Ezgo ST 480 2007 User manual

OWNER’S MANUAL AND SERVICE GUIDE
ÄGARHANDBOK OCH SERVICEGUIDE
606420-SE
GASOLINE POWERED UTILITY VEHICLES
BENSINDRIVET NYTTOFORDON
ISSUED DECEMBER 2006 REVISED FEBRUARY 2010
UTGIVEN DECEMBER 2006 REVIDERAD FEBRUARI 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.
These are the original instructions as defined by 2006/42/EC.
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.

Owner’s Manual and Service Guide Page ix
SAFETY INFORMATION
• 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. Carbon
monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal.

Owner’s Manual and Service Guide
Notes:
Page x
SAFETY INFORMATION

Owner’s Manual and Service Guide Page xi
SAFETY INFORMATION
GENERAL
The following text is provided as recommended by part II of ANSI/ITSDF B56.8 - 2006. The manufacturer strongly
endorses the contents of this specification.
6 GENERAL SAFETY PRACTICES
6.1 Introduction
6.1.1 Like other machines, carriers can cause injury if improperly used or maintained. Part II contains broad safety
practices applicable to carrier operation. Before operation, the user shall establish such additional specific safety prac-
tices as may reasonably be required for safe operation.
6.1.2 Premise review — The user shall periodically review their premises, and as conditions warrant, identify areas
where carriers should not be operated and to identify possible hazards such as the following examples:
a) Steep Grade — In areas where steep grades exist, carrier operation should be restricted to the designated vehi-
cle’s pathways where possible, and shall be identified with a suitable warning giving the following information:
“Warning, steep grade.”
b) Wet Areas — Wet areas could cause a carrier to lose traction and could affect steering, stability and braking.
c) Sharp Turns, Blind Spots, Bridge Approaches — Sharp turns, blind spots, bridge approaches, and other poten-
tially hazardous areas shall be identified with a suitable warning to the operator of the nature of the hazard and
stating the proper precautions to be taken to avoid the hazard.
d) Loose Terrain — Loose terrain could cause a carrier to lose traction and could affect steering, stability, and
braking.
6.2 Operation
Experience has shown that carriers, which comply with the provisions, stated in paragraph 9.3.9 are stable when
properly operated and when operated in accordance with specific safety rules and practices established to meet actual
operating terrain and conditions. However, improper operation, faulty maintenance, or poor housekeeping may contrib-
ute to a condition of instability and defeat the purpose of the standard. Some of the conditions which may affect stability
are failure of the user to follow safety practices; also, ground and floor conditions, grade, speed, loading, the operation
of the carrier with improper loads, battery weight, dynamic and static forces, and the judgment exercised by the carrier
operator.
a) The user shall train carrier operators to adhere strictly to the operating instructions stated in this Standard.
b) The user shall survey specific operating conditions and environment, and establish and train carrier operators to
comply with additional, specific safety practices.
6.3 Nameplates, Markings, Capacity, and Modifications
6.3.1 The user shall maintain in a legible condition all nameplates, warnings, and instructions, which are supplied by
the manufacturer.
6.3.2 Except as provided in 6.3.4, no modifications or alterations to a carrier, which may affect the capacity, stability,
or safe operation of the carrier, shall be made without the prior written approval of the original carrier manufacturer or a
successor thereof. When the carrier manufacturer or its successor approves a modification or alteration, appropriate
changes shall be made to capacity plates, decals, tags, and operation and maintenance manuals
6.3.3 As required under paragraphs 6.3.1 or 6.3.2, the manufacturer shall be contacted to secure new nameplates,
warnings, or instructions, which shall then be affixed in their proper place on the carrier.
6.3.4 In the event that the carrier manufacturer is no longer in business and there is no successor in interest to the
business, the user may arrange for a modification or alteration to a carrier, provided however, the controlling party
shall:

