Ezgo 611103 Operating instructions

RXV ELECTRIC SERVICE & REPAIR
ISSUED FEBRUARY 2009 REVISED JULY 2010
611103

(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 understand all labels located on the vehicle. Always replace any damaged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre-
vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed
on level ground. See GENERAL SPECIFICATIONS. Limit speed by applying the service brake.
Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above
specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered
abuse and will not be covered under warranty.
Use extra caution when towing the vehicle(s). Do not tow a single vehicle at speeds in excess of 12 mph (19 kph). Do
not tow more than three vehicles at a time. Do not exceed 5 mph (8 kph) while towing multiple vehicles. Towing the
vehicle at above the recommended speed may result in personal injury and/or damage to the vehicle and other prop-
erty. Vehicles equipped with the AC Drive motor must be towed with the Run-Tow switch, located under the passenger
seat, in the ‘Tow’ position.
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
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. NOTICES, CAUTIONS AND WARNINGS
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
GOLF CARS & PERSONAL VEHICLES
RXV FLEET GOLF CAR
RXV FREEDOM GOLF CAR
RXV SHUTTLE 2+2
STARTING MID-MODEL YEAR 2009
(MANUFACTURED BEGINNING FEBRUARY 23, 2009)
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:
SALES PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON INC., 1451 MARVIN GRIFFIN ROAD, AUGUSTA, GEORGIA USA 30906-3852

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.
On PDS vehicles, disconnect the controller from the battery set by selecting the ‘TOW/
MAINTENANCE’ position on the RUN-TOW/MAINTENANCE SWITCH located under the
passenger seat.
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.
GENERAL INFORMATION

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
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 manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings
This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with proce-
dures 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 pay-
ing particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employ-
ees 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 publi-
cation, 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
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 pro-
hibits 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.
Always read and observe all warnings and operation instruction labels affixed to the vehicle.
Always follow all safety rules established in the area where the vehicle is being operated.

Page vi
SAFETY INFORMATION
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings.
B
Always reduce speed to compensate for poor terrain or conditions.
Always apply service brake to control speed on steep grades.
Always maintain adequate distance between vehicles.
Always reduce speed in wet areas.
Always use extreme caution when approaching sharp or blind turns.
Always use extreme caution when driving over loose terrain.
Always use extreme caution in areas where pedestrians are present.
MAINTENANCE
Always maintain your vehicle in accordance with the manufacturer’s periodic service schedule.
Always ensure that mechanics performing repairs are trained and qualified to do so.
Always 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.
Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by short-
ing the battery terminals or associated wiring. Remove the batteries or cover exposed terminals with an insulating
material.
Always check the polarity of each battery terminal and be sure to rewire the batteries correctly.
Always use specified replacement parts. Never use replacement parts of lesser quality.
Always use recommended tools.
Always 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.
Always 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.
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.
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.
Always replace damaged or missing warning, caution or information labels.
Always keep complete records of the maintenance history of the vehicle.

SAFETY INFORMATION
Page vii
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings.
B
B
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.
Always use a dedicated circuit for each battery charger. Do not permit other appliances to be plugged into the recepta-
cle 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 all Notices, Cautions and Warnings.

TABLE OF CONTENTS FOR SECTION ‘A’
SECTION TITLE PAGE NO.
GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-i
Repair and Service Manual
SERIAL NUMBER LOCATION ................................................................................. A - 1
TOWING ................................................................................................................... A - 2
PARKING BRAKE .................................................................................................... A - 3
SERVICING VEHICLE .............................................................................................. A - 3
ROUTINE MAINTENANCE ...................................................................................... A - 3
REAR AXLE.............................................................................................................. A - 4
TIRES........................................................................................................................ A - 4
VEHICLE CLEANING AND CARE............................................................................ A - 4
SUN TOP AND WINDSHIELD .................................................................................. A - 4
HAULING .................................................................................................................. A - 4
HARDWARE ............................................................................................................. A - 5
CAPACITIES AND REPLACEMENT PARTS ........................................................... A - 5
PERIODIC SERVICE SCHEDULE ............................................................................ A - 6
LIST OF ILLUSTRATIONS
Fig. 1 Serial Number Location on Steering Column ............................................... A - 1
Fig. 2 Serial Number on Front Frame .................................................................... A - 1
Fig. 3 Serial Number on Rear Frame ..................................................................... A - 1
Fig. 4 Initial Service Chart ..................................................................................... A - 1
Fig. 5 Run Tow Switch........................................................................................... A - 2
Fig. 6 Capacities ................................................................................................... A - 5
Fig. 7 Replacement Parts ...................................................................................... A - 5
Fig. 8 Torque Specifications and Bolt Grades........................................................ A - 5
Fig. 9 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 attempting any procedure. Pay particular attention to all Notices, Cautions and Warnings.

