Ezgo TXT FLEET User manual

GASOLINE POWERED PERSONNEL
CARRIERS
ISSUED FEBRUARY 2010
TECHNICIAN’S
REPAIR AND SERVICE MANUAL
614276

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.
For towing/transporting vehicle, refer to “TRANSPORTING VEHICLE”.
Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.
Be sure that this manual remains as part of the permanent service record should the vehicle be sold. Throughout this
guide NOTE, CAUTION and WARNING will be used.
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.
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˚
A NOTICE 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.
Engine exhaust from this product contains
chemicals known, in certain quantities, to
cause cancer, birth defects, or other reproduc-
tive harm.
The exhaust emissions of this vehicles’ engine complies with
regulations set forth by the Environmental Protection Agency
(EPA) of the United States of America (USA) at time of manu-
facture. Significant fines could result from modifications or tam-
pering with the engine, fuel, ignition or air intake systems.
Battery posts, terminals and related accesso-
ries contain lead and lead compounds. Wash
hands after handling.
This spark ignition system meets all requirements of the Cana-
dian Interference-Causing Equipment Regulations.
NOTICE
NOTICE
NOTICE
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleur
du Canada.
(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

Page i
Repair and Service Manual
SERVICE AND REPAIR MANUAL
GASOLINE POWERED GOLF
CAR
TXT FLEET
TXT FREEDOM
TXT VALOR
Starting Model Year 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 the E-Z-GO Division, and therefore is subject to change without notice.
The E-Z-GO Division DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR
INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
TO CONTACT US
NORTH AMERICA:
TECHNICAL ASSISTANCE & WARRANTY PHONE: [phone], FAX: [phone]
SERVICE PARTS PHONE: 1-888-GET-EZGO (1-888-438-3946), FAX: [phone]
INTERNATIONAL: PHONE: [phone], FAX: [phone]
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.
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).

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

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 attempting any procedure. 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 or property damage, the following must be carefully observed:
Certain replacement parts can be used independently and/or in combination with other accessories to modify an E-Z-
GO-manufactured vehicle to permit the vehicle to operate at or in excess of 20mph. When an E-Z-GO-manufactured
vehicle is modified in any way by the Distributor, Dealer or customer to operate at or in excess of 20mph, UNDER
FEDERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of
Federal Motor Vehicle Safety Standard 571.500. In these instances, pursuant to Federal law the Distributor or Dealer
MUST equip the product with headlights, rear lights, turn signals, seat belts, top, horn and all other modifications for
LSV’s mandated in FMVSS 571.500, and affix a Vehicle Identification Number to the product in accordance with the
requirements of FMVSS 571.565. Pursuant to FMVSS 571.500, and in accordance with the State laws applicable in
the places of sale and use of the product, the Distributor, Dealer or customer modifying the vehicle also will be the
Final Vehicle Manufacturer for the LSV, and required to title or register the vehicle as mandated by State law.
E-Z-GO will NOT approve Distributor, Dealer or customer modifications converting E-Z-GO products into LSV’s.
The Company, in addition, recommends that all E-Z-GO products sold as personal transportation vehicles BE OPER-
ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES, AND IN ACCORDANCE WITH APPLICABLE STATE
REQUIREMENTS. This restriction is important to the SAFE USE AND OPERATION of the product. On behalf of E-Z-
GO, I am directing that E-Z-GO Branch personnel, Distributors and Dealers advise all customers to adhere to this
SAFETY RESTRICTION, in connection with the use of all products, new and used, the Distributor or Dealer has rea-
son to believe may be operated in personal transportation applications.
Information on FMVSS 571.500 can be obtained at Title 49 of the Code of Federal Regulations, section 571.500, or
through the Internet at the website for the U.S. Department of Transportation - at Dockets and Regulation, then to Title
49 of the Code of Federal Regulations (Transportation).
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.

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 Warnings and Dangers
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.
• 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.

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,Warnings and Dangers
• 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.
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. Car-
bon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

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 Warnings and Dangers

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
STARTING THE VEHICLE WITH A DISCHARGED BATTERY................................A - 1
SERVICING THE VEHICLE ......................................................................................A - 1
FUEL.........................................................................................................................A - 2
TOWING ...................................................................................................................A - 2
ROUTINE MAINTENANCE.......................................................................................A - 3
POWERTRAIN MAINTENANCE...............................................................................A - 3
BRAKES...................................................................................................................A - 4
TIRES........................................................................................................................A - 4
TRAILERING ............................................................................................................A - 4
TOP AND WINDSHIELD...........................................................................................A - 4
WINTER OR PROLONGED STORAGE....................................................................A - 4
CARE AND CLEANING OF THE VEHICLE............................................................A - 4
VEHICLE CARE PRODUCTS...................................................................................A - 5
HARDWARE.............................................................................................................A - 6
TORQUE SPECIFICATIONS ....................................................................................A - 6
PERIODIC SERVICE SCHEDULE............................................................................A - 7
LIST OF ILLUSTRATIONS
Fig. 1 Serial Number Plate and Location ...............................................................A - 1
Fig. 2 Intial Service Chart .....................................................................................A - 2
Fig. 3 Fuel Tank ....................................................................................................A - 2
Fig. 4 Neutral Lock................................................................................................A - 3
Fig. 5 Lubrication Points........................................................................................A - 3
Fig. 6 Torque Specifications..................................................................................A - 6
Fig. 7 Periodic Service Schedule...........................................................................A - 7

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, Warnings and Dangers.