Owner’s Manual and Service Guide
Page xii
SAFETY INFORMATION
(1) Arrange for the modification or alteration to be designed, tested, and implemented by an engineer(s) expert in
carrier(s) and their safety;
(2) Maintain a permanent record of the design, test(s), and implementation of the modification or alteration;
(3) Make appropriate changes to the capacity plate(s), decals, tags, and operation and maintenance manuals;
(4) Affix a permanent and readily visible label on the carrier stating the manner in which the carrier has been mod-
ified or altered together with the date of the modification or alteration, and the name of the organization that
accomplished the tasks.
6.4 Fuel Handling and Storage
6.4.1 The user shall supervise the storage and handling of liquid fuels (when used) to be certain that it is in accor-
dance with ANSI/NFPA 505 and ANSI/NFPA 30 or as required by local ordinance.
6.4.2 Storage and handing of liquefied petroleum gas fuels shall be in accordance with ANSI/NFPA 505 and ANSI/
NFPA 58 or as required by local ordinance. If such storage or handling is not in compliance with these standards, the
user shall prevent the carrier from being used until such storage and handling is in compliance with these standards.
6.4.3 Prevent fire and explosion caused by static electric discharge. Use only non-metal, portable fuel containers
approved by the Underwriter’s Laboratory (U.L.) or the American Society for Testing & Materials (ASTM). If using a fun-
nel, make sure it is plastic and has no screen or filter.
Static electric discharge can ignite gasoline vapors in an ungrounded fuel container. Remove the fuel container from
the bed of a carrier or the trunk of a car ban place on the ground away from the carrier before filling. Keep nozzle in
contact with container opening while filling. When practical, remove equipment from trailers or truck beds and re -fuel
them on the ground. If this is not possible, use a portable, plastic fuel container to refuel equipment on a truck bed or
trailer.
6.5 Changing and Charging Storage Batteries for Electric Personnel and Burden Carriers
6.5.1 The user shall require battery changing and charging facilities and procedures to be in accordance with ANSI/
NFPA 505 or as required by local ordinance.
6.5.2 The user shall periodically inspect facilities and review procedures to be certain that ANSI/NFPA 505 or as
required by local ordinance, are strictly complied with, and shall familiarize carrier operators with it.
6.5.3 Maintenance and storage areas for carriers shall be properly ventilated to avoid fire hazards in accordance
with applicable fire codes and ordinances.
Ventilation for internal combustion engine powered carriers shall be provided to remove flammable vapors (gases),
fumes and other flammable materials. Consult applicable fire codes for specific levels of ventilation.
Ventilation for electric powered carriers shall be provided to remove the accumulation of flammable hydrogen gas
emitted during the battery charging process. The amount of hydrogen gas emitted depends upon a number of factors
such as the condition of the batteries, the output rate of the battery charger and the amount of time the batteries are on
charge. Because of the highly volatile nature of hydrogen gas and its propensity to accumulate in pockets, a minimum
number of air changes per hour is required during charging.
Consult applicable fire and safety codes for the specific ventilation levels required as well as the use of explosion
proof electrical apparatus. SAE J1718 can be followed to check for hydrogen gas levels.
6.6 Hazardous Locations
6.6.1 The user shall determine the hazard classification of the particular atmosphere or location in which the carrier
is to be use in the accordance with ANSI/NFPA 505.
6.6.2 The user shall permit in hazardous areas only those carriers approved and of the type required by ANSI/NFPA
505.

