Textron EZGO Workhorse ST Series User manual

OWNER'S MANUAL & SERVICE GUIDE
Starting Model Year 2003
R

MANUAL INFORMATION
For any questions on materialcontained in this manual, contact a representative
for clarification.
Read and understand all labels located on the vehicle. Always replace any dam-
aged or missing labels.
On steep hills it is possible for vehicles to coast at greater than normal speeds
encountered on a flat surface. To prevent loss of vehicle control and possible
serious injury, speeds should belimited to no more than the maximum speed on
level ground. (See vehicle specification.) Limit speed by applying the service
brake.
Catastrophic damage to the drive train 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.
Be sure that this manual remains as part of the permanent service record
should thevehicle be re-sold.
Throughout this guide, NOTE, CAUTION and WARNING will be used.
A NOTE indicates a condition that should be
observed.
ACAUTION indicates a condition that
may result in damage to the vehicle.
A WARNING indicates a hazard-
ous condition which could result
in severe injury or death.
Please observe these notes, cautions, and warnings; be aware that servicing a
vehicle requires mechanical skill and a regard for conditions that could be haz-
ardous. Improper service or repair may damage the vehicle or render it unsafe.
Engine exhaust from this product
contains chemicals known, in cer-
tain quantities, to cause cancer,
birth defects, or other reproductive harm.
The exhaust emissions of this vehicles’ engine
complies with regulations set forth by the Environ-
mental Protection Agency (EPA) of the United States of America
(USA) at time of manufacture. Significant fines could result from
modifications or tampering with the engine, fuel, ignition or air
intake systems. Battery posts, terminals and relat-
ed accessories contain lead and
lead compounds. Wash hands
after handling.
This spark ignition system meets all requirements
of the Canadian Interference-Causing Equipment
Regulations.
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! !
! !
Ce système d'allumage par étincelle de véhicule respecte
toutes les exigences du Règlement sur le matériel brouilleu
r
du Canada.

i
OWNER’S MANUAL & SERVICE GUIDE
ST 350
ST SPORT
Textron Golf, Turf & Specialty Products reserves the right to make design changes without obligation to makethese changes on units previously sold and the information containedin
this manual is subject to change without notice.
Textron Golf, Turf & Specialty Products isnot liable for errorsin this manual or for incidental or consequential damage that result from the use of material in this manual.
CUSTOMER SERVICE DEPARTMENT IN USA PHONE: [phone] FAX: [phone]
OUTSIDE USA PHONE: [phone] FAX: [phone]
TEXTRON GOLF, TURF & SPECIALTY PRODUCTS, P.O. BOX 388 AUGUSTA, GEORGIA 30903-0388 USA

ii
NOTES
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 manufacture date code.
The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty.
Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void
the vehicle warranty.
When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to
maintain the United States of America Federal and State emission certification applicable at the time of manufacture.
BATTERY PROLONGED STORAGE
All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature
and the age and condition of the battery.
A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75° F (-60° C).

