMATION & ROUTINE MAINTENANCE

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-2 Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
Wear eye protection when working 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 batteryexplosion, turn
off all electrical loads from the battery before
removing any heavy gauge battery wires.
To prevent the possibility of powertrain failure,
never operate vehicle at full throttle for more than
4 - 5 seconds while vehicle is in a “no load” condi-
tion.
Do not attempt any type of servicing operations before
reading and understanding all notes, cautions and warn-
ings in this manual.
It is in the best interest of both vehicle owner and servic-
ing dealer, to carefully follow the procedures recom-
mended in this manual. Adequate preventative
maintenance, applied at regular intervals, is the best
guarantee for keeping the vehicle both dependable and
economical.
In any product, components will eventually fail to perform
properly as the result of normal use, age, wear or abuse.
It is virtually impossible to anticipate all possible compo-
nent failures or the manner in which each component
may fail.
A vehicle requiring repair indicates the vehicle is no
longer functioning as designed and should be considered
potentially hazardous. Use extreme care when working
on a vehicle. When diagnosing, removing or replacing
any components that are not operating properly, consider
the safety of yourself and those around you, should the
component move unexpectedly.
Some components are heavy, spring loaded, highly cor-
rosive, explosive, may produce amperage or reach high
temperatures. Gasoline, carbon monoxide, battery acid
and hydrogen gas could result in serious bodily injury to
the technician/mechanic and bystanders, if not treated
with the utmost caution. Be careful not to place hands,
face, feet or body in a location that could expose them to
injury, should an unforeseen dangerous situation occur.
Always use the appropriate tools listed in the tool list and
wear approved safety equipment.
Before a new vehicle is put into operation, it is recom-
mended the items shown in the INITIAL SERVICE
CHART be performed (Ref Fig. 2 on page A-2).
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 suit-
able transport.
JUMP STARTING To reduce possibility of
severe personal injury or
death resulting from a
battery explosion, follow jump starting instructions
explicitly.
To reduce possibility of permanent
damage to battery, promptly charge a
discharged battery.
Turn key switch to OFF. Apply parking brake. Place
direction selector in neutral position.
Attach one end of red positive cable to positive post of
weak battery and other end to positive post of strong bat-
tery (Ref Fig. 3 on page A-3). Attach one end of black
negative cable to negative post of strong battery and
other end to the front frame receiver of the vehicle to be
started.
Start vehicle as usual. Once started, disconnect cables in
reverse order and charge the battery as soon as possi-
ble.
Fig. 2 Initial Service Chart
ITEM SERVICE OPERATION
Battery Charge battery
Seats Remove protective plastic covering
Brakes Check operation and adjust if necessary
Check hydraulic brake fluid level
Establish new vehicle braking distance
Tires Check pressure
Fuel Fill tank with correct fuel
Engine Check oil level (Initial change after 5 - 8 hours)
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GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-3
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
ROUTINE MAINTENANCE
Some items must be serviced more frequently
on vehicles used under severe driving condi-
tions.
This vehicle will give years of satisfactory service, pro-
vided it receives regular maintenance. Refer to the Peri-
odic Service Schedule for appropriate service intervals
(Ref Fig. 7 on page A-8). Refer to ‘Lubrication’ in FRONT
SUSPENSION AND STEERING section for appropriate
lubrication locations.
POWERTRAIN MAINTENANCE
To prevent severe per-
sonal injury or death,
always install a positive
stop to prevent load bed from falling.
Wrap wrenches with vinyl tape to prevent the possi-
bility of a dropped wrench ‘shorting out’ a battery,
which could result in an explosion.
To prevent accidental starting, remove and ground
spark plug wires and disconnect battery at negative
terminal before servicing.
Access the powertrain by raising or removing seats. Full
access to powertrain may be obtained by raising the load
bed. Some service procedures may require the vehicle
be lifted (Ref Lifting The Vehicle in SAFETY) for proper
lifting procedure and safety information.
For maintenance procedures relating to the engine,
speed control, fuel system, transmission, and rear axle or
suspension, refer to the particular section. See the
TABLE OF CONTENTS for section location.
NEUTRAL POSITION
To prevent the driven clutch from turning the rear axle/front
axle during any service operations, move direction selector
lever located on the instrument panel to the neutral position
indicated. (Ref Fig. 4 on page A-3)
Fig. 3 Jump Starting
+
-
+
-
Strong
Battery
Weak
Battery
Front of
Vehicle
! !