Page A-1
Repair and Service Manual
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
SERIAL NUMBER PLATE AND
LOCATION
Two serial number and manufacture date code labels are
on the vehicle. One is on the body below the front, driver
side of the seat. The other two are located on the chassis
under the seat. The serial number is also engraved on the
flat portion of the frame rail.
Fig. 1 Serial Number Plate & Location
Design changes take place on an ongoing basis. In order
to obtain correct components for the vehicle, the manu-
facture date code, serial number and vehicle model must
be provided when ordering service parts.
STARTING THE VEHICLE WITH A
DISCHARGED BATTERY
Do not attempt to ‘jump start’ a vehicle using
another vehicle.
The vehicle is equipped with a starter/generator. When
starting the engine, the starter/generator functions as a
starter and with the engine running, it functions as a gen-
erator.
With the short running times associated with this kind of
vehicle, the generator is more than adequate to maintain
the battery charge level. The generator is not designed to
charge a discharged battery.
Since the engine stops when the accelerator is released,
jump starting should not be attempted.
If the vehicle is equipped with lights and/or accessories
that are used when the vehicle is not in motion, the
starter/generator may not be adequate to maintain battery
charge. In this situation, the battery may require charging
with a 12V 10 amp max charger.
Observe all instructions provided by the manufacturer of
the charger.
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 understanding
all notes, cautions and
warnings in this manual.
Any servicing requiring adjustments to be
made to the powertrain while the motor is
running must be made with both drive
wheels raised.
Wear eye protection when working on the
vehicle. In particular, use care when work-
ing around batteries, or using solvents or
compressed air.
To reduce the possibility of causing an
electrical arc, which could result in a bat-
tery explosion, turn off all electrical loads
from the batteries before removing any
heavy gauge battery wires.
To prevent the possibility of motor disinte-
gration, never operate vehicle at full throt-
tle for more than 4 - 5 seconds while
vehicle is in a “no load” condition.
It is in the best interest of both vehicle owner and 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
Serial Number
Labels

Page A-2
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
the safety of yourself and those around you, should the
component move unexpectedly.
Some components are heavy, spring loaded, highly corro-
sive, 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.
Fig. 2 .Initial Service Chart
FUEL
The fuel tank is located under the seat, on the passenger
side of the vehicle. Fill tank with fresh, clean, automotive
grade, unleaded, 87 octane (minimum) gasoline. Heavy
use/load applications may benefit from higher octane
gasoline.
DO NOT over fill the fuel tank. Allow adequate space for
the expansion of gasoline. Leave at least 1" (2.5 cm) of
space below the bottom of the filler neck.
Fig. 3 Fuel Tank
When refueling, inspect the fuel tank cap for
leaks or breaks in the housing that could result
in fuel spillage.
To prevent a possible explosion, do not smoke
near the fuel tank or refuel near open fire or
electrical items which could produce a spark.
Always wear safety glasses while refueling to
prevent possible injury from gasoline or gaso-
line vapor.
Do not handle fuel in an area that is not ade-
quately ventilated. Do not permit anyone to
smoke in an area where vehicles are being
fueled.
TOWING
To prevent personal injury, do not ride on vehi-
cle being towed. Do not attempt to tow the
vehicle with ropes, chains or any device other
than a factory approved tow bar. Towing a dis-
abled vehicle can be dangerous and requires
extra caution. Attempting to tow with devices
other than an approved tow bar may result in
severe personal injury or death.
Place direction selector in neutral. The neutral lock
should be used to lock the direction selector in position.
This will reduce the possibility of it moving into ‘F’ (for -
ITEM SERVICE OPERATION
Battery Charge battery
Seats Remove protective plastic covering
Brakes Check operation and adjust if necessary
Establish new vehicle braking distance
Tires Check pressure
Fuel Fill tank with correct fuel
Engine Check oil level
Leave 1” airspace
for ventilation FUEL