TABLE OF CONTENTS
1-1
TITLE PAGE TITLE PAGE
MANUAL INFORMATION..........................Inside Front Cover
NOTES ......................................................................................i
SAFETY INFORMATION......................................................2-1
OPERATION AND SERVICE INFORMATION .....................3-1
BEFORE INITIAL USE ................................................................................3-1
Fig. 1 Initial Service Chart ..........................................................3-2
TERRAIN .....................................................................................................3-2
VEHICLE CAPACITY ..................................................................................3-2
MODIFICATIONS TO VEHICLE ..................................................................3-2
COMMON SENSE OPERATION .................................................................3-3
POWER CONSUMPTION ...........................................................................3-3
ENVIRONMENTAL CONCERNS ................................................................3-4
OPTIONAL WINCH .....................................................................................3-4
OPERATION OF THE WINCH ...............................................................3-4
Fig. 2 Winch Mounted to Vehicle ................................................3-4
Fig. 3 Winch Remote Control .....................................................3-5
Fig. 4 Winch Clutch Knob ...........................................................3-5
WINCH APPLICATIONS ........................................................................3-5
Fig. 5 Never Operate Winch with Less Than
Five Turns Around Drum ..................................................3-6
Fig. 6 Do Not Hook Cable to Itself ..............................................3-7
Fig. 7 Use a Nylon Sling and
Install a Damper when Winching ......................................3-7
Fig. 8 Do Not Pull at Angle .........................................................3-7
CONTROLS AND INDICATORS .................................................................3-8
KEY/LIGHT SWITCH ............................................................................3-8
Fig. 9 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge 3-8
DIRECTION SELECTOR .......................................................................3-9
Fig. 10 Direction Selector ...........................................................3-9
CHOKE ...................................................................................................3-9
Fig. 11 Choke .............................................................................3-9
FUEL GAUGE ........................................................................................3-9
LOW OIL PRESSURE INDICATOR LIGHT ...........................................3-9
ACCELERATOR PEDAL .....................................................................3-10
Fig. 12 Accelerator and Brake Controls ...................................3-10
COMBINATION BRAKE AND PARK BRAKE PEDAL .........................3-10
HORN ...................................................................................................3-10
Fig. 13 Horn Button ..................................................................3-10
LOAD BED ................................................................................................3-11
ELECTRIC LIFT BED OPERATION (ST350 ONLY) ............................3-11
Fig. 14 Electric Lift Switch ........................................................3-11
OPERATING THE VEHICLE .....................................................................3-12
RUN-IN .................................................................................................3-13
Fig. 15 Check Oil Level on Dipstick .........................................3-13
COLD STARTING ................................................................................3-14
STARTING AND DRIVING ..................................................................3-14
STARTING THE VEHICLE ON A HILL ................................................3-14
COASTING ..........................................................................................3-14
FUEL ....................................................................................................3-15
Fig. 16 Fueling .........................................................................3-15
BATTERY .............................................................................................3-15
LABELS AND PICTOGRAMS ..............................................................3-16
SUN TOP AND WINDSHIELD .............................................................3-16
12 VOLT POWER OUTLET .................................................................3-16
Fig. 17 12 Volt Power Outlet ....................................................3-16
TOWING A TRAILER ...........................................................................3-16
VEHICLE CLEANING AND CARE ...........................................................3-17
VEHICLE CLEANING ..........................................................................3-17
VEHICLE CARE PRODUCTS ..............................................................3-18
REPAIR .....................................................................................................3-18
LIFTING THE VEHICLE .......................................................................3-18
Fig. 18 Lifting the Vehicle .........................................................3-19
WHEELS AND TIRES ..........................................................................3-19
Tire Repair .....................................................................................3-19
Wheel Installation ..........................................................................3-20
Fig. 19 Wheel Installation .........................................................3-21
LIGHT BULB REPLACEMENT ............................................................3-21
Fig. 20 Headlight and Turn Signal Bulb Replacement .............3-21
Fig. 21 Tail and Brake Light Bulb Replacement .......................3-22
FUSE REPLACEMENT ........................................................................3-21
VEHICLE WITH A DISCHARGED BATTERY ......................................3-21

