Ezgo ST 400 CARB User manual

19
17
18
13
6
5
9
15
16
78
10
4
3
11
1-INCLUDESITEMS3 - 16
GASOLINE POWERED UTILITY VEHICLE
ISSUED MARCH 2008
SERVICE PARTS MANUAL
606915
ISSUED MARCH 2008 REVISED JULY 2008

Page i
Service Parts Manual
SERVICE PARTS MANUAL
GASOLINE POWERED
UTILITY VEHICLES
ST 400
ST 400 CARB
ST SPORT
ST SPORT CARB
ST SPORT II CARB
JAC 4000
STARTING MODEL YEAR 2008
DISCLAIMER: The 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 LIABLITY FOR ERRORS IN THIS MANUAL, and the E-Z-GO Division SPECIFICALLY DISCLAIMS LIABILITY FOR INCI-
DENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual.
CUSTOMER SERVICE DEPARTMENT IN USA PHONE: [phone] FAX: [phone]
OUTSIDE USA PHONE: [phone], FAX: [phone]
E-Z-GO DIVISION OF TEXTRON, INC., MARVIN GRIFFIN RD., AUGUSTA, GEORGIA USA 30906

Page ii
NOTES
Service Parts Manual
To obtain a copy of the limited warranty applicable to the vehicle, call or write a local
Distributor, authorized Branch or the Warranty Department with vehicle serial number and
manufacturer code.
The use of non Original Equipment Manufacturer (OEM) parts may void the warranty.
Overfilling of batteries may void the warranty.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the
ambient temperature and the age and condition of the batteries.
A fully charged battery will not freeze in winter temperatures unless the temperature falls
below -75 F (-60 C).
As with all electric vehicles, the batteries must be checked and recharged as required or at a
minimum of 30 day intervals.

Page iii
Service Parts Manual
SECTION Page No.
TABLE OF CONTENTS
HOW TO USE THE SERVICE PARTS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
ILLUSTRATED PARTS BREAKDOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
• Pedal Box Assembly
• Actuator Pedal Assembly
• Governor Cover/Decal
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
• Air Cleaner
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
• Instrument Panel Assembly
• Cowl
• Front Bracket Assembly
• Rear Body
• Foot Rest Assembly
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
• Brake Pedal Assembly
• Brake Drum Assembly
CARBURETOR AND CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
• Carburetor
• Choke Cable
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
• Drive Clutch
• Driven Clutch Assembly
DIRECTION SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
• Direction Selector Handle
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
• Battery
• Ground Cable
• Electrical Plate Assembly
• Horn
ENGINE AND MUFFLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
• Engine
• Muffler
ENGINE MOUNTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
• Front Engine Mount

Page iv Service Parts Manual
TABLE OF CONTENTS
• Engine Pan Mount
• Iso Mount
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1
• Front Axle
• Spindle Assembly
• Shock Absorber
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
• CARB Fuel Tank Assembly
• Fuel Pump
• Carbon Canister
REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N-1
• Axle Tube
• Axle Shaft
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
• Heavy Duty Leaf Spring
• Flanged Bushing
SEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q-1
• Seat Bottom Assembly
• Seat Back Assembly
STARTER / GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-1
• Insulating Brush Assembly
• Starter/Generator Adjuster
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-1
• Steering Shaft
• Steering Column
• Tie Rod Assembly
WEATHER PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1
• Sun Top Kit
• Windshield Kit
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U-1
SPECIALTY PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX A-1
OPTIONS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX B-1

Page v
Service Parts Manual
This manual is divided into several sections:
GENERAL INFORMATION
•TABLE OF CONTENTS
•HOW TO USE THE SERVICE PARTS MANUAL
ILLUSTRATED PARTS BREAKDOWN
•Contains illustrations and parts lists for all systems of the vehicle
APPENDIX
•Contains a listing of specialty products and options/accessories
USE OF THE MANUAL
To use this manual, consult the TABLE OF CONTENTS (page iii) to locate the information or illustration required.
Introduction of some revisions varies due to supply of components; therefore, it is possible that various combinations of
components may be found that are not directly reflected by each illustration. Consult the illustration that best suits your
situation. Locate the serial number plate (see BODY located in the Illustrated Parts Breakdown section of this manual
for its location) and note the complete number shown on the plate. It is important that the serial number of your vehicle
and its model number be supplied to Service Parts when ordering any replacement components.
HOW TO USE THE SERVICE PARTS MANUAL