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 Notices, Cautions, Warnings and Dangers.
ward) or ‘R’ (reverse) while being towed, causing possible
damage to the rear axle.
Use extra caution when towing vehicle. Do not tow a sin-
gle vehicle at speeds in excess of 12 mph (19 kph). Tow-
ing the vehicle at above recommended speed may result
in personal injury and/or damage to vehicle and other
property.
To operate neutral lock, first turn the key switch to ‘OFF’,
place direction selector in ‘R’ and remove seat. Pull out
(1) and rotate (2) the neutral lock pin handle so that the
pointed portion of the handle is over the side of the direc-
tion selector cam. Move direction selector lever towards
the area between ‘F’ and ‘R’. During that motion, the pin
will snap into the hole in the direction selector mounting
bracket, preventing any movement of the lever. When in
this position, the direction selector remains locked in the
neutral position.
Spring loaded mechanism. To prevent possibil-
ity of fingers becoming pinched in the direction
selector mechanism, hold direction selector
lever when releasing neutral lock pin handle.
Fig. 4 Neutral Lock
To activate the direction selector, pull the neutral lock pin
handle out and rotate until the pointed portion of the han-
dle fits into the hole (3) in the direction selector cam
ROUTINE MAINTENANCE
This vehicle will give years of satisfactory service, provid-
ing it receives regular maintenance. Refer to the Periodic
Service Schedule for appropriate service intervals (Ref.
Fig. 7).
Some maintenance items must be serviced more frequently on
vehicles used under severe driving conditions.
Periodic lubrication of the steering is recommended.
Do not use more than three pumps of grease in each
grease fitting at any one time. Excess grease may cause
grease seals to fail or grease migration into areas that
could damage components.
Fig. 5 Lubrication Points
POWERTRAIN MAINTENANCE
Access the powertrain by raising or removing seat. Some
service procedures may require the vehicle be lifted.
Refer to LIFTING THE VEHICLE in section ‘B’ 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.
2
1
3
NOTICE
View from Underside of Vehicle
Rack
Ball
Joint

Page A-4
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
BRAKES
After the vehicle has been put into service, it is recom-
mended that the brakes be checked by periodically con-
ducting a brake performance test.
To prevent severe injury or death resulting
from operating a vehicle with improperly oper-
ating brake system, the braking system must
be properly maintained. All driving brake tests
must be done in a safe location with regard for
the safety of all personnel
Over time, a subtle loss of performance may take place.
Therefore, it is important to establish the standard with a new
vehicle.
For test method and brake service, refer to MECHANI-
CAL BRAKES section.
TIRES
Tire condition should be inspected on a daily basis. Infla-
tion pressures should be checked on a weekly basis
when the tires are cool. Be sure to reinstall valve dust
cap after checking or inflating tire. For additional informa-
tion, refer to WHEELS AND TIRES section.
TRAILERING
To prevent personal injury to occupants of oth-
er 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. Lock the parking brake and
secure the vehicle to the trailer using ratchet tie downs.
TOP AND WINDSHIELD
The top does not provide protection from roll
over or falling objects.The windshield does not
provide protection from tree limbs or flying
objects.
Clean with lots of water and a clean cloth. Minor
scratches may be removed using a commercial plastic
polish or Plexus plastic cleaner.
WINTER OR PROLONGED STORAGE
Keep hands, clothing and jewelry away from
moving parts. Use care not to contact hot
objects. Raise the rear of the vehicle and sup-
port on jack stands before attempting to run
the engine.
Preparing the engine for winter or a prolonged storage
calls for a few simple steps to prevent build up of varnish
and gum in the carburetor and corrosion in the engine.
Place the direction selector in the neutral position and
engage the neutral lock (Ref. Fig. 4). Add fuel stabilizer
to the tank in accordance with the manufacturer’s rec-
ommendations. Disconnect the fuel line from the engine
at the fuel tank. With proper area of ventilation, start
the engine and allow to run until the engine stops due to
lack of fuel. Remove the air filter and spray a commer-
cial fogging or cylinder oil into the carburetor while oper-
ating the starter for 2 - 3 seconds. Reinstall the air filter
and reattach the fuel line to the tank.
CARE AND CLEANING OF THE
VEHICLE
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.
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.
NOTICE

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 Notices, Cautions, Warnings and Dangers.
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 could cause corrosion of underbody parts. It is rec-
ommended that the underbody be flushed occasionally
with plain water. Thoroughly clean any areas where mud
or other debris can collect. Sediment packed in closed
areas should be loosened to ease it’s removal, taking
care not to chip or otherwise damage paint.
If the engine does not start or runs improperly after washing,
remove the spark plug wire (by pulling the spark plug boots,
never the wires) and blow them dry. Reinstall the wires.
Remove moisture from coil by blowing across top.
VEHICLE CARE PRODUCTS
To help maintain the vehicle, the manufacturer has sev-
eral products, available through a local Distributor, an
authorized Branch, or the Service Parts Department,
among them are
• Touch-up paint specially formulated to match vehi-
cle colors for use on both metal and TPE (plastic)
bodies. (P/N 28432-G**)
• Multi-purpose Battery Protectant formulated to form
a long-term, flexible, non-tacky, dry coating that will
not crack, peel or flake over a wide temperature
range. (P/N 606312)
• Multi-purpose Hand Cleaner is an industrial
strength cleaner containing no harsh solvents, yet
gently lifts grease off hands. May be used with or
without water. (P/N 607636)
• Plexus plastic cleaner and polish removes minor
scratches from windshield. (P/N 606314)
HARDWARE
Periodically the vehicle should be inspected for loose
fasteners. Fasteners should be tightened in accordance
with the Torque Specifications table (Ref. Fig. 6). 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 (Ref. Fig. 6)
NOTICE