1-2
TABLE OF CONTENTS
TITLE PAGE TITLE PAGE
TRANSPORTING VEHICLE .....................................................................3-22
TOWING ..............................................................................................3-22
NEUTRAL LOCK .................................................................................3-22
Fig. 22 Neutral Lock .................................................................3-23
HAULING .............................................................................................3-22
SERVICE AND MAINTENANCE ..............................................................3-23
SERIAL NUMBER PLATE LOCATION ................................................3-25
Fig. 23 Serial Number Plate Location ......................................3-25
PERIODIC SERVICE SCHEDULE .....................................................3-26
Fig. 24 Periodic Service Schedule ...........................................3-26
TIRE INSPECTION ..............................................................................3-28
REPLACING THE FUEL FILTER ........................................................3-28
CHECKING THE OIL LEVEL ...............................................................3-29
Fig. 25 Clean Entire Dipstick ...................................................3-29
Fig. 26 Check Oil Level on Dipstick .........................................3-29
CHANGING THE OIL ...........................................................................3-29
Fig. 27 Oil Viscosity Chart .......................................................3-30
Fig. 28 Cleaning Top of Engine ...............................................3-30
Fig. 29 Remove Oil Filter .........................................................3-30
Fig. 30 Clean the Oil Filter .......................................................3-31
Fig. 31 Blow Out Oil Filter ........................................................3-31
Fig. 32 Add Engine Oil .............................................................3-31
LUBRICATION .....................................................................................3-32
Fig. 33 Lubrication Points ........................................................3-32
AIR CLEANER INSPECTION AND REPLACEMENT .........................3-32
Fig. 34 Air Cleaner ...................................................................3-32
Cleaning the Air Filter Element ......................................................3-33
REAR AXLE .........................................................................................3-33
Checking the Lubricant Level ........................................................3-33
Fig. 35 Add, Check and Drain Rear Axle Lubricant .................3-33
STARTER/GENERATOR BELT TENSION .........................................3-33
Fig. 36 Checking Belt Tension with Gauge ..............................3-34
Fig. 37 Checking Belt Tension Manually .................................3-34
Adjusting the Belt ..........................................................................3-34
Fig. 38 Adjust Belt Tension ......................................................3-34
BATTERY CLEANING .........................................................................3-35
Fig. 39 Preparing Acid Neutralizing Solution ...........................3-35
AIR INTAKE AND COOLING FINS ......................................................3-35
Fig. 40 Cleaning the Air Intake ................................................3-36
Fig. 41 Cleaning the Cooling Fins ........................................... 3-36
SPARK PLUGS ................................................................................... 3-36
BRAKES ..............................................................................................3-37
Periodic Brake Test for Mechanical Brakes ..................................3-37
Fig. 42 Typical Brake Performance Test ................................. 3-37
PROLONGED STORAGE ................................................................... 3-38
HARDWARE ........................................................................................ 3-39
Fig. 43 Torque Specifications and Bolt Grades ....................... 3-39
CAPACITIES AND REPLACEMENT PARTS ..................................... 3-40
Fig. 44 Capacities and Replacement Parts ............................. 3-40
GENERAL SPECIFICATIONS..............................................4-1
ST 350 ...................................................................................................4-1
ST SPORT.............................................................................................. 4-2
Fig. 1 Vehicle Dimensions for ST 350 ........................................ 4-3
Fig. 2 Vehicle Dimensions for ST SPORT.................................. 4-4
Fig. 3 Vehicle Incline Specifications........................................... 4-5
Fig. 4 Vehicle Turning Clearance Diameter and
Intersecting Aisle Clearance............................................. 4-6
LIMITED WARRANTY..........................................................5-1
DECLARATION OF CONFORMITY.....................................6-1
LABELS AND PICTOGRAMS.............................APPENDIX A

SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Payparticular attention to all Notes, Cautions and Warnings
2-1
The Owner’s Manual and Service Guide has been designed to assist in main-
taining the vehicle in accordance with procedures developed by the manufac-
turer. 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:
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 possi-
ble combination of circumstances that may occur.
Good common sense and prudent driving practices do more to prevent acci-
dents and injury than all of the warnings and instructions combined. The manu-
facturer 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,contact your closest representative
or write to the address on the back cover of this publication, Attention: Product
Service Department.
• Textron Golf, Turf & Specialty Products is not liablefor errors in this manual
or for incidental or consequential damages that result from the use of the
material in this manual.
• Textron Golf, Turf & Specialty Products 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.
• This vehicle conforms to the current applicable standard for safety and
performance requirements.
• These vehicles are designed and manufactured for off-road use. They do
not conform to Federal Motor Vehicle Safety Standards of the United
States of America (USA) and are not equipped for operation on public
streets. Some communities may permit these vehicles to be operated on
their streetson a limited basis and in accordance withlocal ordinances.
• Vehicle capacity is limited to a maximum of two persons.
• Never modify the vehicle in any way that will alter the weight distribution of
the vehicle, decrease its stability or increase the speedbeyond 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 vehi-
cle. 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.
GENERAL OPERATION
The following information is very important in the operation of the vehicle. The
operator should read, understand and always observe the following:
• Use the vehicle in a responsible manner and maintain the vehicle in safe
operating condition.
• Read, understand and observe all warnings and operation instruction
labels affixed to the vehicle.
• Follow all safety rules established in the area where the vehicle is being
operated.
• Reduce speed to compensate for unsuitable terrain or conditions.
• Apply service brake to control speed on steep grades.
• Reduce speed in wet areas.
• Use extreme caution andreduced speed when approaching sharp or blind
turns.
• Use extreme caution and reduced speed when driving over looseterrain.
• Use extreme caution and reduced speed in areas where pedestrians are
present.

SAFETY INFORMATION
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
2-2
MAINTENANCE
The following information is very important in the maintenance of the vehicle.
The person performing maintenance procedures should read, understand and
always observe the following:
• Maintain your vehicle in accordance with the manufacturer’s periodic ser-
vice schedule.
• Ensure that mechanics performing repairs are trained and qualified to do
so.
• Follow the manufacturer’s directions if you perform maintenance on your
own vehicle. Be sure to disable the vehicle before performing any mainte-
nance. Disabling includes removing the key from the key switch and
removal of a battery wire.
• Insulateany tools used within the battery area in orderto 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.
• Check the polarity of each battery terminal and be sure to rewire the bat-
tery correctly.
• Use specified replacement parts. Never use replacement parts of lesser
quality.
• Use only tools recommended by the manufacturer.
• 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.
• Never attempt to perform vehicle maintenance in an area where exposed
flame ispresentor persons are smoking.
• Be aware that a vehicle that is not performing as designed is a potential
hazard and must notbe operated until inspectedand repaired.
• The manufacturer cannot anticipate all dangerous situations. People
attempting to maintain or repairthe vehicle must have the skill and experi-
ence to recognize and protect themselves from potential dangerous situa-
tions. These situations could result in severe personal injury or death and
damage to the vehicle. Use extreme caution and if unsure as to the poten-
tial for injury refer the repair or maintenance to a qualified mechanic.
• Test drive the vehicle after any repairs are made or maintenance proce-
dures performed to assure the vehicle is safe to return to service. All tests
must be conducted in a safe area that is free of both vehicular and pedes-
trian traffic.
• Replace damaged or missing warning, caution orinformation labels.
• Keep complete records of the maintenance history of the vehicle.
VENTILATION
• Alwaysstoregasoline vehicles in a wellventilated area to prevent gasoline
fumes from accumulating.
• Never fuel a vehicle in an area that issubject to flame or spark. Pay partic-
ular attentionto natural gas or propane water heatersand 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 cancause unconsciousness and is potentially lethal.

OPERATION AND SERVICE INFORMATION
3-1
Read all of manual to become thoroughly familiar with this vehicle. Payparticular attention to all Notes, Cautions and Warnings
\
Thank you for purchasing a light duty utility vehicle. Before driving the
vehicle, we ask you to spend some time reading this Owner’s Manual
and Service Guide. This guide contains the information that will assist
you in maintaining this highly reliable vehicle. Some illustrations may
show items that are optional for your vehicle. This guide covers the
operation of several vehicles; therefore, some pictorial views may not
represent your vehicle. Physical differences in controls will be illus-
trated.
This vehicle has been designed and manufactured as a ‘World Vehi-
cle’. Some countries have individual requirements to comply with their
specifications; therefore, some sections may not apply in your country.
Most of the service procedures in this guide can be accomplished
using common automotive hand tools. Contact your service represen-
tative on servicing the vehicle in accordance with the Periodic Service
Schedule.
Service Parts Manuals and Technician’s Repair and Service Manuals
are available from a local Distributor, an authorized Branch or the Ser-
vice Parts Department. When ordering parts or requesting information
for your vehicle, provide vehicle model, serial number and manufacture
date code. BEFORE INITIAL USE
Read, understand and follow the safety label on the instrument panel
(Ref Appendix A). Be sure you understand how to operate the vehicle,
its equipment and how to use it safely. Maintaining good performance
depends toa large extent on the operator.
Improper use of this vehicle could
result in severe injury or death. The
ST Series vehicle is a light duty utili-
ty vehicle. It is NOT an all terrain vehicle (ATV).
This vehicle is not a toy andusing it whileengaging in horse-
play is dangerous.
Plan carefully before using the vehicle to go significant dis-
tances 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 venti-
lated (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 batter-
ies in an area that has open flame or electrical equipment that
could cause an electrical arc.
! !

OPERATION AND SERVICE INFORMATION
3-2
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
Before a new vehicle is put into operation, the items shown in the INI-
TIAL SERVICE CHART must be performed (Ref Fig. 1 on page 3-2).
Vehicle battery must befully charged before initial use.
Check for correct tire inflation. SeeGENERAL SPECIFICATIONS.
Check for oil or fuel leaks that could have developed in shipment from
the factory.
Determine and record braking distance required to stop vehicle for
future brake performance tests.
Remove the protective clear plastic, that protect the seat bottom and
back rest during shipping, before placing the vehicle in service.
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 vehi-
cle 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 compartment and cargo in the load
bed. Never carry passengers in the load bed. The total payload of
the ST 350 is 800 lbs. (363 kg) and theST SPORT is 650 lbs. (295 kg).
The weight of the driver and passenger plusany options oraccessories
must be deducted from the total payload rating to determine the load
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 vehicle and increase the potential for roll over and dam-
age 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 tothe weight distribution or the cen-
ter of gravity may make it unstable or prone to roll over which could
result in injuryor death to the operator or passenger.
Fig. 1 Initial Service Chart
ITEM SERVICE OPERATION
Battery Charge battery
Seats Remove protective plastic covering
Brakes Check operation and adjust if necessary
Establish acceptable stopping distance
Tires Check air pressure (see SPECIFICATIONS)
Fuel Fill tank with correct fuel
Engine Check oil level
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OPERATION AND SERVICE INFORMATION
3-3
Read all of manual to become thoroughly familiar with this vehicle. Payparticular attention to all Notes, Cautions and Warnings
COMMON SENSE OPERATION
This vehicle is not a toy. If not operated properly and responsibly, it
can cause severe injury or death to the operator, passenger or
bystanders. All operators should possess a valid driver’s license. Chil-
dren should not be permitted to operate the vehicle. Children may not
have the skill, judgement orstrength to operate this or similar vehicles.
Alcohol, drugs and manyoverthe counter medications reduce the abil-
ity of the driver to operate the vehicle safely. Always review side effects
of any medication with a doctoror pharmacist before operating vehicle.
Protective clothing and an approved motorcycle helmet are recom-
mended foroperator and passenger at all times.
When driving at full speed on a dirt road, loose surfaces or wet grass,
vehicle stopping distance will increase. If the vehicle is fully loaded, it
will take longer to stop than with no load. When operating vehicle in wet
weather conditions, remember that the brakes may need to be lightly
applied in order to provide enough friction to dry the brake unit. If wet,
the brakes will lose much of their effect.
Slow down whenin unfamiliar terrain. Slow down when crestinga hill in
an area that you are unfamiliar with.
Some hills are too steep to climb. If you attempt to climb a hill that is too
steep or if you are unable to achieve adequate traction, do not attempt
to turn around on the hill.Slowly back straight down the hill using
the servicebrake to control speed.
POWER CONSUMPTION
The vehicle uses a combination starter/generator to both start the
engine and charge the battery. The engine will not idle; therefore, the
battery cannot be charged while the vehicle is stopped. Do not operate
accessory items (such as accessory lights, radios, winch, etc.) exces-
sively whilethe vehicle is stopped.
Overuse of accessories may drain
the battery and leave insufficient
reserve to start the vehicle.
The generator is only capable of supplying 35 amps; therefore, opera-
tion of all accessories could result in the discharge of the battery even
though the engine is running and the generator operating. Discharging
the battery is known as deep cycling. The battery is not a deep cycle
model, but is a starting battery. Multiple deep cycling of the battery will
result in the premature failure ofthe battery.
Vehiclebattery must be fully charged before initial use.
Hydrogen gas is generated as a nat-
ural part of the lead acid battery
charging process. A 4% concentra-
tion 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 batter-
ies in an area that has open flame or electrical equipment that
could cause an electrical arc.
! !

OPERATION AND SERVICE INFORMATION
3-4
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
ENVIRONMENTAL CONCERNS
As a responsible user, practice respect for all wildlife and their habitat.
Respect private property and comply with all local laws and regulations
governing the use of light duty utility vehicles. Do not tamper with the
exhaust system or governor. The exhaust system has been tuned to
the engine for maximum performance. Removal or modification of the
exhaust is annoying to other people and will not improve the perfor-
mance ofthe vehicle. To prevent severe injury or death
while driving, be aware of the follow-
ing:
Environmental hazards such as steep slopes, overhanging
limbs, etc.
Danger of fire when vehicle is operated over dry combusti-
ble organic material.
When driving, be aware of environmental hazards such as steep
slopes, overhanging limbs, etc. Be aware of the danger of fire whenthe
vehicle isoperatedoverdry combustible organic material.
OPTIONAL WINCH
This vehicle may be equipped with an optional winch (not available on
ST SPORT). Read, understand and follow all of the following informa-
tion on the operation and use of winch before attempting to operate it.
OPERATION OF THE WINCH
The winch can be mounted at the front or rear of the vehicle and
moved to accommodate different situations. At the front, it is mounted
under the center of the front cowl to a bracket attached to the front axle
as shown (Ref Fig. 2 on page 3-4). At the rear, the winch is mounted
upside down in the hitch receiver.
If mounting winch at rear of vehicle, the winch must
be mounted upside down.
Before moving the winch, unplug the winch connector from the wire
harness. To move the winch from one end of the vehicle to the other,
remove the spring pin, pull out the clevis pin and remove the winch
mount tube from the receiver. Move to opposite end of vehicle and
install by inserting clevis pin and securing with spring pin. Plug the
winch connector into wire harness.
The winch remote control plugs into the receptacle on the seat support
(Ref Fig. 3 on page 3-5).
To unwind the cable, locate the clutch knob on the winch. Pull out knob
and rotate 90° to lock out. Using handsaver bar, pull cable from winch
drum. Leave at least five turns of cable on drum. Re-engage drum by
! !
Fig. 2 Winch Mounted to Vehicle
Front Axle
Clevis Pin
Spring Pin
Winch shown mounted at front of vehicle