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-1
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings.
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 as a
‘World Vehicle’. Some countries have individual require-
ments to comply with their specifications; therefore,
some sections may not apply in your country.
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, serial number and manufac-
ture date code.
SERIAL NUMBER LOCATION
Three serial number and manufacture date code labels
are on the vehicle. One is placed on the steering column
(Ref. Fig. 1), the second is located on the frame member
under the front splash shield on the driver side (Ref. Fig.
2) and the third is located on the passenger side frame
rail at the rear of the vehicle (Ref. Fig. 3).
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. 1 Serial Number Location on Steering Column
Fig. 2 Serial Number on Front Frame
Fig. 3 Serial Number on Rear Frame
Before a new vehicle is put into operation, the items
shown in the INITIAL SERVICE CHART must be per-
formed (Ref. Fig. 4).
.
Fig. 4 Initial Service Chart
The vehicle batteries must be fully charged before initial
use.
Serial Number
Serial Number
Serial Number
ITEM SERVICE OPERATION
Batteries Charge batteries
Seats Remove protective plastic covering
Brakes Check operation
Establish acceptable stopping distance
Tires Check air pressure (see SPECIFICATIONS)
Portable Remove from vehicle and properly mount
Charger

Page A-2
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings.
B
TOWING
To reduce the possibility of severe injury or
death:
Use extra caution when towing a vehicle.
DO NOT ride on the vehicle being towed.
DO NOT attempt to tow the vehicle with
ropes, chains or any device other than a
factory approved tow bar.
DO NOT tow the vehicle on highways.
DO NOT tow a single vehicle at speeds in
excess of 12 mph (19 kph).
DO NOT tow more than three vehicles at a
time.
DO NOT exceed 5 mph (8 kph) while tow-
ing multiple vehicles.
DO NOT use the tow bar system on slopes-
more than 10% garde.
Place key switch in ’N’ and the Run/Tow switch in the
‘TOW’ position prior to towing the vehicle to prevent
damage to the electric motor and controller.
Do not tow a single vehicle at speeds in excess of 12
mph (19 kph). Do not tow more than three vehicles at a
time. Do not exceed 5 mph (8 kph) while towing multi-
ple vehicles. The maximum slope that the tow bar sys-
tem can be used is 10% grade. Towing the vehicle
above the recommended speed may result in severe
injury and/or damage to the vehicle and other property.
Tow bars are not intended for road use.
If a vehicle is towed in excess of 15 mph the motor brake will
engage and slow the vehicle down.
This vehicle is equipped with a ‘Run/Tow’ switch located
underneath the seat on the passenger side. The ‘TOW’
position, with the key switch in the ’N’ position, allows
the vehicle to roll freely without activating the warning
beeper and eliminating potential damage to controller or
motor. Check to see that vehicles to be towed are
switched to the ‘TOW’ position and the key is turned to
the neutral (’N’) position.
Never use ropes or chains to tow vehicle(s). Tow bars
are available from the E-Z-GO Service Parts Depart-
ment.
Tow bars are not intended for highway use. Before tow-
ing, place the direction selector in neutral (N) and make
sure that the ’Run/Tow’ switch in ’TOW’. Do not ride on a
vehicle being towed. Tow bars are designed to tow only
one vehicle at a maximum speed of 12 mph (19 kph)
and up to three vehicles at a maximum speed of 5 mph
(8 kph). Return the Run/Tow switch to the ’RUN’ position
and make sure the key is turned to ’OFF’ and removed
after towing the vehicle.
The RUN/TOW switch should always be returned to the ’RUN’
or (on CE vehicles) position after towing the vehicle. If
the switch is left in the ’TOW’ or (on CE vehicles) position
for an extended period of time it will drain the batteries.
The run/tow switch (8) is located under the seat on the
passenger side of the vehicle (Ref. Fig. 5).
Fig. 5 Run/Tow Switch
NOTICE
NOTICE
608769
F
R
OFF
O
ON
N
610991