Page A-6
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
TORQUE SPECIFICATIONS
Fig. 6 Torque Specifications
ALL TORQUE FIGURES ARE IN FT. LBS. (Nm)
BOLT SIZE
Grade 2
1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4" 7/8" 1"
Unless otherwise noted in text, tighten all hardware in accordance with this chart.
This chart specifies 'lubricated' torque figures. Fasteners that are plated or lubricated when
installed are considered 'wet' and require approximately 80% of the torque required for 'dry' fasteners.
4
(5) 8 (11) 15 (20) 24 (33) 35 (47) 55 (75) 75 (102) 130 (176) 125 (169) 190 (258)
Grade 5
Grade 8
6
(8) 13 (18) 23 (31) 35 (47) 55 (75) 80 (108) 110 (149) 200 (271) 320 (434) 480 (651)
6
(8) 18 (24) 35 (47) 55 (75) 80 (108) 110 (149) 170 (230) 280 (380) 460 (624) 680 (922)
BOLT SIZE
Class 5.8
(Grade 2)
M4 M5 M6 M8 M10 M12 M14
1
(2) 2 (3) 4 (6) 10 (14) 20 (27) 35 (47) 55 (76.4)
Class 8.8
(Grade 5) 2
(3) 4 (6) 7 (10) 18 (24) 35 (47) 61 (83) 97 (131)
Class 10.9
(Grade 8) 3
(4) 6 (8) 10 (14) 25 (34) 49 (66) 86 (117) 136 (184)
5.8
8.8
10.9

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 Notices, Cautions, Warnings and Dangers.
PERIODIC SERVICE SCHEDULE
*- CHECK C&A - CHECK & ADJUST CL - CLEAN R- REPLACE
REMARKS
before each use DAILY WEEKLY
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 ******
Hardware - loose or missing ******
Reverse Warning Indicator ******
Overall Vehicle Condition ******
Battery - state of charge, condition, loose terminals,
corrosion, hold down & hardware **CL CL CL CL
Service Brake (Mechanical) - smooth operation ******
Brakes - aggressive stop test C&A C&A C&A C&A
Park Brake - operation, does it hold on a hill **C&A C&A C&A C&A
Accelerator - smooth operation ******
Starter/Generator Belt - tension, wear, cracks *****
Wiring - loose connections, broken or missing insula-
tion ****
Carburetor Linkage - attachment C&A C&A C&A C&A
Carburetor CL
Direction Selector - attachment and mechanism C&A C&A C&A C&A
Cooling Fan - build up of debris inside blower housing C&A C&A C&A C&A C&A
Engine Oil ** - oil level C&A C&A C&A C&A C&A
Engine Oil **& Filter - drain and change R R
Engine - noise, vibration, acceleration, oil leaks C&A C&A C&A C&A
Valves - check cold - Ref: Repair & Service Manual C&A
Cylinder Head & Pistons - remove carbon CL
Choke Cable - smooth movement & adjustment C&A C&A C&A C&A
Cooling Fan - build-up of foreign matter inside hous-
ing & fins CL CL CL CL
Steering Assembly - excessive play, loose or missing
hardware ****
Fig. 7 PERIODIC SERVICE SCHEDULE
**Initial oil change after 8 hours of run time.
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.

Page A-8
GENERAL INFORMATION & ROUTINE MAINTENANCE
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
Tie Rods - excessive play, bent rods, loose or missing
hardware ****
Rear Axle - fluid level, oil leakage, noise, loose or
missing hardware ****
Rear Axle - drain & replace fluid R
Rear Suspension - shock oil leakage, worn bushings,
loose or missing hardware ***
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
Fuel System - leaks at tank, cap, system lines for
cracks/deterioration, filters, pump ***
Fuel Filter R
Spark Plug R
Throttle/Governor Linkage - operation & governed
speed ***
Air Filter Element - check & replace as necessary **
Drive Belt - cracks, frayed, excessive wear **
REMARKS
before each use DAILY WEEKLY
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
Fig. 7 PERIODIC SERVICE SCHEDULE
**Initial oil change after 8 hours of run time.
NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions.