Motrec G-320 Installation instructions

G-320
OPERATOR AND MAINTENANCE MANUAL
SPARE PARTS LISTS INCLUDED
SERIAL NUMBER : 1040233 & UP
Printed in Canada

19/05/2006
One Year Limited Warranty
Effective April 25, 2005, MOTREC, Inc. (MOTREC) hereby warrants to the Original Retail Purchaser (Owner) that any of its
vehicles shall be free from any defect in materials for a period of 90 DAYS while in the possession of such Original Retail
Purchaser. This warranty IS NOT TRANSFERABLE to any subsequent Buyer.
The warranty period is extended to one year or one thousand (1,000) hours, which ever first occurs, on the electric motor,
differential (parts that bathe in oil) and the electronic speed controller. MOTREC makes no warranty or representation with
respect to the internal combustion engine, tires and batteries, since their respective manufacturers cover such parts.
Accessories (light, gage, horn, etc), electrical contacts (switch, solenoid, contactor, relay), diodes & fuses, belts & pulleys,
filters & spark plugs, lubricants, brake linings & shoes, brake drums & discs, seals, seats, trim and other items subject to
wear are not included in this warranty; nor is any item that in MOTREC sole opinion, shows evidence of neglect, misuse,
abuse, collision or alteration.
This warranty shall not apply to normal maintenance requirements as described in the User Manual, and to damages during
shipment. The latter is the carrier's responsibility. No compensation will be allowed for delays.
To initiate warranty coverage on any MOTREC vehicle, the Dealer must complete and return the “Sales/Installation Report”
to MOTREC within 30 days after delivery to the Original Retail Purchaser; or within 90 days after the delivery date to the
Dealer, which ever occurs first. Failure to follow these procedures will result in considering the warranty coverage effective
as of the shipment date from the factory.
The defective vehicle must be returned, at the Owner's expense, to an authorised MOTREC Dealer within 30 days after
failure. The Owner will not be charged for parts and labour required for warranty repairs, which must be performed by an
authorised MOTREC Dealer only. The vehicle will be returned at the owner’s expense. The Warranty Claim Forms must be
completed and returned with the defective part(s) to MOTREC within 30 days after repair was done. No compensation will be
allowed for damages caused by vehicle downtime.
It is the responsibility of the owner of the vehicle to make sure that the driver is properly trained and instructed in the safety
features and operation of the vehicle, including vehicle stability, as required by OSHA and ANSI-B56. Operators shall read,
understand and follow the safety and operating instructions in MOTREC Manual before driving the vehicle. Operators shall
not be permitted to drive the vehicle unless a complete and adequate training has been provided. Driving a vehicle
constitutes a hazard. The driver is responsible for the control of the vehicle while driving and must always evaluate and care
for all peculiar situations that he or she may meet while driving. The driver assumes the inherent hazards related to this
activity. The vehicle is designed for off-road use only. MOTREC disclaims any liability for incidental or consequential
damages, to include, but not be limited to, personal injury or property damage arising from vehicle misuse, lack of
maintenance or any defect in the vehicle.
It is the responsibility of the Owner of the vehicle to make sure that the service technicians are properly trained as required
by OSHA and ANSI-B56. Service technicians shall read, understand and follow instructions in the MOTREC manual before
servicing the vehicle. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect the
vehicle.
MOTREC prohibits, and disclaims responsibility for, any vehicle modification altering the weight distribution and stability,
increasing the speed or affecting the safety of the vehicle. Such modifications can cause serious personal injury or property
damage for which MOTREC disclaims any responsibility.
For Owners that are located outside North America, the warranty period starts the date of shipment from the factory, and the
defective parts must be returned at the Owner's expense to MOTREC prior to warranty repair.