Fig. 4 Neutral
73777G01
Neutral
Forward
Reverse

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-4 Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
BRAKES To prevent severe per-
sonal injury or death
resulting from operating
a vehicle with an improperly operating 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.
After the vehicle has been put into service, it is recom-
mended that the brakes be checked periodically conduct-
ing a brake performance test.
For test method and brake service, refer to BRAKES
section.
TIRES
Standard tires for this vehicle are uni-direc-
tional and should never be moved from one
side of vehicle to the other. driver side tires should always
remain on the driver side of the vehicle. passenger side tires
should always remain on the passenger side of the vehicle.
Uni-directional tires have an arrow on the sidewall indicating
direction of rotation when moving forward.
Tire condition should be inspected and inflation pres-
sures checked per the Periodic Service Schedule when
tires are cool. Be sure to install the dust valve cap after
checking or inflating tire. For additional information, refer
to WHEELS AND TIRES section.
CARE AND CLEANING OF THE VEHICLE
To reduce possibility of
severe injury or vehicle
damage, read and under-
stand all instructions supplied by manufacturer of
pressure washer.
When pressure washing vehicle, do not
use pressure in excess of 700 psi. To
prevent cosmetic damage, do not use any abrasive or reactive
solvents to clean plastic parts.
If engine does not start or runs improperly after
washing, remove spark plug wires (by pulling
the spark plug boots, never the wires). Dry all connections with
compressed air. Reinstall wires.
It is important that proper techniques and cleaning mate-
rials be used.
Normal cleaning of vinyl seats and plastic or rubber trim
requires 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 pre-
serving the 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 prod-
ucts 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 mate-
rials will accelerate corrosion of underbody parts. It is
recommended that the underbody be flushed occasion-
ally 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
There are several products, available through a local dis-
tributor, an authorized Branch, or the Service Parts
Department, to help maintain the vehicle. Among them
are:
•Touch-up paint specially formulated to match vehi-
cle colors for use on both metal and TPE (plastic)
bodies. (P/N 28140-G**, 28432-G** and 75831-
G01)
•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 tem-
perature range. (P/N 75500-G01)
•White Lithium Grease designed to provide lubrica-
tion protection in areas where staining or discolor-
ing is a problem, or in areas of extreme
temperature ranges. (P/N 75502-G01)
•Penetrant/Lubricant, a 4-in-1 product that pene-
trates the most stubborn of frozen parts, lubricates
leaving a light lubricating film, prevents corrosion
by adhering to wet or dry surfaces and displaces
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GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-5
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
moisture, sealing against future moisture return.
(P/N 75503-G01)
•Multi-purpose Cleaner and Degreaser that con-
tains natural, environmentally safe solvents. (P/N
75504-G01)
•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 75505-G01)
•Battery Cleaner that promotes easy, non-violent
neutralization of battery acids and battery acid
crystals. The resulting sodium salts are water sol-
uble and easily washed away. (P/N 75506-G01)
•Biodegradable Cleaner that cleans the toughest
dirt and heavy soils by breaking down grease to
be easily wiped or rinsed away. (P/N 75507-G01)
•Multi-purpose Value Pack sampler package
including 4 ounce (118 ml) aerosol cans of Battery
Protector, Penetrant/Lubricant, White Lithium
Grease, and Carburetor and Choke Cleaner. (P/N
75508-G01)
•Plexus plastic cleaner and polish removes minor
scratches from windshield. (P/N 28433-G**)
TOP AND WINDSHIELD (IF EQUIPPED)
The support structure for
the top and windshield
provide roll over protec-
tion.The top and windshield do not provide protection
from falling objects.
The top and windshield are designed for weather protec-
tion only.
TRAILERING To prevent personal inju-
ry to occupants of other
highway vehicles, be
sure that the vehicle and contents are adequately
secured to trailer.
Do not ride on vehicle being trailered.
Remove windshield before trailering.
Maximum speed with top is 50 mph (80 kph).
If the vehicle is to be transported on a trailer at highway
speeds, the windshield and top must be removed and the
seat bottom secured. Always check that the vehicle and
contents are adequately secured before trailering the
vehicle. The rated capacity of the trailer must exceed the
weight of the vehicle (see GENERAL SPECIFICATIONS
for vehicle weight) and load. Engage the parking brake
and secure the vehicle to the trailer using ratchet tie
downs.
PROLONGED STORAGETo prevent severe per-
sonal injury or death
resulting from a possi-
ble explosion:
Do not handle fuel in an area that is not adequate-
ly ventilated. Do not smoke near the fuel tank or
refuel near open flame or electrical items which
could produce a spark.
Store vehicle in a clean, dry area. Do not store in
same area as a stove, furnace, water heater, or
other appliance that uses a pilot light or has a
device that can create a spark.
Always wear safety glasses to prevent possible
eye injury from gasoline or gasoline vapor.
Keep hands, clothing and jewelry away from mov-
ing parts. Use care not to contact hot objects.
Raise the rear of the vehicle and support on jack
stands before attempting to run the engine.
Preparing the engine for a prolonged storage period (30
days or more) calls for a few simple steps to prevent a
build up of varnish and gum in the carburetor and corro-
sion in the engine.
•Add fuel stabilizer to the fuel tank in accordance
with the directions provided with the additive
shortly before the vehicle is to be stored. If fuel
stabilizer is to be added at the time of storage,
operate the vehicle for several minutes to circulate
the stabilizer throughout the fuel system.
•Raise the rear of the entire vehicle and support on
jack stands. Refer to ‘Lifting the Vehicle’ in Section
B for proper lifting procedure and safety informa-
tion.
•Raise the seat bottom and disconnect the fuel
hose at the fuel tank. Keep end of hose up near
the top of the tank to prevent spilling fuel. With
proper ventilation, place the direction selector in
NEUTRAL, start the engine and allow to run until it
stops due to lack of fuel. Reattach fuel line to tank
and replace seat bottom.
•While engine is still warm, change oil to remove
contaminants. See ENGINE section.
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GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-6 Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
•Remove spark plugs and pour about 1 oz. (30 ml)
of engine oil into each cylinder. Replace spark
plugs, ground spark plug wires and use starter to
turn engine over a few seconds to distribute oil.
•Clean body, chassis and engine of debris, mud,
chaff or grass. See ENGINE section.
HARDWARE
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref Fig. 5 on page
A-7). Use care when tightening fasteners and refer to the
sections in this manual for specific torque values
Generally, two grades of hardware are used in the vehi-
cle. Grade 5 hardware can be identified by the three
marks on the hexagonal head. Unmarked hardware is
Grade 2.

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-7
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
TORQUE SPECIFICATIONS
CAPACITIES
Fig. 5 Torque Specifications
ALLTORQUE 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
Re
f
Ts
p
1
Fig. 6 Capacities
Fuel Tank
Engine Oil
Front Differential
Rear Axle
Transfer Case
6.7 gal (25.4 liters)
unleaded, 87 octane or higher
Refer to Engine Manual
15.2 1 oz (450 ml) of 80 - 90W GL5
+
-
15.2 1 oz (450 ml) of 80 - 90W GL5
+
-
24 oz (700 ml) MOBILFLUID 424

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-8 Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
PERIODIC SERVICE SCHEDULE.
ITEM
BEFORE
EACH
USE WEEKLY
EVERY
20
HOURS
EVERY
50
HOURS
EVERY
100
HOURS
EVERY
200
HOURS
EVERY
300
HOURS
EVERY
500
HOURS SEE PAGE *
Service Brake
(Pedal Pressure) Check X
(Fluid Level) Check X
(Pads & Shoes) Inspect X
(Rotors & Drums) Clean X
Park Brake Clean X X
Reverse Warning Buzzer (if
equipped) Check X
Tires Check X X
Overall Vehicle Condition Check X
Wheels Check X
Fuel Gauge Check X
Alternator Belt Check X
Engine Fan and Cooling Fins Clean X
CVT Enclosure Clean X#
Wiring Check X
Accelerator Check X
Choke Check X
Carburetor Linkage Check X
Direction Selector Check X
Engine Oil Check X
Change X ** X
Engine Oil Filter Replace X
Air Filter Check X
Clean X#
Replace X#
Spark Plugs Check X
Replace X
Idle Speed Check X**
Valve Clearance Check X**
Fuel Filter Check X
Replace X
Combustion Chamber Clean X
Steering Check X
Fig. 7 Periodic Service Schedule