Owner’s Manual and Service Guide Page xiii
SAFETY INFORMATION
6.7 Lighting for Operating Area
The user, in accordance with his responsibility to survey the environment and operating conditions, shall determine if
the carrier requires lights and, if so, shall equip the carrier with appropriate lights.
6.8 Control of Noxious Gases and Fumes
When equipment powered by internal combustion engines is used in enclosed areas, the atmosphere shall be main-
tained within limits specified in the American Conference of Governmental Industrial Hygienists publication,:Threshold
Limit Values for Chemical Substances and Physical Agents in the Workroom Environment.” This may be accomplished
by ventilation maintenance of emission control equipment recommended or provided by the manufacturer of the equip-
ment.
6.9 Warning Device(s)
6.9.1 The user shall make periodic inspections of the carrier to be certain that the sound-producing and/or visual
device(s) if so equipped are maintained in good operating condition.
6.9.2 The user shall determine if operating conditions require the carrier to be equipped with additional sound-pro-
ducing or visual devices or both and be responsible for providing and maintaining such devices, in accordance with the
manufacturer’s recommendations.
6.10 Safety Interlocks
The user shall make periodic inspections of the carrier to be certain that the safety interlock system, if so equipped,
is operating properly.
7 OPERATING SAFETY RULES AND PRACTICES
7.1 Personnel and Burden Carrier Operator Qualifications
Only persons whoa are trained in the proper operation of the carrier shall be authorized to operate the carrier. Oper-
ators shall be qualified as to visual, auditory, physical, and mental ability to safely operate the equipment according to
Section 7, all other applicable parts of this Standard and the operators’ manual.
7.2 Personnel and Burden Carrier Operators’ Training
7.2.1 The user shall conduct an operators’ training program.
7.2.2 Successful completion of the operators’ training program by the operator shall be required before operation of
the carrier. The program shall be presented in its entirely to all-new operators and not condensed for those claiming
previous experience.
7.2.3 The user shall include as a minimum in the operators’ training program the following.
a) Instructional material provided by the manufacturer including the operators; manual;
b) Emphasis on safety of passengers, material loads, carrier operator, and other person(s);
c) General safety rules contained within this Standard and the additional specific rules determined by the user in
accordance with this Standard, and why they were formulated;
d) Introduction of equipment, control locations of the environment which could affect carrier operation;
e) Operator competency evaluations.
7.3 Personnel and Burden Carrier Operator Responsibility
7.3.1 General Operator Responsibility

Owner’s Manual and Service Guide
Page xiv
SAFETY INFORMATION
7.3.1.1 Read and follow operators’ manual
7.3.1.2 Do not operate carrier under the influence of drugs and alcohol.
7.3.1.3 Safeguard the pedestrians at all times. Do not drive carrier in a manner that would endanger other persons.
7.3.1.4 Riding on the carrier by persons other than the operator is authorized only on personnel seat(s) provided by
the manufacturer. All parts of each person’s body shall remain within the plan view outline of the carrier.
7.3.1.5 When a carrier is to be left unattended, stop the carrier, apply the parking brake, stop the engine or turn off
power, turn off the control or ignition circuit, and remove the key if provided. Additionally, for the electric carriers, the forward and
reverse directional controls, should be neutralized if a means is provided. Block the wheels if the carrier is on a n incline.
7.3.1.6 A carrier is considered unattended when the operator is 7.6m (25 ft.) or more from the carrier which remains
in his view, or whenever the operator leaves the carrier and it is not within his view. When the operator is dismounted and within
7.6m (25 ft.) of the carrier still in his view, he still must have controls neutralized, and the parking brake(s) set to prevent movement.
7.3.1.7 Maintain a safe distance from potential hazards, such as edges of ramps and platforms.
7.3.1.8 Use only approved carriers in hazardous locations, as defined in the appropriate safety standards.
7.3.1.9 Report all accidents to the user.
7.3.1.10 Do not add to, or modify, the carrier.
7.3.1.11 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles, access to stair-
ways, or fire equipment.
7.3.1.12 Only operate carrier while within operator’s station.
7.3.2 Traveling
7.3.2.1 Observe all traffic regulations, including authorized speed limits. Under normal traffic conditions keep to the
right. Maintain a safe distance, based on speed of travel, from a carrier or vehicle ahead, and keep the carrier under control at all
times. 7.3.2.2 Yield the right of way to pedestrians, ambulances, fire trucks, or other carriers or vehicles in emergency sit-
uations. 7.3.2.3 Do not pass another carrier or vehicle traveling in the same direction at intersections, blind spots, or at other
dangerous locations.
7.3.2.4 Keep a clear view of the path of travel, observe other traffic and personnel, and maintain a safe clearance.
7.3.2.5 Slow down or stop, as conditions dictate, and activate the sound-producing warning device at cross aisles
and when visibility is obstructed at other locations.
7.3.2.6 Ascend or descend grades slowly.
7.3.2.7 Avoid turning, if possible, and use caution on grades, ramps, or inclines, normally travel straight up and
down. 7.3.2.8 Under all travel conditions the carrier shall be operated at a speed that will permit it to be brought to a stop
in a safe manner.
7.3.2.9 Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift the load, endanger
passengers, or lose control of the carrier.
7.3.2.10 Do not operate carrier in a dangerous manner.
7.3.2.11 Slow down when approaching, or on, wet or slippery surfaces.
7.3.2.12 Do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly,
and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off power, and
set parking brakes. It is advisable that all other personnel leave the elevator before a carrier is allowed to enter or exit.
7.3.2.13 Avoid running over loose objects, potholes, and bumps.
7.3.2.14 Reduce carrier speed to negotiate turns.
7.3.2.15 Avoid any action verbal or physical by an operator or passenger, which could cause the operator to be dis-
tracted.
7.3.3 Loading
7.3.3.1 Refer to operators’ manual for loading instruction.

