Ezgo 606420-FI User manual

OWNER’S MANUAL
AND SERVICE GUIDE
KÄYTTÖ- JA HUOLTO-OHJE
606420-FI
GASOLINE POWERED UTILITY VEHICLES
BENSIINIKÄYTTÖISET MONITOIMIAJONEUVOT
ISSUED DECEMBER 2006 REVISED FEBRUARY 2010
JULKAISTU JOULUKUUSSA 2006 MUUTETTU HELMIKUUSSA 2010

(NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
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.
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˚
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
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.
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleur du
Canada.
SAFETY

Page i
Owner’s Manual and Service Guide
OWNER’S MANUAL
AND SERVICE GUIDE
GASOLINE POWERED
UTILITY VEHICLES
ST 480
Starting Model Year 2007
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
information 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.
2006/42/EC These are the Original instructions verified by E-Z-GO a Textron Company.
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 Owner’s Manual and Service Guide
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 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
PREPARATION OF SEATS FOR SERVICE ............................................................................. 1
Fig. 2 Safety and Operation Label ........................................................................................... 2
TERRAIN .................................................................................................................................... 2
VEHICLE CAPACITY ................................................................................................................. 2
MODIFICATIONS TO VEHICLE ................................................................................................ 2
DUMP BED ................................................................................................................................ 2
Fig. 3 Dump Bed Warning Label .............................................................................................. 3
TOP AND WINDSHIELD (IF EQUIPPED) ................................................................................. 3
COMMON SENSE OPERATION ............................................................................................... 3
ENVIRONMENTAL CONCERNS ............................................................................................... 3
OPTIONAL WINCH .................................................................................................................... 4
Operation of the Winch ....................................................................................................................................... 4
Fig. 4 Winch Mounted to Vehicle ............................................................................................. 4
Fig. 5 Winch Remote Control ...................................................................................................4
Fig. 6 Winch Clutch Knob ......................................................................................................... 4
Winch Applications .............................................................................................................................................. 4
Fig. 7 Never Operate Winch with Less Than Five Turns Around Drum ................................... 5
Fig. 8 Do Not Hook Cable to Itself ............................................................................................6
Fig. 9 Use a Nylon Sling and Install a Damper when Winching .............................................. 6
Fig. 10 Do Not Pull at Angle ..................................................................................................... 6
TOWING A TRAILER ................................................................................................................. 7
POWER CONSUMPTION .......................................................................................................... 7
SERIAL NUMBER PLATE AND LOCATION ............................................................................ 7
Fig. 11 Serial Number Plate and Location ............................................................................... 7
CONTROLS AND INDICATORS ............................................................................................... 8
Key/Light Switch .................................................................................................................................................. 8
Fig. 12 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge .......................................... 8
Low Oil Pressure Light ........................................................................................................................................ 8
Fuel Gauge ......................................................................................................................................................... 8
Direction Selector ................................................................................................................................................ 8
Parking Brake ...................................................................................................................................................... 8
Differential Lock .................................................................................................................................................. 8
Fig. 13 Console Controls .......................................................................................................... 9
Choke .................................................................................................................................................................. 9
Accelerator Pedal ................................................................................................................................................ 9
Fig. 14 Accelerator, Brake and Horn ........................................................................................ 9
Service Brake Pedal ............................................................................................................................................ 9
Horn .................................................................................................................................................................... 9
12 Volt Power Outlet ........................................................................................................................................... 9
Fig. 15 12V Power Outlet ......................................................................................................... 9
Optional Electric Dump Bed .............................................................................................................................. 10
Fig. 16 Electric Lift Toggle Switch .......................................................................................... 10
BEFORE ENTERING VEHICLE .............................................................................................. 10
Run-in ................................................................................................................................................................ 10
Fig. 17 Check Oil Level on Dipstick ....................................................................................... 10
OPERATING THE VEHICLE ................................................................................................... 10

