Ezgo 602080 User manual

TM
602080
REVISED DATE: JAN. 2007

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. A NOTE indicates a condition that should be
observed.
A CAUTION indicates a condition that
may result in damage to the vehicle.
A WARNING indicates a
hazardous condition that
could result in severe
injury or death.
Observe these NOTES, CAUTIONS and WARNINGS;
be aware that servicing a vehicle requires mechanical
skill and a regard for conditions that could be hazardous.
Improper service or repair may damage the vehicle or
render it unsafe.
Engine exhaust from this
product contains chemi-
cals known, in certain
quantities, to cause cancer, birth defects, or other
reproductive harm.
The exhaust emissions of this vehicles’ engine
complies with regulations set forth by the Envi-
ronmental 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.
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.
Read and understand 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, engage parking
brake, move direction selector to ‘F’ (forward)
position, turn key to ‘OFF’ position and remove key.
Drive vehicle only as fast as terrain and safety
considerations allow. Consider the terrain and traffic
conditions. Consider environmental factors which
effect the terrain and the ability to control the vehicle.
Avoid driving fast down hill. Sudden stops or change
ofdirectionmayresult in a loss of control.Useservice
braketocontrolspeed whentravelingdownanincline.
Use extra care and reduced speed when driving on
poor surfaces, such as loose dirt, wet grass, gravel,
etc.
All travel should be directly up or down hills.
Use extra care when driving the vehicle across an
incline.
Stay in designated areas and avoid steep slopes. Use
the parking brake whenever the vehicle is parked.
Keep feet, legs, hands and arms inside vehicle at all
times.
Avoid extremely rough terrain.
! !
! !
! !
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleu
r
du Canada.
! !
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. See APPENDIX
A.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre-
vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed
on level ground. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.
Catastrophic damage to the 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.
Be sure that this manual remains as part of the permanent service record should the vehicle be sold.
For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.

Page i
Owner’s Manual and Service Guide
OWNER’S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED
UTILITY VEHICLE
ST 4x4
STARTING MODEL YEAR 2005
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 infor-
mation 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.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: [phone]
INTERNATIONAL:
PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON, INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

Page ii
GENERAL INFORMATION
Owner’s Manual and Service Guide
This vehicle has been designed and manufactured in the United States of America (USA) as
a ‘World Vehicle’. The Standards and Specifications listed in the following text originate in
the USA unless otherwise indicated.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the
warranty.
Overfilling battery may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory
specifications will void the vehicle warranty.
When servicing engines, all adjustments and replacement components must be per original
vehicle specifications in order to maintain the United States of America Federal and State
emission certification applicable at the time of manufacture.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75°F (-60°C).

Page iii
TABLE OF CONTENTS
Owner’s Manual and Service Guide
SAFETY ................................................................................................................inside covers
GENERAL INFORMATION ....................................................................................................... ii
SAFETY INFORMATION .........................................................................................................vii
WELCOME ................................................................................................................................. 1
BEFORE INITIAL USE ..............................................................................................................1
Fig.1 Initial Service Chart ...........................................................................................................1
CAPABILITIES ..........................................................................................................................1
TERRAIN .............................................................................................................................................................1
VEHICLE CAPACITY ..........................................................................................................................................1
MODIFICATIONS TO VEHICLE ..........................................................................................................................2
COMMON SENSE OPERATION ...............................................................................................2
RUN-IN .......................................................................................................................................2
CONTROLS & INDICATORS ....................................................................................................3
SERVICE BRAKE PEDAL ...................................................................................................................................3
Fig. 2 Service Brake Pedal ........................................................................................................3
Fig. 3 Park Brake and Indicator .................................................................................................3
CHOKE ................................................................................................................................................................3
Fig. 4 Choke ..............................................................................................................................4
IGNITION SWITCH ..............................................................................................................................................3
Fig. 5 Ignition Switch ..................................................................................................................4
DIRECTION SELECTOR .....................................................................................................................................4
Fig. 6 Direction Selector and Differential Locks .........................................................................4
2WD/4WD SELECTOR ....................................................................................................................................... 5
Fig. 7 2WD/4WD Selector ..........................................................................................................5
DIFFERENTIAL LOCK ........................................................................................................................................5
Fig. 8 Differential Lock ...............................................................................................................5
ACCELERATOR ..................................................................................................................................................6
Fig. 9 Accelerator Pedal ............................................................................................................6
FUEL ..........................................................................................................................................6
FUEL GAUGE ......................................................................................................................................................6
Fig. 10 Fuel Tank and Gauge ....................................................................................................7
LOW OIL PRESSURE INDICATOR LIGHT .........................................................................................................6
Fig. 11 Low Pressure Oil Light ...................................................................................................7
LIGHT SWITCHES ..............................................................................................................................................7
Fig. 12 Light Switches ................................................................................................................7
12 VOLT POWER OUTLET .................................................................................................................................7
Fig. 13 Power Outlet ..................................................................................................................7
STARTING AND DRIVING ........................................................................................................ 8
STARTING VEHICLE ON A HILL ........................................................................................................................8
COASTING ..........................................................................................................................................................8
LOAD BED ................................................................................................................................. 8
TAILGATE ...........................................................................................................................................................9
MANUAL LIFT BED .............................................................................................................................................9
Fig. 14 Manual Lift Bed Release ................................................................................................9
ELECTRIC LIFT BED OPERATION ....................................................................................................................9
Fig. 15 Electric Lift Bed Switch ..................................................................................................9
WINCH ....................................................................................................................................... 9
WINCH APPLICATIONS .....................................................................................................................................9
Fig. 16 Do Not Pull at Angle ....................................................................................................10
WINCH MOUNTING ..........................................................................................................................................10
Fig. 17 Mounting Winch ...........................................................................................................11
WINCH OPERATION ........................................................................................................................................10
Fig. 18 Use Nylon Sling and Install a Damper when Winching ................................................11
Fig. 19 Winch Operation ..........................................................................................................12