Owner’s Manual and Service Guide Page xv
SAFETY INFORMATION
7.3.3.2 Handle only stable and safely arranged loads. When handling off-center loads, which cannot be centered,
operate with extra caution.
7.3.3.3 Handle only loads within the capacity of each cargo area of the carrier as specified by the manufacturer.
7.3.3.4 Avoid material loads exceeding the physical dimensions of the carrier or as specified by the carrier manu-
facturer.
7.3.4 Operator Care of Personnel and Burden Carriers
7.3.4.1 Read and follow operators’ manual.
7.3.4.2 At the beginning of each shift during which the carrier will be used, the operator shall check the carrier con-
dition and inspect the tires, warning devices, lights, battery(s), speed and directional controllers, brakes, safety interlocks, and steer-
ing mechanism. If the carrier is found to be in need of repair, or in any way unsafe, the matter shall be reported immediately to the
user and the carrier shall not be operated until it has been restored to safe operating condition.
7.3.4.3 If during operation the carrier becomes unsafe in any way, the matter shall be reported immediately to the
user, and the carrier shall not be operated until it has been restored to safe operating condition.
7.3.4.4 Do not make repairs or adjustments unless specifically trained and authorized to do so.
7.3.4.5 Before refueling, the engine shall be stopped and allowed to cool. The operator and passengers shall leave
the carrier before refueling.
7.3.4.6 Spillage of hazardous materials shall be contained immediately and addressed via appropriate hazardous
materials regulations.
7.3.4.7 Do not operate a carrier with a leak in the fuel system or battery(s). Battery(s) shall be charged and serviced
per manufacturer’s instructions.
7.3.4.8 Do not use open flames for checking electrolyte level in storage battery(s) or liquid level in fuel tanks.
8 MAINTENANCE PRACTICES
8.1 Introduction
Carriers may become hazardous if maintenance is neglected. Maintenance facilities, trained personnel, and proce-
dures shall be provided. Such facilities may be on or off the premises.
8.2 Maintenance Procedures
Maintenance and inspection of all carriers shall be performed in conformance with the following practices and should
follow the manufacturer’s recommendations.
a) A scheduled preventive maintenance, lubrication, and inspection system shall be followed.
b) Only trained and authorized personnel shall be permitted to maintain, repair, adjust, and inspect carriers.
c) Before undertaking maintenance or repair follow the manufacturer’s recommendations for immobilizing the car-
rier.
d) Chock wheels and support carrier, before working underneath it.
e) Before disconnecting any part of the engine fuel system, be sure the shutoff valve, if so equipped, is closed and
follow carrier manufacturer’s recommended practice.
f) Operation to check performance of the carrier shall be conducted in an authorized area where suitable condi-
tions exist, free of vehicular and pedestrian traffic.
g) Before returning carrier to service, follow the manufacturer’s instructions and recommended procedure.
h) Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to
check level or leakage of fuel, battery electrolyte, or coolant.
i) Properly ventilate the work area in accordance with applicable regulations or local ordinance.
j) Handle fuel cylinders with care. Physical damage, such as dents, scrapes, or gouges, may dangerously weaken
the tank and make it unsafe for use.

