Ezgo 2Five User manual

2Five Electric
Repair & Service Manual
606779
ISSUED: APRIL 2010 REVISED: DECEMBER 2012

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
SAFETY
For any questions on material contained in this manual, contact an authorized representative for clarification.
Read and 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. To prevent loss of vehicle control and
possible serious injury, speeds should be limited to no more than 25 mph.
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.
Observe these NOTICES, CAUTIONS, WARNINGS and Dangers; be aware that servicing a vehicle requires
mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehi-
cle or render it unsafe.
NOTICES, CAUTIONS, WARNINGS AND DANGERS
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˚
Address practices not related to personal injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, will result in death or serious
injury.
Battery posts, terminals and related
accessories contain lead and lead compounds.
Wash hands after handling.
NOTICE
DANGER

Page i
Repair and Service Manual
SERVICE AND REPAIR MANUAL
ELECTRIC POWERED
PERSONAL VEHICLES
2Five 2 PASSENGER
2Five 4 PASSENGER
STARTING YEAR 2010
(MANUFACTURED BEGINNING April 2010)
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 E-Z-GO, and therefore is subject to change without notice.
E-Z-GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSE-
QUENTIAL 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:
SALES 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).
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 as well as 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 batteries must be checked and recharged as required or at a minimum of 30 day
intervals.
TOWING
Set the key switch to ‘N’ and the ‘RUN/TOW’ switch, located under the passenger seat, to the
‘TOW’ position before towing the vehicle.

Page iii
Repair and Service Manual
TABLE OF CONTENTS
TITLE PAGE
SAFETY .......................................................................................................................Inside Covers
MODELS........................................................................................................................................... i
GENERAL INFORMATION...............................................................................................................ii
SAFETY INFORMATION ................................................................................................................. v
TITLE SECTION
GENERAL INFORMATION & ROUTINE MAINTENANCE ..............................................................A
SAFETY ...........................................................................................................................................B
BODY...............................................................................................................................................C
WHEELS AND TIRES......................................................................................................................D
ELECTRONIC SPEED CONTROL (AC MOTOR)............................................................................E
FRONT SUSPENSION ....................................................................................................................F
MOTOR & MOTOR BRAKE............................................................................................................ G
BATTERIES & CHARGING..............................................................................................................H
ON-BOARD BATTERY CHARGER................................................................................................... I
BRAKES........................................................................................................................................... J
ELECTRICAL COMPONENTS & WIRING.......................................................................................K
REAR SUSPENSION....................................................................................................................... L
REAR AXLE.................................................................................................................................... M
WEATHER PROTECTION...............................................................................................................N
TROUBLESHOOTING.................................................................................................................... O
LIGHTNING PROTECTION & GROUNDING ..................................................................................P
SPECIFICATIONS........................................................................................................................... Q

Page iv Repair and Service Manual
TABLE OF CONTENTS
Notes:

SAFETY INFORMATION
Page v
Repair and Service Manual
Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the
manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the
product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully
observed:
GENERAL
All vehicles can be used for a variety of tasks often 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 warning
can replace good common sense and prudent driving practices.
Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings
and instructions combined. E-Z-GO strongly suggests that all users and maintenance personnel read this entire man-
ual paying particular attention to the CAUTIONS, WARNINGS and DANGERS contained therein.
If you have any questions regarding this vehicle, contact your authorized E-Z-GO LSV dealer or write to the address
on the back cover of this publication, Attention: Customer Care Department.
E-Z-GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL. E-Z-GO IS NOT LIABLE FOR INCIDENTAL OR CON-
SEQUENTIAL DAMAGES THAT RESULT FROM THE USE OF, AND THE RELIANCE ON, THE MATERIAL IN
THIS MANUAL.
This vehicle was designed and manufactured in accordance with FMVSS 571.500.
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.
Do not make any such modifications or changes. E-Z-GO prohibits and disclaims responsibility for any such modifica-
tions and alterations, 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
Read the Following warnings before attempting to operate the vehicle.
To prevent personal injury or death, observe the following:
When vehicle is to be left unattended, turn key to OFF positions AND REMOVE KEY.
NOTICE

Page vi
SAFETY INFORMATION
Repair and Service Manual
Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
Drive vehicle only as fast as terrain and safety considerations allow. Consider the terrain and traffic
conditions. Consider the environmental factors which affect the terrain and the ability to control the
vehicle.
Avoid driving fast downhill. Sudden stops or change of direction may result in a loss of control. Use
brake to control speed when traveling down an incline.
Use extra care and reduced speed when driving in poor conditions or on poor surfaces.
Stay in designated areas where provided and avoid steep slopes.
Seat belts must be worn at all times while operating the vehicle.
Keep feet, legs, hands, and arms inside vehicle at all times.
Avoid extremely rough terrain.
Check area behind the vehicle before operating in reverse.
Make sure the direction selector is in correct position before depressing the accelerator pedal.
Slow down before and during turns.
Always bring vehicle to a complete stop before shifting the direction selector.
See GENERAL SPECIFICATIONS for vehicle load and seating capacity.
Read the following text and warnings before attempting to service vehicle:
In any product, components may eventually fail to perform properly as the result of normal use, age, wear, or abuse.
It is impossible to anticipate all possible component failures or the manner in which each component may fail.
A vehicle requiring repair is no longer functioning as designed and therefore could be potentially hazardous. There-
fore, use extreme care when working on any vehicle. When diagnosing, removing, or replacing any components that
are not operating correctly, take time to consider the safety of yourself and others around you.
Some components are heavy, spring-loaded, highly corrosive, explosive, may produce high amperage, or reach high
temperatures. Exposure to battery acid and hydrogen gas could result in serious bodily injury. Be careful to protect
hands, face, feet, and body from injury.
Always use the appropriate tools listed in the tool list and wear approved safety equipment.
Before working on the vehicle, remove all jewelry.
Be sure no loose clothing or hair can contact moving parts.
Use care not to touch hot objects.
Wear eye protection when working on or around the vehicle. In particular, use care when working
around batteries, using solvents or compressed air.
Hydrogen gas is formed when charging batteries. Do not charge batteries without adequate venti-
lation.
Do not permit open flame or anyone to smoke in an area that is being used for charging batteries.
NOTICE

SAFETY INFORMATION
Page vii
Repair and Service Manual
Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
B
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
use extreme caution in areas where pedestrians are present
maintain adequate distance between vehicles
follow all safety rules established in the area where the vehicle is being operated
reduce speed to compensate for poor terrain or conditions
apply brake to control speed on steep grades
reduce speed in wet areas
use extreme caution when approaching sharp or blind turns
use extreme caution when driving over loose terrain
MAINTENANCE
ALWAYS:
replace damaged or missing warning, caution, or information labels
maintain the vehicle in accordance with the manufacturer’s periodic service schedule
ensure that repairs are performed by trained and qualified personnel
follow the manufacturer’s maintenance procedures
insulate any tools used within the battery area in order to prevent sparks or battery explosion
use specified replacement parts, NEVER use replacement parts of lesser quality
use recommended tools
maintain the vehicle in an area away from exposed flame or persons who are smoking
test drive the vehicle after all repairs or maintenance in a safe area that is free of both vehicular and pedestrian traffic
keep complete records of the maintenance history of the vehicle
support the vehicle using wheel chocks and safety stands, NEVER get under a vehicle that is supported by a jack,
always 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 viii
SAFETY INFORMATION
Repair and Service Manual
Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
VENTILATION
ALWAYS:
charge the vehicle in a well ventilated area
charge in an area free of flammable liquids and items
charge the vehicle in an area that is free from flame or spark, pay particular attention to natural gas or propane water
heaters and furnaces
use a dedicated 15-amp circuit for each battery charger, DO NOT permit other appliances to be plugged into the
receptacle when the charger is in operation
operate the charger in accordance with E-Z-GO’s recommendations or applicable electrical codes
SEAT BELTS
Always operate the vehicle with seat belts properly fastened.
Be certain the seat belts are latched securely and are free from twists.
Position the shoulder belt across the top of the shoulder. DO NOT place the shoulder belt under an
arm.
Loose fitting safety belts significantly reduce protection. Keep belts snug and positioned low on the
hips.
DO NOT exceed the recommended number of occupants for the vehicle:
bucket seats are designed for one occupant only
bench seats are designed for two occupants only
The driver and all passengers must wear seat belts, one person per belt.
The two passenger LSV has two bucket seats and is equipped with two safety belts, one for the driver and one for the
passenger. The four passenger LSV has a rear facing bench seat with two additional passenger seat belts. The safety
belts must be used at all times while operating the vehicle.
This vehicle has not been tested for use with automotive style child safety seats or booster seats.
Do not use automotive style child safety seats or booster seats with this vehicle.
Inspect the safety belt webbing and hardware periodically. Check for cuts, frays or loose parts. Replace components if
excessive wear or damage is noticed.
Keep safety belts clean and dry. To clean, use mild soap and warm water. Do not use bleach, dye or abrasive cleaners
as this will weaken the belt webbing material.
Do not insert any foreign objects into the retractor mechanism.
Periodically check for smooth operation and replace if the mechanism is not operating properly.
Pregnant, disabled, or injured persons should consult their doctor for specific recommendations before using the LSV.

SAFETY INFORMATION
Page ix
Repair and Service Manual
Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
B
Seat Belt Operation
To properly secure the seat belts, pull the metal tab out away from the retractor and insert into the appropriate buckle
located near the center of the seat. A click will be heard when the tab is securely latched. Position the lap belt as low
as possible on the hips, not the waist. Properly adjust and ensure a snug fit by pulling the shoulder portion upward.
The retractor will lock the belt during sudden stops. it may also lock if the person leans forward too quickly. slow, easy
motions will allow for free travel.
To release the safety belt, press the buckle release button and allow the belt to retract. If the belt does not retract,
check for twists. REPORTING SAFETY DEFECTS
If you believe that a vehicle has a defect which could cause a crash or could cause injury or death, you should imme-
diately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying E-Z-GO Division of
Textron Inc.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual prob-
lems between owner, dealer or E-Z-GO Division of Textron Inc.
To contact NHTSA, you may call the Vehicle Safety Hot-line toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to
http://nhtsa.safecar.gov; or write to:
Administrator, NHTSA
1200 New Jersey Avenue SE
Washington, DC 20590
You can also obtain other information about motor vehicle safety from http://www.safercar.gov

Page x Repair and Service Manual
Notes:
SAFETY INFORMATION
Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.

TABLE OF CONTENTS FOR SECTION ‘A’
SECTION TITLE PAGE NO.
GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-i
Repair and Service Manual
VIN LOCATION.........................................................................................................A - 1
Fig. 1 VIN Location ....................................................................................A - 1
SERIAL NUMBER LOCATION .................................................................................A - 1
Fig. 2 Serial Number Location on Steering Column....................................A - 1
Fig. 3 Serial Number on Front Frame .........................................................A - 1
Fig. 4 Serial Number on Rear Frame..........................................................A - 1
NEW VEHICLE INITIAL SERVICE............................................................................A - 2
Fig. 5 Initial Service Chart..........................................................................A - 2
BRAKE BURNISHING PROCEDURE.............................................................. A - 2
TRANSPORTING VEHICLE .....................................................................................A - 2
Fig. 6 Brake Release Wires Under Controller Splash Shield.......................A - 3
SERVICING VEHICLE ..............................................................................................A - 3
ROUTINE MAINTENANCE...................................................................................... A - 3
REAR AXLE..............................................................................................................A - 3
TIRES........................................................................................................................A - 3
VEHICLE CLEANING AND CARE............................................................................A - 4
TOP AND WINDSHIELD...........................................................................................A - 4
CAPACITIES AND REPLACEMENT PARTS ...........................................................A - 4
Fig. 7 Capacities ........................................................................................A - 4
Fig. 8 Replacement Parts...........................................................................A - 4
Fig. 9 Key Number Location.......................................................................A - 4
Fig. 9 Torque Specifications and Bolt Grades.............................................A - 5
HARDWARE.............................................................................................................A - 5
Fig. 10 Torque Specifications and Bolt Grades...........................................A - 5
PERIODIC SERVICE SCHEDULE............................................................................A - 6
Fig. 11 Periodic Service Schedule..............................................................A - 6

Page A-ii Repair and Service Manual
Notes:
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-1
Repair and Service Manual
Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
B
Thank you for purchasing this vehicle. This repair man-
ual contains information that will assist you in repairing
and maintaining this vehicle. Some illustrations may
show items that are optional for your vehicle. This guide
covers the operation of several vehicles, therefore,
some illustrations may not represent your vehicle. Phys-
ical differences in controls will be illustrated.
This vehicle has been designed and manufactured in the
United States of America (USA). Some states or com-
munities have individual requirements to comply with
their specifications; therefore, some sections may not
apply in your state or community.
Most of the service procedures in this guide can be
accomplished using common automotive hand tools.
Contact your service representative on servicing the
vehicle in accordance with the Periodic Service Sched-
ule.
Service Parts Manuals as well as Repair and Service
Manuals are available from a local Distributor, an autho-
rized Branch or the Service Parts Department. When
ordering parts or requesting information for your vehicle,
provide the vehicle model, and VIN; you may be asked
for the serial number and manufacture date code.
VIN LOCATION
The VIN is located on the driver side near the top of the
windshield.
Fig. 1 VIN Location
SERIAL NUMBER LOCATION
Three serial number and manufacture date code labels
are on the vehicle. One is placed on the steering column
(Ref. Fig. 2), the second is located on the frame member
under the front splash shield on the driver side (Ref. Fig.
3) and the third is located on the passenger side frame
rail at the rear of the vehicle (Ref. Fig. 4).
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.
Fig. 2 Serial Number Location on Steering Column
Fig. 3 Serial Number on Front Frame
Fig. 4 Serial Number on Rear Frame
VIN
Serial Number
Serial Number
Serial Number

Page A-2
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
NEW VEHICLE INITIAL SERVICE
Before a new vehicle is put into operation, the items
shown in the INITIAL SERVICE CHART must be per-
formed (Ref. Fig. 5).
.
Fig. 5 Initial Service Chart
The vehicle batteries must be fully charged before initial
use.
BRAKE BURNISHING PROCEDURE
For new vehicles or after replacement of brake pads or
rotors, it is recommended that approximately 20 stops
with moderate braking from 20 mph to 5 mph should be
made without coming to a complete stop. This proce-
dure will assure that your new brakes will function to
their full potential and maintain maximum wear resis-
tance.
Determine and record the braking distance required to
stop the vehicle for future brake performance tests.
TRANSPORTING VEHICLE
To reduce the possibility of severe injury or
death while transporting the vehicle:
Secure the vehicle and contents
NEVER ride on the vehicle being transport-
ed
ALWAYS transport the vehicle facing for-
ward
Maximum speed while hauling the vehicle
is 70 mph (112 kph)
If the vehicle is to be transported at highway speeds, the
seat bottom and controls must be secured. 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 SPECIFICATIONS for vehicle weight)
and the load plus 1000 lbs. (454 kg). secure the vehicle
using ratchet tie-downs.
In the event that the vehicle will not move in forward or
reverse, the parking brake can be released using the
Run/Tow switch located under the seat on the passen-
ger side. With the switch toggled to the ’TOW’ position
and the key switch in neutral (N) position, the vehicle will
roll freely without activating the reverse warning beeper
or damaging the controller and motor. After moving the
vehicle, return the Run/Tow switch to the ’RUN’ position;
leaving the switch in the ’TOW’ position will drain the
batteries.
In case of total power loss and the Run/Tow switch does
not release the parking brake the instructions below con-
troller splash shield must be used. Chock the tires to
prevent the vehicle moving when the brake is released.
To access the instructions raise the seat and remove
three re-usable rivets securing the controller splash
shield to the body and the controller. To remove the re-
usable rivets, press the center of the rivet with the vehi-
cle key, when the center pin snaps into place the rivet
can be removed, repeat the process for each remaining
rivet. Turn the splash shield over to reveal the instruc-
tions for releasing the parking brake.
THIS PRCEDURE SHOULD ONLY BE PER-
FORMED BY QUALIFIED TRAINED PER-
SONNEL.
Make sure that the key is in the ’OFF’ position and the
tires are chocked to prevent the vehicle moving ; then
perform the following.
1. Locate the ’Auxiliary Power’ line (3) and remove the
weather pack seal (4) from the connector.
2. Locate the ’Primary Power’ line connector (1) and dis-
connect it from line (2).
ITEM SERVICE OPERATION
Batteries Charge batteries
Seats Remove protective plastic covering
Brakes Check master cylinder fluid level & brake operation
Perform brake burnishing procedure
Establish acceptable stopping distance
Tires Check air pressure (see SPECIFICATIONS)