Page iv Owner’s Manual and Service Guide
TABLE OF CONTENTS
Cold Starting ..................................................................................................................................................... 12
Starting the Vehicle on a Hill ............................................................................................................................. 12
Starting the Vehicle with a Discharged Battery ............................................................................................. 12
COASTING ............................................................................................................................... 12
FUEL ........................................................................................................................................ 12
Fig. 18 Fuel Tank Location ..................................................................................................... 13
TOWING ................................................................................................................................... 13
SERVICING THE VEHICLE ..................................................................................................... 13
Neutral Lock ...................................................................................................................................................... 14
Fig. 19 Neutral Lock ............................................................................................................... 14
Lifting the Vehicle .............................................................................................................................................. 15
Routine Maintenance ........................................................................................................................................ 15
Fig. 20 Lifting the Vehicle ....................................................................................................... 15
Fig. 21 Lubrication Points ....................................................................................................... 15
POWERTRAIN MAINTENANCE .............................................................................................. 16
Removing Debris .............................................................................................................................................. 16
Fig. 22 Cleaning Cooling Fins and Air Intake ......................................................................... 16
Replacing the Fuel Filter ................................................................................................................................... 16
Oil Capacity ....................................................................................................................................................... 16
Oil Recommendations ....................................................................................................................................... 16
Fig. 23 Oil Viscosity Chart ...................................................................................................... 17
Checking the Oil Level ...................................................................................................................................... 17
Fig. 24 Oil Fill Cap, Dipstick and Fuel Filter ........................................................................... 17
Fig. 25 Clean Entire Dipstick .................................................................................................. 17
Fig. 26 Check Oil Level on Dipstick ....................................................................................... 18
Changing the Oil ............................................................................................................................................... 18
Fig. 27 Oil Drain and Filter ..................................................................................................... 18
Changing the Oil Filter ...................................................................................................................................... 18
AIR CLEANER MAINTENANCE ..............................................................................................18
Fig. 28 Air Cleaner ................................................................................................................. 19
Pre-Cleaner Service .......................................................................................................................................... 19
Cartridge Service .............................................................................................................................................. 19
REAR AXLE .............................................................................................................................19
Checking the Lubricant Level ............................................................................................................................ 19
Fig. 29 Add, Check and Drain Rear Axle Lubricant ............................................................... 19
STARTER/GENERATOR BELT TENSION .............................................................................20
Fig. 30 Check Belt Tension with Gauge ................................................................................. 20
Fig. 31 Check Belt Tension with Finger ................................................................................. 20
Adjusting the Belt .............................................................................................................................................. 20
SPARK PLUGS ........................................................................................................................20
Fig. 32 Adjust Belt Tension .................................................................................................... 20
Fig. 33 Gap Spark Plugs ........................................................................................................ 21
BRAKES ................................................................................................................................... 21
DAILY BRAKE TEST ...............................................................................................................21
TIRES .......................................................................................................................................21
Wheel and Tire Service ..................................................................................................................................... 22
Fig. 34 Wheel Installation ....................................................................................................... 22
LIGHT BULB AND FUSE REPLACEMENT ............................................................................22
Fig. 35 Headlight Replacement .............................................................................................. 23
PROLONGED STORAGE ........................................................................................................23
CARE AND CLEANING OF THE VEHICLE ............................................................................23
TRANSPORTING VEHICLE .................................................................................................... 24

Page v
TABLE OF CONTENTS
Owner’s Manual and Service Guide
TOWING ............................................................................................................................................................24
HAULING ...........................................................................................................................................................24
HARDWARE ............................................................................................................................ 24
TORQUE SPECIFICATIONS ................................................................................................... 25
Fig. 36 Torque Specifications .................................................................................................25
PERIODIC SERVICE SCHEDULE .......................................................................................... 25
Fig. 37 Periodic Service Schedule ..........................................................................................27
GENERAL SPECIFICATIONS ................................................................................................. 29
ST 480 ...............................................................................................................................................................30
Fig. 38 Vehicle Dimensions ....................................................................................................31
Fig. 39 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter ...........32
LABELS AND PICTOGRAMS ............................................................................ Appendix A - 1
VEHICLE WARRANTIES ................................................................................... Appendix B - 1
DOMESTIC WARRANTY .............................................................................................................................. B - 2
FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY .................................................................... B - 3
CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT ..................................... B - 5
DECLARATION OF CONFORMITY (EUROPE ONLY) ...................................... Appendix C - 1

Page vi Owner’s Manual and Service Guide
TABLE OF CONTENTS
Notes:

Owner’s Manual and Service Guide Page vii
SAFETY INFORMATION
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 FED-
ERAL LAW the modified product will be a Low Speed Vehicle (LSV) subject to the strictures and requirements of Fed-
eral 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.

Owner’s Manual and Service Guide
Page viii
SAFETY INFORMATION
These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety
Standards of the United States of America (USA) and are not equipped for operation on public streets. Some commu-
nities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordi-
nances.
Refer to GENERAL SPECIFICATIONS for vehicle seating capacity.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability
or increase the speed beyond the factory specification. Such modifications can cause serious personal injury
or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may
reduce the stability of the vehicle. Do not make any such modifications or changes. The manufacturer prohibits and
disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the
vehicle.
Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when
used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions,
terrain and common sense.
Operation of this vehicle is limited to persons above the height of 59 inches (150 cm).
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.
• Leave the vehicle when there is a risk of lightning.
• 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.