Table of contents
- 3 -
TABLE OF CONTENTS
INSTRUCTIONS 4
SAFETY WARNINGS FOR OPERATORS 5
VEHICLE CONTROLS (B&S -KOHLER) 6
MAINTENANCE 7
SAFETY WARNINGS FOR SERVICE TECHNICIANS 8
DECALS AND LABELS 9
PREVENTIVE MAINTENANCE SCHEDULE -MOTREC I.C. UNITS 10
OIL GRADE CHART 11
FORWARD/REVERSE TRANSMISSION 12
ACCELERATOR ADJUSTMENT 13
HYDRAULIC BRAKES 14
FRONT AXLE AND STEERING 15
SAFETY PRECAUTIONS 16
ENGINE INFORMATION 19
OIL AND FUEL RECOMMANDATIONS 20
OPERATING INSTRUCTIONS 22
MAINTENANCE INSTRUCTIONS 24
WARRANTY 29
SPARE PARTS 32
BODY 33
DIFFERENTIAL 34
HYDRAULIC DRUM BRAKES 36
BRAKE CONTROLS 37
FRONT ASSEMBLY 38
DRIVE 40
MUFFLER 41
MUFFLER 42
REAR SUSPENSION 43
ELECTRICAL DIAGRAM –BRIGGS AND STRATTON 44
ELECTRICAL DIAGRAM -KOHLER 45
ELECTRICAL DIAGRAM -ACCESSORIES 46
ENGINE CONTROLS 48
F/R SELECTOR 49
MOTREC ILLUSTRATED ACCESSORIES 50
BRIGGS AND STRATTON ILLUSTRATED PARTS LIST 52

Instructions
- 4 -
INSTRUCTIONS

Instructions
- 5 -
SAFETY WARNINGS FOR OPERATORS
•FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY.
•It is the responsibility of the owner of this vehicle to train operators to ensure that they understand the operating
characteristics of this vehicle, including training in vehicle stability, and obey the following safety rules and
guidelines. Owner shall comply with OSHA and ASME/ANSI B56.8 & B56.9 regulations for vehicle use,
safety rules, operator training and certification. Do not drive this vehicle unless you are a qualified operator.
•Do not drive this vehicle under the influence of drugs or alcohol.
•Do not drive this vehicle on public roads and highways. This vehicle is designed to be driven in buildings.
•This vehicle can make sparks which can ignite inflammable materials. Never use the vehicle in hazardous areas
where there are inflammable materials, explosive dust or fumes in the air.
•Never run the engine in a confined area and avoid inhaling engine poisonous fumes which contain CO.
•Have your vehicle inspected regularly by trained personnel, and cease operation if a malfunction occurs.
•Do not open motor compartment. Keep clear from moving, rotating(wheels, sheaves, etc) or lifting parts.
•Keep clear from hot parts of exhaust system.
•Never carry more passengers than number allowed for this vehicle. Wait until all occupants are seated and
holding on before moving. Always keep all body parts inside vehicle. Keep both hands on steering wheel.
•Do not exceed the vehicle cargo load capacity and gross trailing weight capacity, rated for flat hard even surface.
Different operating conditions such as loose terrain or ramps reduce vehicle capacity.
•Avoid loose, unbalanced or top-heavy loads to keep a good stability and prevent overturn. Do not load cargo that
can fall off the vehicle. Do not carry cargo that is longer, wider or higher than this vehicle.
•Always depress slowly the accelerator for smooth acceleration. Avoid stunt driving or horseplay.
•Avoid sharp turns, always slow down before turning, to prevent vehicle overturn or trailer jack knife. Vehicle is
more sensitive to overturn and jack knife when traveling on inclines or when carrying a heavy load.
•Always drive straight up and down the face of an incline, never across the face, to prevent overturn and trailer
jack knife. Drive slower and start applying brakes sooner on inclines to adjust for longer stopping distance.
•Use extra care and drive slowly in reverse, in congested areas or on wet or slippery ground.
•Keep to the right under normal conditions. Maintain a safe distance from all objects.
•Slow down and sound the horn when approaching a corner or other blind intersections.
•Before leaving the vehicle, park on level ground flat surface, turn off all switches, set forward/reverse selector to
neutral, set parking brake, remove the key. Do not park the vehicle on an incline.
•Use another driver to steer this vehicle while it is towed. Be sure the driver uses brakes when you slow or stop
the towing vehicle. Do not exceed 5 MPH or carry any passenger while towing this vehicle.