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-3
Repair and Service Manual
Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
B
Fig. 6 Parking Brake Release Wires under Controller
Splash Shield
3. Connect the ’Auxiliary Power’ line (3) to the ’Primary
Power’ line (1) which will release the brake. If the tires
are not chocked and the vehicle is not on flat ground
the vehicle will move immediately.
4. Move the vehicle to desired, safe location and chock
the tires immediately.
5. Disconnect the ’Auxiliary Power’ line (3) from the ’Pri-
mary Power’ line (1).
6. Connect the ’Primary Power’ line (3) to line (2).
7. Replace the weather pack seal (4) on the ’Auxiliary
Power’ line connector (3).
Reinstall the controller splash shield when finished mov-
ing the vehicle. Place the splash shield in position and
align the mounting holes with the holes in the body.
Push the center pin of each rivet upward so the top of
the pin is above the rivet head. Place a rivet in each
mounting hole and press down on the center pin until
the top of the pin is flush with the rivet head.
SERVICING THE VEHICLE
To prevent severe injury or death resulting
from improper servicing techniques, observe
the following WARNINGS:
DO NOT attempt any type of servicing
operations before reading and understand-
ing all notes, cautions and warnings in this
manual.
ANY servicing requiring adjustments to the
powertrain while the motor is running must
be made with both rear wheels raised.
Wear eye protection when
working on the vehicle. Use
extra care when working
around batteries, or using
solvents or compressed air.
To reduce the possibility of causing an
electrical arc, which could result ina battery
explosion, turn off all electrical loads from
the battery before removing battery wires.
Wrap wrenches with vinyl tape
to reduce the possibility of a
dropped wrench ‘shorting out’ a
battery, which could result in an explosion.
ROUTINE MAINTENANCE
This vehicle will give years of satisfactory service provid-
ing it receives regular maintenance. Refer to the Peri-
odic Service Schedule for service intervals.
REAR AXLE
The only maintenance required for the first five years or
1000 hours of operation is to check the Torque to Rotate
(TTR) and the periodic inspection of the lubricant level.
Unless leakage is evident, the lubricant need only be
replaced after five years.
TIRES
The condition of the tires should be inspected daily,
inflation pressures should be checked at least once a
week when the tires are cool. All dust caps for the valves
need to be reinstalled after checking the tire pressure.
For additional information, refer to the section on TIRES
AND WHEELS.
609694
Failure to follow these instructions can result in DEATH or SERIOUS INJURY
THIS PROCEDURE SHOULD ONLY BE TO CLEAR VEHICLE FROM AN UNSAFE AREA AND BE PERFORMED
ONLY BY QUALIFIED TRAINED PERSONNEL
In Case Of Total Power Loss And The ‘Run-tow’ Switch DOES NOT Release The Brake To Move The Vehicle:
Turn the ignition key to the ‘OFF’ position and ‘chock’ tires to prevent inadvertent movement.
Connect ‘Auxiliary Power’ line (3) to ‘Primary Power’ line (1) which will release the brake. THIS WILL
CAUSE THE VEHICLE TO MOVE IMMEDIATELY IF NOT ON LEVEL GROUND.
Move vehicle to desired location and park it properly on level ground, chock tires, IMMEDIATELY
DISCONNECT ‘AUXILIARY POWER’ AND RECONNECT ‘PRIMARY POWER’ (1, 2) FOR SAFETY
AND TO AVOID BATTERY DRAIN.
Reconnect the Weather Pack Seal (4) to the Auxiliary Power line (3) and perform required service
procedures following all Safety guidelines as outlined in your repair manual.
Identify the ‘Auxiliary Power’ line (3) and remove the Weather Pack Seal (4) from the connector.
Identify the ‘Primary Power’ line (1) connector and disconnect the line (2).