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-3
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings.
B
B
With the switch in the ‘TOW’ or (on CE vehicles)
position and the key in ’N’.
• the electronic parking brake is deactivated, which
allows the vehicle to be towed or roll freely, except
in the event of a controller failure
• the service brake is still active
• the reverse warning beeper is deactivated
With the switch in ‘RUN’ or (on CE vehicles) posi-
tion:
• the electronic parking brake is deactivated and the
reverse warning beeper features are activated
PARKING BRAKE
This vehicle is equipped with an automatic parking
brake; when the vehicle is stopped the parking brake is
automatically set. The parking brake is released when
the key switch/direction selector is in forward (’F’) or re-
verse (’R’) and the accelerator is depressed. The park-
ing brake is also released when the run/tow switch is
placed in the ’TOW’ or (on CE vehicles) position
with the key switch turned to neutral (’N’).
In the event that the vehicle will not move in forward or
reverse, the parking brake can be released using the in-
structions located on the controller splash shield be-
neath the seat on the passenger side of the vehicle. To
move the vehicle, turn the key switch to ’N’, flip the
RUN-TOW switch to the ’TOW’ position and move the
vehicle to a safe location on level ground and chock the
tires, turn the key to ’OFF’ and return the Run/Tow
switch ’RUN’ position.
In case of total power loss and the RUN-TOW does not
release the parking brake the instructions below the
controller splash shield must be used. Chock the tires to
prevent the vehicle moving when the
brake is released.
To access the instructions remove
three re-usable plastic 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 vehicle key, when
the center pin snaps into place the
rivet can be removed, repeat the pro-
cess for each remaining rivet. Turn the
splash shield over to reveal the instruc-
tions for releasing the parking brake.
To reinstall the controller splash shield,
position the splash shield by aligning the
mounting holes with the holes in the body, push the cen-
ter pin of each rivet upward so that the
top of the pin is above the rivet head.
Place a rivet in each mounting hole of
the controller splash shield and push
down on the center pin untill 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 sol-
vents 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 possibil-
ity 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.

Page A-4
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings.
B
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.
VEHICLE CLEANING AND CARE
To reduce the possibility of severe injury or
vehicle damage, read and understand 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.
SUN TOP AND WINDSHIELD
The sun top does not provide protection from
roll-over or falling objects.
The windshield does not provide protection
from tree limbs or flying objects.
The sun top and windshield provide some protection
from the elements; however, they will not keep the oper-
ator and passenger dry in a downpour. This vehicle is
not equipped with seat belts and the sun top has not
been designed to provide roll-over protection. In addi-
tion, the sun top does not protect against falling objects
nor does the windshield protect against flying objects
and tree limbs. Keep arms and legs inside of the vehicle
while it is moving.
HAULING
To reduce the possibility of severe injury or
death while transporting the vehicle:
Secure the vehicle and contents.
Never ride on the vehicle being transported.
Always remove the windshield before trans-
porting.
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.

GENERAL INFORMATION & ROUTINE MAINTENANCE
Page A-5
Repair and Service Manual
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings.
B
B
When transporting vehicle below highway speeds,
check for tightness of hardware and cracks in sun top at
mounting points. Always remove windshield when trans-
porting. 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 vehi-
cle weight) and load plus 1000 lbs. (454 kg). Secure the
vehicle using ratchet tie downs.
T
HARDWARE
Periodically, the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref. Fig. 8).
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.
CAPACITIES AND REPLACE-
MENT PARTS
Fig. 8 Torque Specifications and Bolt Grades
FLUID QUANTITY
Rear Axle Lubricant Mobile 424 25 oz. (739 ml)
Fig. 6 Capacities
ITEM PART NUMBER
Fuse ATC 10A (E-Z-GO P/N 35212G07)
Headlight Bulb 894 (E-Z-GO P/N 74004G01)
Turn Signal Bulb 912-NA (E-Z-GO P/N 74005G01)
Tail Light Bulb 2057 (E-Z-GO P/N 604311)
Fig. 7 Replacement Part
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 this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings.
B
PERIODIC SERVICE SCHEDULE
3- 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 33333 9
Hardware - loose or missing 33333
Reverse Warning Indicator 33333
Overall Vehicle Condition 33333
Batteries - state of charge, condition, loose terminals, corro-
sion, hold down & hardware 3CL CL CL CL 17
Batteries* - check electrolyte level, fill if required C&A C&A C&A C&A 18
Brakes - smooth operation of pedal, stopping distance 33333
Brakes - aggressive stop test, does brake hold on a hill 3333
Accelerator - smooth operation 33333
Wiring - loose connections, broken or missing insulation 3333
Charger Receptacle - clean connections CL CL CL CL
Steering Assembly - excessive play, loose or missing hard-
ware 3333
Tie Rods - excessive play, bent rods, loose or missing hard-
ware 3333
Rear Axle - oil leakage, noise, loose or missing hardware 3333 14
Rear Axle - drain & replace fluid R14
Front Suspension - strut oil leakage, excessive play in hubs
or kingpins, worn bushings, loose or missing hardware 3333
Front Wheel Alignment - unusual tire wear C&A C&A C&A
Rear Suspension - shock oil leakage, worn bushings, loose
or missing hardware 333
Fig. 9 Periodic Service Schedule

Page A-7
Repair and Service Manual
Notes:
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings.
GENERAL INFORMATION & ROUTINE MAINTENANCE

Page A-8 Repair and Service Manual
Notes:
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions and Warnings.