Instructions
- 6 -
VEHICLE CONTROLS (B&S - KOHLER)
The owner of this vehicle shall ensure that the operator understands the operating characteristics of this
vehicle, and obeys the safety instructions in this manual and ANSI B56.8 & 56.9 standards.
Do not drive this vehicle unless you are a qualified operator, and certified by the owner.
Engine Oil
Never open engine compartment while engine is running. Before checking engine oil, stop engine.
Avoid touching hot engine, muffler and exhaust parts.
Fuel Tank
The fuel tank is located on the right. Do not remove the fuel cap while the engine is running. Do not fill
the fuel tank to point of overflowing. Use clean, fresh, lead-free gasoline intended for automotive use.
A minimum of 85 octane is recommended. Do not mix oil with gasoline.
Oil Sentry
When the red light on the instrument panel turns on, the engine oil pressure is too low, and engine must
be serviced. Otherwise, damage to the engine may result.
Horn button
The horn button is located on the steering column.
Park brake lever
To actuate the parking brake, depress the brake pedal and pull up the hand lever. Never park on an
incline. Before leaving vehicle, set FWD/REV shifter to NEUTRAL, set parking brake, remove key
Accelerator and brake pedals
The accelerator and brake pedals operate the same way as the pedals of an automobile. Depress the
accelerator pedal with the right foot to speed the vehicle up and release it to slow down. Depress the
brake pedal with the right foot to reduce the vehicle speed.
Forward/Reverse Selector
Shift only when the vehicle is not moving and engine is at idle speed.
Before leaving vehicle, set FWD/REV shifter to NEUTRAL, set parking brake, remove key.
Manual Choke
GAS ENGINE: before starting a cold engine, pull out the choke knob and depress the accelerator pedal
halfway to the floor; as the engine warms up, push the knob in until the engine responds properly.
LPG ENGINE: before starting the engine, pull out the choke and depress the accelerator pedal halfway
to the floor; while starting, after two seconds, push the knob halfway; as the engine warms up, push the
knob in until the engine responds properly.
Key switch / starter
Before starting, set the F/R selector in NEUTRAL. To avoid starter damage do not crank the engine
continuously for more than 10 seconds at a time; wait 60 seconds before attempting to start again.
Before leaving vehicle, set FWD/REV shifter to NEUTRAL, set parking brake, remove key.

Maintenance
- 7 -
MAINTENANCE

Maintenance
- 8 -
SAFETY WARNINGS FOR SERVICE TECHNICIANS
FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY.
Owner shall comply with OSHA and ASME/ANSI B56.8 & B56.9 regulations for vehicle maintenance.
Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect carriers,
vehicles, tractors, and batteries.
Maintenance operations must be made by properly trained service technicians.
Before any maintenance work, park the vehicle on a flat level surface, set the shift lever to park, turn off all
the switches, remove the key, lift the wheels off the ground and secure with jack stands of adequate capacity.
Keep clear from moving parts such as tires, sheaves, drive shaft and engine.
Keep clear from hot parts of exhaust system.
Avoid increasing engine RPM and vehicle speed to prevent accident and severe injuries.
Follow the maintenance instructions applicable to the type of repair, maintenance, or service.
Always wear a face shield and gloves when working around batteries. Use insulated tools to avoid sparks
that can cause battery explosion and acid splashing. Use two counteracting tools, double-wrench technique,
when disconnecting or tightening terminals on the battery to avoid damaging battery posts.
Keep cables and wires clear from mechanical and rubbing action. Make sure cable covering is free from
cutting or visible damage.
Before replacing a fuse or circuit breaker, identify the cause of failure and repair.
Always ensure the integrity of the warning labels. If they suffered damage and are not readable, replace them
promptly. The following images depict the dashboard and general security warning labels:

Maintenance
- 9 -
DECALS AND LABELS
! CAUTION !
The images included in this section depict the decals/markings installed on the vehicle. It is of
the utmost importance that theses decals/markings remain unaltered and readable. Else, the
sticker or the part baring the marking has to be replaced.
Dashboard security warning label:
General security warning label:
Respectively, key switch markings, forward/reverse selector markings and light switch marking:

