Ezgo 625619 2012 User manual

GASOLINE POWERED UTILITY VEHICLE
TECHNICIAN’S REPAIR AND SERVICE MANUAL
625610
625619
ISSUED JUNE 2012 REVISED AUGUST 2012

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 NOTICES, CAUTION and WARNING will be used.
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.
WASH HANDS
AFTER HANDLING!
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemicals known
to cause cancer and
reproductive harm.
WAS H HANDS
AFTER HANDLING!
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to cause cancer and reproductive harm.
CONTAIN LEAD
AND RELATED PARTS
BATTERY WARNING
BATTERIES
!
<
˚
25
DO NOT
DRIVE ACROSS
SLOPES IN
EXCESS OF 14˚
(NOTICES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)
A NOTICE indicates a condition that should be observed.
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.
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
tampering 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
Canadian Interference-Causing Equipment Regulations.
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleur
du Canada.
NOTICE
NOTICE
NOTICE

Page i
Repair and Service Manual
SERVICE AND REPAIR MANUAL
GASOLINE POWERED
UTILITY VEHICLE
TERRAIN 1500
STARTING MODEL YEAR 2012
E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to
include these changes on units leased/sold previously.
The information contained in this Manual may be revised periodically by E-Z-GO, and therefore is subject to change without notice.
E-Z-GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL, and E-Z-GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CON-
SEQUENTIAL 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]

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).
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer
or lead smelter for recycling. For neutralized spills, place residue in acid-resistant
containers with absorbent material, sand or earth and dispose of in accordance with local,
state and federal regulations for acid and lead compounds. Contact local and/or state
environmental officials regarding disposal information.

Page iii
Repair and Service Manual
TITLE PAGE
TABLE OF CONTENTS
SAFETY ....................................................................................................................... Inside Covers
GENERAL INFORMATION...............................................................................................................ii
SAFETY INFORMATION ................................................................................................................. v
TITLE SECTION
GENERAL INFORMATION & ROUTINE MAINTENANCE ..............................................................A
SAFETY ...........................................................................................................................................B
BODY...............................................................................................................................................C
BRAKES...........................................................................................................................................D
CONTINUOUSLY VARIABLE TRANSMISSION (CVT)....................................................................E
DIRECTION SELECTOR.................................................................................................................F
ELECTRICAL ................................................................................................................................. G
ENGINE............................................................................................................................................H
FRONT SUSPENSION AND STEERING ........................................................................................ J
FUEL SYSTEM ................................................................................................................................K
REAR AXLE AND SUSPENSION.................................................................................................... L
ELECTRONIC SPEED CONTROL ................................................................................................. M
TROUBLESHOOTING.....................................................................................................................N
WEATHER PROTECTION...............................................................................................................P
WHEELS AND TIRES..................................................................................................................... Q
GENERAL SPECIFICATIONS .........................................................................................................R

Page iv Repair and Service Manual
NOTES:
TABLE OF CONTENTS

Page v
Repair and Service Manual
B
B
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to 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 Repair and Service Manual
B
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to 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.
• Insuate 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.

Page vii
Repair and Service Manual
B
B
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
• 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
B
SAFETY INFORMATION
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
NOTES:

TABLE OF CONTENTS FOR SECTION ‘A’
SECTION TITLE PAGE NO.
Page A-i
Repair and Service Manual
GENERAL INFORMATION & ROUTINE MAINTENANCE
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
NEUTRAL LOCK .......................................................................................................A -2
ROUTINE MAINTENANCE .......................................................................................A - 3
POWERTRAIN MAINTENANCE...............................................................................A - 3
BRAKES...................................................................................................................A - 4
TIRES........................................................................................................................A - 4
CARE AND CLEANING OF THE VEHICLE..............................................................A - 4
VEHICLE CARE PRODUCTS...................................................................................A - 4
SUN TOP AND WINDSHIELD ..................................................................................A - 5
TRAILERING ............................................................................................................A - 5
WINTER OR PROLONGED STORAGE....................................................................A - 5
HARDWARE.............................................................................................................A - 5
TORQUE SPECIFICATIONS ....................................................................................A - 6
PERIODIC SERVICE SCHEDULE............................................................................A - 7
LIST OF ILLUSTRATIONS
Fig. 1 Serial Number 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 Bolt Grades..................................................................................................A - 6
Fig. 7 Torque Specifications ..................................................................................A - 6
Fig. 8 Periodic Service Schedule ...........................................................................A - 7

Page A-ii Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
NOTES:

Page A-1
Repair and Service Manual
B
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
SERIAL NUMBER LOCATION
Three 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 Location
Design changes take place on an ongoing basis. 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.
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
generator.
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 bat-
tery 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 per-
form 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 lon-
ger functioning as designed and should be considered
potentially hazardous. Use extreme care when working
on a vehicle. When diagnosing, removing or replacing
Serial Number
Labels

Page A-2
Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
any components that are not operating properly, con-
sider the safety of yourself and those around you,
should the component move unexpectedly.
Some components are heavy, spring loaded, highly cor-
rosive, 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 passen-
ger side of the vehicle. Fill tank with fresh, clean, auto-
motive 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
This vehicle is not designed to be towed.
To activate the direction selector, pull the neutral lock pin
handle out and rotate until the pointed portion of the
handle fits into the hole (3) in the direction selector cam.
NEUTRAL LOCK
To prevent the driven clutch from turning the rear axle
during any service operations, a neutral lock is located
on the rear axle (Ref Fig. 3 on page A-2). To operate,
place the direction selector in a position between 'F' and
'R'. Turn the key switch to 'OFF'. Raise bed for access to
the rear axle. Rotate the tabs on the rear axle shift lever
as shown. The attached pin will snap into a cavity in the
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