Owner’s Manual and Service Guide
Page xvi
SAFETY INFORMATION
k) Brakes, steering mechanisms, speed and directional control mechanisms, warning devices, lights, governors,
guards, and safety devices shall be inspected regularly and maintained in accordance with manufacturer’s rec-
ommendations.
l) Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure
that maintenance preserves the original approved safe operating features.
m) Fuel systems shall be checked for leaks and condition of parts. If a leak is found, action shall be taken to prevent
the use to the carrier until the cause of the leak has been repaired.
n) The carrier manufacturer’s capacity, operation, and maintenance instruction plated, tags, or decals shall be
maintained in legible condition.
o) Batteries, motors, speed and directional controllers, limit switches, protective devices, electrical conductors/
insulators, and connections shall be inspected and maintained per carrier manufacturer’s recommendation.
p) Carriers shall be kept in a clean condition to minimize hazards and facilitate detection of components needing
service.
q) Modifications and additions which affect capacity and safe carrier operation shall not be performed without man-
ufacturer’s prior written authorization; where authorized modifications have been made, the user shall ensure
that capacity, operation, warning, and maintenance instruction plates, tags, or safety labels are changed accord-
ingly.
r) Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a
quality at least equal to that provided in the original equipment.
s) Disconnect batteries, negative connection(s) first. When reconnecting, connect positive connection first.
t) Hydraulic systems, if so equipped, shall be checked for leaks, for condition of parts. Keep body and hands away
from pin-holes or nozzles that eject fluids under high pressure. Use paper or cardboard, not hands, to check for
leaks.
ANSI/ITSDF B56.8 - 2006

OPERATION AND SERVICE INFORMATION
Page 1
Owner’s Manual and Service Guide
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
WELCOME
Thank you for purchasing this Utility Vehicle. This vehicle
is equipped with a 480 cc twin cylinder, overhead valve, 4
cycle, air-cooled engine. Before driving the vehicle, we
ask you to spend some time reading this Owner’s Man-
ual and Service Guide and the Operating and Mainte-
nance Instructions manual provided by the engine
manufacturer. These manuals contain the information
that will assist you in the safe operation of the vehicle.
They will also assist you in maintaining this highly reliable
vehicle. Some illustrations show items that may be
optional for your vehicle.
Most of the service procedures in this guide can be
accomplished by an individual using common automotive
hand tools. If you prefer to have service procedures per-
formed on your vehicle, contact your local dealer.
To facilitate maintenance, a Service Parts Manual, a
Technician’s Repair and Service Manual and an engine
Repair Manual is available from a local dealer. When
ordering parts or requesting information for your vehicle,
provide vehicle model, serial number and manufacture
date code.
BEFORE INITIAL USE
Record the four digit key number and store in a safe place. Indi-
vidual keys can only be replaced if the key number is known.
Without a key number, the entire ignition switch will have to be
replaced if keys are lost.
Improper use of this vehicle could result in
severe injury or death. The vehicle is a light
duty utility vehicle. It is NOT an all terrain vehi-
cle (ATV).
This vehicle is not a toy and using it while
engaging in horseplay is dangerous.
Plan carefully before using the vehicle to go
significant distances over questionable terrain.
Remember that a one hour drive may take
many hours to walk out should you run out of
fuel or be stranded by becoming stuck on
unsuitable terrain.
Hydrogen gas is generated as a natural part of
the lead acid battery charging process. A 4%
concentration of hydrogen gas is explosive and
could cause severe injury or death. Charging
must take place in an area that is adequately
ventilated (minimum of 5 air exchanges per
hour).
To reduce the chance of battery explosion that
could result in severe injury or death, never
smoke around or charge batteries in an area
that has open flame or electrical equipment that
could cause an electrical arc.
Read, understand and follow the SAFETY AND OPERA-
TION label located on the center of the instrument panel
above the drink holders (Ref Fig. 2 on page 2).
Be sure you understand the vehicle, its equipment and
how to use it safely. Although the vehicle has been
designed to provide safe and reliable operation, main-
taining good performance depends, to a large extent, on
the operator.
Before a new vehicle is put into operation, it is recom-
mended that the items shown in the INITIAL SERVICE
CHART be performed (Ref Fig. 1 on page 1).
Fig. 1 Initial Service Chart
PREPARATION OF SEATS FOR
SERVICE
Remove the protective plastic coverings from the seats
before placing the vehicle in service. The only function of
the plastic covering is to protect the seat bottom and
back rest during shipping. If the plastic covering is left on
the seat and becomes torn, dirt may get under the plastic
covering and be ground into the cover material. Water
getting under the plastic covering can become trapped
and eventually will damage the seat assembly.
ITEM
Battery Charge battery
Seats Remove protective plastic covering
Brakes Check operation and adjust if necessary
Check hydraulic brake fluid level
Establish new vehicle braking distance
Tires Chec k pressure
Fuel Fill tank with correct fuel
Engine Check oil level (Initial change after 5 - 8 hours
)
Keys Record key number and store in safe location
R
ef Isc 3
SERVICE OPERATION

OPERATION AND SERVICE INFORMATION
Page 2 Owner’s Manual and Service Guide
Read all of Manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Fig. 2 Safety and Operation Label
TERRAIN
The vehicle is designed for use on improved roads (but
not on public highways). The vehicle may also be used
on established trails or open terrain that is free from
stumps, large rocks or holes.
The vehicle should not be used to cross water.
VEHICLE CAPACITY
Due to the variety of ways the vehicle may be
used, it is important that the operator consider
any potential hazards before use to prevent
serious injury or death.
The vehicle may be used to transport a maximum of
two people within the operator/passenger compart-
ment and cargo in the dump bed. Never carry passen-
gers in the dump bed. The total payload is 800 lbs. (363
kg).
The weight of the driver and passenger plus any options
or accessories must be deducted from the total payload
rating to determine the dump bed capacity. Remember
that towing a trailer will reduce the payload of the vehicle
itself.
Remember that volume of your load can be misleading.
Loading the vehicle to its rated capacity with dry sand,
fertilizer, sod, etc. can be handled with complete safety.
The same load when wet will grossly overload the vehi-
cle and increase the potential for roll over and damage to
the vehicle.
MODIFICATIONS TO VEHICLE
Changes to the weight distribution or the center
of gravity may make it unstable or prone to roll
over which could result in injury or death to the
operator or passenger.
Do not modify the vehicle in any manner that will change
the weight distribution of the vehicle. Changes to the
weight distribution or the center of gravity may make it
unstable or prone to roll over which could result in injury
or death to the operator or passenger.
DUMP BED
Be careful when loading the vehicle. Secure loads to pre-
vent shifting. Do not overload vehicle. A dump bed warn-
ing label is affixed to the inside of the bed on the front
panel (Ref Fig. 3 on page 3).
This label must be understood and observed at all times
for safe operation of the vehicle. The dump bed is limited
to a maximum load of 500 lbs (228 kg). The load must be
positioned in the bed as far forward as possible, its cen-
ter of gravity must not be higher than 5" (12 cm) above
the bed floor, and securely fastened down. Failure to fol-
low these instructions could cause personal injury, dam-
age to the vehicle and/or cause the vehicle to tip over.
Operate the vehicle with awareness of the load.
Do not drive the vehicle with the dump bed raised or with
the tailgate unsupported.
When using the optional electric dump, be sure to avoid
backing up to the edge of a drop off, such as a loading
dock or ravine. A misjudgment of distance or an unstable
surface could result in the vehicle falling backwards.
Always insure that no one is behind or close to the dump
bed while the electric dump mechanism is being ope
rated
Passengers should never be allowed to ride in
the dump bed. Severe injury or death could
result if they should fall out or the vehicle is
involved in an accident or sudden maneuver.
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