Maintenance
- 10 -
PREVENTIVE MAINTENANCE SCHEDULE - MOTREC I.C. UNITS
! WARNING ! Read safety instructions before maintenance operations to avoid severe injury.
! WARNING ! Maintenance operations must be made by properly trained service technicians.
Follow OSHA and ANSI B56 regulations.
Change engine oil after first 8 hours of use. S/N: _________________ Hour Meter reading: ________
ESTIMATED TIME (MINUTES)
PERIOD
DESCRIPTION SHIFT
START 100H
200 H 1000 H YEAR
CHECK
Stop engine, check engine oil level. 3
Check vehicle for visual damage 2
Examine floor around and beneath unit for signs of
transmission oil, differential oil, brake fluid leaks. 2
Turn steering, check for hard steering, excessive
free play, or unusual sound when turning. 1
Check accelerator for free & smooth movement. 2
Shift in neutral, before starting engine. 1
Check reverse alarm, horn, strobe light. 2
Check brake pedal travel and parking brake for
secure hold. Start slowly and check service brake. 2
Check tire pressure, see pressure rating on tire 5
Check transmission & hydraulic oil level, if appl. 5
Check radiator coolant level, if applicable. 2
Check master cylinder fluid level (DOT 3) 2
Check brake pedal travel 1
Turn front wheels straight, check steering play 1
Check parking brake, requires 10 lbs. force to apply 1
Check brake lines and drive for leaks 5
Check fuel pipe, hose, clamps for damage & leaks 5
Check radiator fan belt, CVT belt, if applicable 3
Service air filter, check intake pipe & clamps 5
Check muffler, exhaust pipe, clamps, spark arrester 5
Air cooled engines only, change engine oil 20(X)
Water-cooled engines only, change engine oil X(20)
WARNING LABELS & MARKINGS 2
Inspect wheel bearings and king pins for play 8
Inspect steering suspension linkages & frame. 10
Check pedal & master cylinder linkages for wear 10
Check service brake linings and linkages for wear 15
Check Spark Plugs 20
Change Oil Filter 20
Change air filter 10
Clean radiators and engine shrouds 20
Lubricate the vehicle 5
Service fuel filter, LP vaporizer & regulator 20
Check engine valve clearance & seats 40
Check ignition wires, tighten all nuts and bolts 20
Change differential oil, transmission oil & filter 20
Clean & repack front hubs 20
Flush/change brake fluid 30
Flush/change radiator coolant, if applicable 30
TOTAL TIME (MINUTES) 15 60 120 120 60

Maintenance
- 11 -
OIL GRADE CHART
Vehicle system Oil grade
Engine 10W30
Differential SAE30
Brakes DOT 3, concurring with DMVSS116 standard

Maintenance
- 12 -
FORWARD/REVERSE TRANSMISSION
! ATTENTION !
Make sure that the technician disposes of the proper qualifications and training to perform the
following.
Before attempting to make any repairs, hoist the vehicle, immobilize and hold the vehicle in
place by chocking the wheels and putting chassis stands underneath.
TRANSMISSION IS HARD TO SHIFT:
-check engine idle speed, it must be between 1150 and 1250 RPM;
-if a new belt has been installed, the problem should disappear in a week;
-check if the belt is standard length;
-check F/R lever adjustment;
-check if the shift rod (item 9) has been damaged.
TRANSMISSION POPS OUT OF GEAR:
-check F/R lever adjustment;
-tighten the adjustment screw of the detent ball of the shift rod;
-check if the shift rod has been damaged.
F/R LEVER ADJUSTMENT:
If the F/R cable have been disassembled, put the F/R selector and differential shifter in neutral, and
adjust the yoke and cable so that the clevis pin is easy to install.
Start the engine and push the lever in forward. Slowly pull the lever toward the center until the wheels
stop turning and than measure F.
Pull the lever in reverse. Slowly push the lever toward the center until the wheels stop turning and
than measure R.
F and R distances must be equal. To adjust, slightly loosen the two nuts on the F/R cable at the
differential end. Turn the nuts until F and R distances are equal. If there is not enough play, the two
nuts at the lever end can be used. Tighten all the nuts and measure F and R distances. Repeat the
adjustment until F and R are equal.