Page A-4
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
VEHICLE CLEANING AND CARE
To reduce the possibility of severe injury or
vehicle damage, read all instructions supplied
by the manufacturer of the pressure washer.
When pressure washing the exterior of the vehicle, do
not use pressure in excess of 700 psi. To reduce the
possibility of cosmetic damage, do not use any abra-
sive or reactive solvents to clean plastic parts.
It is important that proper techniques and cleaning mate-
rials be used. Using excessive water pressure may
cause severe injury to the operator or bystander, dam-
age to the seals, plastics, seat material, body finish or
electrical system. Do not use pressure in excess of 700
psi to wash the exterior of the vehicle.
Clean the windshield with lots of water, a mild soap and
a clean cloth.
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 wiped with a damp cloth.
Removal of oil, tar, asphalt, shoe polish, etc., requires
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 and mild detergent is
required to preserve the painted surfaces.
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
materials will cause corrosion of underbody parts unless
flushed occasionally with plain water. Thoroughly clean
any areas where mud or other debris can collect. Sedi-
ment packed in closed areas should be loosened to
ease its removal, taking care not to chip or otherwise
damage paint.
TOP AND WINDSHIELD
The top does not provide protection from roll-
over or falling objects.
The windshield does not provide complete pro-
tection from tree limbs or flying objects.
The top and windshield provide some protection from
the elements; however, they will not keep the operator
and passenger dry in a downpour.
CAPACITIES AND REPLACE-
MENT PARTS
Fig. 7 Capacities
Fig. 8 Replacement Parts
* If replacing a lost key, the number on the key must
match the number on the ignition.
FLUID QUANTITY
Rear Axle Lubricant Mobil 424
Gear Oil 25 oz. (740 ml)
Brake Fluid, DOT 3 As Required
ITEM PART NUMBER
Fuses ATC 10A (E-Z-GO P/N 35212G07)
ATC 7.5A (E-Z-GO P/N 35212G05)
Headlight Bulb 894 (E-Z-GO P/N 74004G01)
Front Turn Signal
Bulb 92057 (E-Z-GO P/N 604311))
Taillight/Brake Light
Bulb 92057 (E-Z-GO P/N 604311))
*Vehicle Key E-Z-GO P/N 609680

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-5
Repair and Service Manual
Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
B
Fig. 9 Key Number Location
HARDWARE
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref. Fig. 10).
Use care when tightening fasteners and refer to the
Technician’s Repair and Service Manual for specific
torque values.
Generally, three classes of standard hardware and two
classes of metric hardware are used in the vehicle.
Grade 5 hardware can be identified by the three marks
on the hexagonal head and grade 8 hardware is identi-
fied by 6 marks on the head. Metric hardware is marked
on the head with 8.8 or 10.9. Unmarked hardware is
Grade 2.
Fig. 10 Torque Specifications and Bolt Grades
The above torque values DO NOT apply to Platsite thread forming screw.
Numbers Must
Match
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

Page A-6
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
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
250 miles/415 kms MONTHLY
750 miles/1250 kms QUARTERLY 1500 miles/2500 kms SEMI-ANNUAL 3000miles/5000 kms ANNUAL REPLACE AFTER PAGE
Tires - pressure, condition of tires & rims 
Hardware - loose or missing 
Reverse Warning Indicator 
Overall Vehicle Condition 
Batteries - state of charge, condition, loose terminals, corro-
sion, hold down & hardware CL CL CL CL
Batteries* - check electrolyte level, fill if required C&A C&A C&A C&A
Brakes - check fluid level in master cylinder 3000 mi/5000 km
Brakes - smooth operation of pedal, stopping distance PPPPP
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 hard-
ware 
Tie Rods - excessive play, bent rods, loose or missing hard-
ware 
Rear Axle - oil leakage, noise, loose or missing hardware 
Rear Axle - drain & replace fluid 5000 mi/8000 km
Front Suspension - strut oil leakage, excessive play in hubs
or kingpins, worn bushings, loose or missing hardware 
Front Wheel Alignment - unusual tire wear 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. 11 Periodic Service Schedule