Page A-3
Repair and Service Manual
B
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
differential case. When in this position, the rear axle
remains locked in the neutral position. To make the
direction selector functional, pull the tab out and rotate
until the pointed portion of the tab fits into the detent
position in the rear axle shift lever.
Fig. 4 Neutral Lock
ROUTINE MAINTENANCE
This vehicle will give years of satisfactory service, pro-
viding it receives regular maintenance. Refer to the Peri-
odic Service Schedule for appropriate service intervals
(Ref. Fig. 8).
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 the seat
bottom. Some service procedures may require the vehi-
cle 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.
Always install a positive stop to prevent severe
injury that could result if the load bed lift mech-
anism should unexpectedly fall. Wrap wrench-
es with vinyl tape to prevent the possibility of a
dropped wrench 'shorting out' a battery, which
could result in an explosion and severe per-
sonal injury or death.To prevent accidental
starting, remove and ground spark plug wires
and disconnect battery at negative terminal
before servicing.
Locked
Position
Unlocked
Position
Pull out and rotate 180°
to lock
Long Tab
Short Tab
Unlocked
Pull out and rotate 180 °
to unlock
1
2
1
2
Locked
NOTICE
Ball Joint
Ball Joint
(2) Ball Joint
Steering Unit
King PinKing Pin Idler Arm
Ball Joint On
Rack And Rod
View From Underside Of Vehicle

Page A-4
Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to 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 BRAKES
section.
TIRES
Standard tires for this vehicles are uni-directional and should
never be moved from one side of vehicle to the other. Left side
tires should always remain on the left side of the vehicle. Right
side tires should always remain on the right side of the vehi-
cle. Uni-directional tires have an arrow on the sidewall indicat-
ing direction of rotation when moving forward.
Tire condition should be inspected on a daily basis.
Inflation 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
information, refer to WHEELS AND TIRES section.
CARE AND CLEANING OF THE
VEHICLE
When pressure washing vehicle, do not use pressure in
excess of 700 psi (48.26 bar). To prevent cosmetic
damage, do not use any abrasive or reactive solvents to
clean plastic parts.
It is important that proper techniques and cleaning
materials 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.
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
products 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 could cause corrosion of underbody parts. It is
recommended that the underbody be flushed occasion-
ally 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
vehicle colors for use on both metal and TPE
(plastic) bodies. (P/N 28432G**)
• 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 tem-
perature 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 plas-
tic cleaner and polish removes minor scratches
from windshield. (P/N 606314)
NOTICE
NOTICE
NOTICE

Page A-5
Repair and Service Manual
B
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
SUN 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.
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 SPEC-
IFICATIONS for vehicle weight) and load. Lock the
parking brake and secure the vehicle to the trailer using
ratchet tie downs.
WINTER OR PROLONGED STORAGE
To reduce the possibility of severe injury or
death resulting from a possible explosion:
Do not handle fuel in an area that is not
adequately ventilated. Do not smoke near
the fuel tank or refuel near open flame or
electrical items which could produce a
spark.
Store vehicle in a clean, dry area. Do not
store in same area as a stove, furnace,
water heater, or other appliance that uses
a pilot light or has a device that can create
a spark.
When refueling, inspect the fuel cap for
leaks or breaks that could result in fuel
spillage.
Always wear safety glasses while refuel-
ing to prevent possible eye injury from
gasoline or gasoline vapour.
Keep hands, clothing and jewelry away
from moving parts. Use care not to con-
tact hot objects. Raise the rear of the vehi-
cle and support on jack stands before
attempting to run the engine.
Preparing the engine for a prolonged storage period
calls for a few simple steps to prevent build up of var-
nish and gum in the carburetor and corrosion in the
engine.
• Turn the Key Switch to OFF position, and leave
the Forward/Reverse switch in the NEUTRAL
position during storage.
• Perform all required routine maintenance per the
Periodic Service Schedule.
• Properly inflate the tires to recommended pres-
sure (psi) stated on sidewall of tires.
• Place the Forward/Reverse handle in the NEU-
TRAL position and engage the neutral lock (Ref.
Fig. 4).
• Turn the Fuel Shut-Off Valve to the closed (OFF)
position.
• With proper ventilation, run engine until the
remaining fuel in carburetor and fuel lines is
depleted and the engine stalls.
• Return the neutral lock to the OPERATE position.
• Loosen, but do not remove the carburetor drain
screw. Drain any fuel remaining in bowl into an
approved container and pour the fuel collected
into the vehicle fuel tank. Add Sea Foam (4 oz.
for a full tank of fuel) to stabilize fuel and install
the tank cap securely.
• Tighten the carburetor drain screw.
• Remove spark plug and pour about 1/2 oz. (15
ml) of SAE 10 - 30 weight oil or Fogging oil into
the cylinder.
• Do not engage the park brake, but secure the car
from rolling.
• While engine is still warm, change oil.
• Clean body, chassis and engine of debris, mud,
chaff or grass.

Page A-6
Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
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).
Fig. 6 Bolt Grades
Grade 2 Grade 5
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.
The table below 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 6 (8) 13 (18) 23 (31) 35 (47) 55 (75) 80 (108) 110 (149) 200 (271) 320 (434) 480 (651)

Page A-7
Repair and Service Manual
B
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to 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
Fig. 8 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
Repair and Service Manual
B
GENERAL INFORMATION & ROUTINE MAINTENANCE
Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Steering Assembly - excessive play, loose or missing
hardware
****
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. 8 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.
(CONTINUED)