Maintenance
- 13 -
ACCELERATOR ADJUSTMENT
! WARNING !
Service technicians shall be trained and qualified to perform the following.
Before any repair or maintenance work, park on a flat level surface, set to neutral, set parking
brake, lift the rear wheels off the ground and secure with jack stands of adequate capacity.
ENGINE IDLE RPM
Check engine idle speed with accelerator released: It should read between 1150 and 1250 RPM
NOTE : The throttle spring on the engine must returns the throttle lever to its idle position.
To adjust idle speed, use the idle adjustment screw located on the engine (figures below).
IMPORTANT: If engine does not run smoothly at idle speed, refer to engine manufacturer’s
instructions.
ENGINE MAXIMUM RPM
Check engine maximum speed with the accelerator fully depressed: It should read between 3350 and
3500 RPM.
NOTE: Make sure the accelerator pedal rests on the floor stopper when fully depressed.
To adjust maximum RPM:
1- Turn CW floor stopper adjustment to increase engine maximum RPM;
2- Turn CCW floor stopper adjustment to decrease engine maximum RPM
3- Check engine RPM.
NOTE: If it’s impossible to reach the required engine maximum RPM with the floor stopper
adjustment, shorten the wire pulling the engine throttle lever and follow steps 1 through 3.
B&S Engine Kohler Engine

Maintenance
- 14 -
HYDRAULIC BRAKES
DRUM BRAKES
Remove brake drums and check linings wear; the linings should have a thickness exceeding 1/16" (1.5
mm). Turn the brake adjustment to reduce the clearance between lining and drum but avoid contact or
drag when the wheels are turned and the pedal is released.
DISC BRAKES
Check pad linings for excessive wear; the linings should have a thickness exceeding 1/16" (1.5 mm).
Disc brakes are self-adjusting.
BRAKE PEDAL
If the brake pedal becomes soft or spongy, air may have entered the hydraulic system and the brake
system has to be bled:
1. fill the master cylinder with brake fluid (DOT-3);
2. bleed front callipers one at a time by having someone applying a steady pressure on the brake
pedal, and close the bleeder before allowing the brake pedal to return to up position;
3. fill the master cylinder with brake fluid (DOT-3);
4. bleed rear wheel brakes one at a time, following the same procedure;
5. fill the master cylinder with brake fluid (DOT-3);
6. clean every fitting and line, remove traces of oil;
7. apply a continuous pressure on the brake pedal for about five minutes ;
8. Finally, inspect brake lines and fittings for leaks ;

Maintenance
- 15 -
FRONT AXLE AND STEERING
! CAUTION !
Before maintenance, turn off all switches, set to neutral, set parking brake, remove the key,
and raise the front end of the vehicle supporting it with two jack stands of adequate capacity
STEERING INSPECTION
−Check tire inflation pressure, suspension components, tie rods straightness, tie rod ends play
(wear), play (wear) in wheel bearings, kingpins and bushings.
REPLACING & ADJUSTING THE STEERING GEAR
−Remove the pitman arm;
−The steering box makes 6.5 turns, center the steering gear (3.25 turns from either side);
−Align the front wheel straight. Install the pitman arm.
TOE-IN ADJUSTEMENT
−With the wheels in straight forward direction, measure the inside (left to right) distance between
the front tires, at the front and rear of the tires;
−Turn the rear tie rod until the distances are equal and tighten the two lock nuts on the tie rod.
REMOVING & GREASING OF FRONT HUBS, required once-a-year
−Remove dust cap and cutter pin, unscrew nut, remove hub;
−Inspect bearings and races for wear and replace worn bearings;
−Replace the seal;
−Pack the hub with wheel bearing grease and re-assemble.
ADJUSTING FRONT HUBS
−Tighten spindle nut to 30 ft-lb to seat the bearing and back off the nut to the next slot;
−Install a new cutter pin and the dust cap.

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- 19 -

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- 20 -
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