Page vi
HOW TO USE THE SERVICE PARTS MANUAL
Service Parts Manual
1. WHEN THE PART NUMBER IS NOT KNOWN
•Determine the function and application of the part required. Turn to the INDEX OF MAJOR COMPONENTS and
select the most appropriate component description.
•Turn to the page number indicated and locate the part description in the parts list. Read the full accompanying
description for specific information regarding the part that was not shown in the index.
•From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying
it with the pictorial representation on the illustrated page.
2. IF YOU KNOW THE PART NUMBER
•Use the INDEX OF MAJOR COMPONENTS to find the page(s) the part number appears on.
•Turn to the page number indicated and locate the part number in the parts list. Refer to the accompanying descrip-
tion for specific information regarding the part.
•From the parts list, obtain the item number assigned to it and confirm that the part selected is correct by verifying
it with the pictorial representation on the illustrated page.
Should an asterisk (*) appear in the part number column on the parts list page, read upwards until a part number is
found. The part number is the lowest assembly sold by Service Parts. The asterisk (*) indicates that the part depicted is
not available for purchase.
NOTE: Descriptions are indented under the assembly that they are used on. That assembly is, in turn listed under the
assembly that it is used on. This process is repeated until the highest final assembly is reached.
To facilitate the maintenance and repair of the vehicle, a Technician’s Repair and Service Manual is
available from the Service Parts Department.
Title Title
Left hand illustration page
(continued on right hand page
if required) Parts list (continued on
rear of page if required)
Front of Vehicle
123
101
100
99
98
120
74 70
71
64
63
65
66
67
121
122
114
119
115
111
73
72
112
118
116
113
62
69
94
96
95
82,87
81,8684,89
83,88
102,104
105
79
91
92
107
106
62 - Includes Items 63 - 66, 69 - 74
70 - Includes Items 71 - 74
81 - Includes Items 82 - 84
86 - Includes Items 87 - 89
94 - Includes Items 95, 96
111 - Includes Items 112 - 114
118 - Includes Items 119 - 121
126 - Includes Items 127 - 131
103
*See Body Section for
decal information
127
128129
130
131
126

Page vii
Service Parts Manual
ILLUSTRATED PARTS BREAKDOWN
ILLUSTRATED PARTS BREAKDOWN

Page A-1 Service Parts Manual
ACCELERATOR
3
35
8
To
Governor
1 - Includes Items 3 - 34
21 17
15
14
13 12
25
5
4
7
6
4
2
9
10
22
11
20
32
33
19
19
31 30
18
34
16
Part of
Frame
23
28

Page A-2
Service Parts Manual
ACCELERATOR
Differential
56
53
45
46
44
43
50 47
58
55
57
52
54
48
49
53
51

Page A-3 Service Parts Manual
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
ACCELERATOR
1 606990 PEDAL BOX ASSEMBLY (INCLUDES ITEMS 2 - 34) .................................... 1
2 70116G02 ACCELERATOR PEDAL BRACKET......................................................... 1
3 01051G01 SCREW, #8 - 16 X 1/2" LG ....................................................................... 4
4 25853G03 PEDAL BOX AND COVER ....................................................................... 1
5 00684G6 SCREW, #8 - 32 X 3/4" LG (STAINLESS STEEL).................................... 2
6 25861G01 MICRO SWITCH ....................................................................................... 1
7 01050G01 SCREW, #4 - 20 X 5/8" LG ....................................................................... 2
8 72716G01 MICRO SWITCH CAM .............................................................................. 1
9 15126G1 LOCK NUT, 5/16 - 24 ................................................................................ 1
10 00487G3 SETSCREW, 1/4 - 20 X 3/8" LG ............................................................... 1
11 00532G4 NUT, 5/16 - 24........................................................................................... 2
12 17677G1 SPRING RETAINER ................................................................................. 1
13 17979G1 ACCELERATOR ROD BUSHING ............................................................. 1
14 73046G01 COMPRESSION SPRING ........................................................................ 1
15 17677G2 SPRING RETAINER ................................................................................. 1
16 72072G01 ACCELERATOR ROD .............................................................................. 1
17 10385G4 CLEVIS YOKE (ADJUSTABLE) ................................................................ 1
18 10386G3 CLEVIS PIN, 5/16" X 13/16" LG................................................................ 1
19 17838G1 NYLON BUSHING .................................................................................... 3
20 17255G1 TEFLON WASHER, 5/16" ......................................................................... 1
21 10387G3 COTTER PIN, 3/32" X 3/4" LG.................................................................. 1
22 74432G01 PEDAL PIVOT PIN.................................................................................... 1
23 12064G6 PUSH NUT, 9/32"...................................................................................... 1
24 12730G1 WHEEL BEARING GREASE (NOT ILLUSTRATED) ................................ A/R
25 72201G04 WIRE HARNESS (PEDAL BOX)............................................................... 1
26
27
28 608608 ACCELERATOR CABLE........................................................................... 1
29
30 25799G03 ACCELERATOR PEDAL ASSEMBLY (INCLUDES ITEMS 31- 33).......... 1
31 27844G01 ACCELERATOR PEDAL PAD KIT (INCLUDES ITEMS 32- 33)............. 1

When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
Page A-4
Service Parts Manual
ACCELERATOR
32 16409G1 OVAL RIVET, 3/16" X 7/16" LG ....................................................... 6
33 27512-G01 ACCELERATOR PEDAL PAD ......................................................... 1
34 * ACCELERATOR PEDAL
35 00715G2 BOLT, 5/16 -18 X 4/5" LG................................................................................ 4
36
37
38
39
40
41
42
43 606083 UPPER GOVERNOR BRACKET.................................................................... 1
44 606005 LOWER GOVERNOR BRACKET ................................................................... 1
45 606265 BOLT, M6 - 1 X 12........................................................................................... 1
46 606421 BOLT, M6 - 1 X 30........................................................................................... 1
47 450452 NUT, M6 - 1.0 .................................................................................................. 1
48 606283 GOVERNOR LEVER BUSHING ..................................................................... 1
49 606284 GOVERNOR ROD .......................................................................................... 1
50 603890 GOVERNOR ROD GUARD ............................................................................ 1
51 606264 BOLT, M6 - 1 X 20........................................................................................... 1
52 606262 BOLT, M8 - 1.25 X 16...................................................................................... 1
53 606074 GOVERNOR CABLE / DIRECTION SELECTOR BRACKET ......................... 1
54 606256 BOLT, M10 - 1.25 X 16.................................................................................... 2
55 14601G11 RIVET.............................................................................................................. 1
56 608527 GOVERNOR WARNING DECAL.................................................................... 1
57 00915G1 WASHER ........................................................................................................ 1
58 606199 GOVERNOR COVER ..................................................................................... 1
59 17618G1 NYLON CLAMP ............................................................................................. 2

Page B-1 Service Parts Manual
AIR FILTER
1
2
3
4
5
6
7
8
9
10
Carburetor

Page B-2
Service Parts Manual
AIR FILTER
UP
1
7
9
9
10
12
13
14
15
16
17

Page B-3 Service Parts Manual
When ordering parts, please specify the model and serial number of the product.
* Indicates a component that is not available as an individual part.
*** Indicates consult Customer Service Department for additional information.
ITEM PARTNO. 12345 DESCRIPTION QTY.
AIR FILTER
1 606952 AIR CLEANER (INCLUDES ITEMS 2 - 6)...................................................... 1
2 607269 BODY & BRACKET ASSEMBLY .............................................................. 1
3 72599G01 AIR CLEANER COVER ............................................................................ 1
4 72604G01 AIR CLEANER CLIP ................................................................................. 2
5 28463G01 AIR FILTER ............................................................................................... 1
6 28462G01 VALVE DUST EJECTOR........................................................................... 1
7 11391G7 HOSE CLAMP, 1.56 - 2.50 DIA ....................................................................... 1
8 607950 HOSE 10" LONG ............................................................................................. 1
9 11391G1 HOSE CLAMP 1.31 - 2.25 DIA........................................................................ 3
10 25532G1 BOLT AND WASHER, M8 X 1.25 X 18 MM .................................................... 4
11
12 72637G03 HOSE, AIR INTAKE, 16" LONG ...................................................................... 1
13 72416G01 INTAKE ASSEMBLY, REMOTE AIR................................................................ 1
14 72415G01 GASKET, REMOTE AIR INTAKE .................................................................... 1
15 71055G01 RIVET, 3/16 DIA .............................................................................................. 4
16 11391G2 CLAMP, HOSE, 2.06 - 3.00 DIA ...................................................................... 1
17 601910 HOSE, 14’ LONG ............................................................................................ 1

Page B-4
Service Parts Manual
Notes:
AIR FILTER

Page C-1 Service Parts Manual
BODY
48
17 - Includes Items 18 - 23
13
14
52
53
55
49
57
15
25
28
50 33 34
10
9
40
29 31
32
2
6
5
4
20
22
23
18
19
21
39
65
72
69
71
68
70
56
3
1
27
26
43
44
45

Page C-2
Service Parts Manual
BODY
OR
See
Electrical
78 77 79
80
81
92
91
74
97
96
84 86 87
85
88
111
121
125
107
106
122
164
165
108
158
167
168
170 136
138 156
155
137
140
163
139
197
198
199
118
119
129
126
113 125
124
132
131
123
127
122
130
166
115
163
123
114
112
160
159
124
120
104
105
105

Page C-3 Service Parts Manual
BODY
186
ST SPORT
170
187
184
185
171
196
208
207
188
189
182
183
195
193
192
194