OPERATION AND SERVICE INFORMATION
3-5
Read all of manual to become thoroughly familiar with this vehicle. Payparticular attention to all Notes, Cautions and Warnings
turning clutch knob 90°, returning it to original position (Ref Fig. 4 on
page 3-5).
To wind cable, use handsaver bar to keep tension on the cable while
activating remote. When winding cable, make sure the cable winds
tightly and evenly onto the drum leaving no gaps that could cause pre-
mature wear to the cable. When using winch under a load, operate the
remote control from as far to the side of the vehicle as possible. Do not
operate winch while sitting in passenger seat. Read the following sec-
tion (Winch Applications) beforeattempting to operate winch.
WINCH APPLICATIONS
The winch may be used for a number of purposes, including pulling the
vehicle if it loses traction onunsuitable terrain.
Improper use of the winch could
result in a number of conditions that
could cause severe injury or death
to operator, occupants of vehicle or bystander.
It is impossible to predict all conditions that the winch could be used,
thereforethe following warnings should not be considered as complete.
Before operating the winch, consider the possible dangers and take
precautionsto protect yourself,yourpassenger and any bystanders.
To prevent severe injury or death to
operator, occupants or bystanders,
select the object to which the cable
is attached with the following considerations:
Make sure the object cannot be pulled over or otherwise
damaged.
The object the winch is attached to could fall on the vehi-
cle and it’s occupants.
If attaching the winch to a dead tree, a section could fall.
When pulling vehicle with winch, pull straight only. Do not permit the
cable to contact the side of the drum.
Do not pull vehicle at angle. If the
vehicle is pulled at an angle, it could
turn over causing severe injury or
death to anyone in the area. The winch cable could also
become overstressed and break causing severe injury or
death to anyone struck by the cable.
Fig. 3 Winch Remote Control
Fig. 4 Winch Clutch Knob
R
eceptacle
Remote Contr
ol
Pull out
E
NGAGED
C
lutch Knob
LOCKED OUT
Turn 90
0
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! !
! !

OPERATION AND SERVICE INFORMATION
3-6
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
If the vehicle becomes stuck or ‘hung up’ on an obstruction, the vehicle
may be moved using the winch.
The winch may be installed in either the front or rear receiver and held
in place with the locking pin provided.
To prevent severe injury or death,
read and understand the following
before attempting to use the winch:
The winch is not intended to be used in any hoisting oper-
ation.
The rolling load capacity of the winch decreases with the
steepness of the slope.
The winch is designed for intermittent duty only. The elec-
tric motor should not be allowed to become excessively
hot. If the motor becomes uncomfortably hot to the touch,
stop winching and allow the motor to cool.
Always wear thick leather gloves when handling the wire
cable.
Replace frayed wire cable with a direct factory replace-
ment only.
Never operate the winch with less than five (5) full turns of
cable around the drum (Ref Fig. 5 on page 3-6).
If the winch motor stalls from overloading, do not continue
to activate the winch remote control. The wire cable may
become overstressed.
Do not attempt to pull loads exceeding 1500 lbs. (680 kg).
To pull out the cable, the free spool clutch knob must be
used. Pull out and rotate the knob. If the cable is under any
load the clutch may not release easily. Jog out some of the
cable to release the tension and operate clutch. Pull out
the desired amount of cable and secure. Engage the drum
by rotating the knob until it snaps in place. Never operate
the winch unless the clutch is engaged.
Have all persons and pets leave the area while operating
winch. Never allow anyone to remain in the vehicle.
To prevent damage to the wire cable, never hook the cable
to itself. Always use a nylon sling (Ref Fig. 6 on page 3-7)
(Ref Fig. 7 on page 3-7).
Stay clear of the winch, the cable and the cable hook.
Place a heavy cloth, jacket or blanket over the cable to act
as a damper should the cable break when operating the
winch (Ref Fig. 7 on page 3-7).
Remember that the winch operation will drain the battery
and may leave insufficient power to start the vehicle.
When operating the winch, keep the entire area in view.
Never release the free spool clutch while the cable is
under load.
! !
Fig. 5 Never Operate Winch with Less Than
Five Turns Around Drum

OPERATION AND SERVICE INFORMATION
3-7
Read all of manual to become thoroughly familiar with this vehicle. Payparticular attention to all Notes, Cautions and Warnings
Never work around the winch drum or the winch cable
while it is under tension.
Unplug the winch switch before working on the winch
drum in order to prevent inadvertent operation.
When operating winch, take up slack slowly. Stop winch
before cable becomes tight and inspect all winching con-
nections. Check winch attachment, hook attachment,
nylon sling (if required) and load attachment.
Do not pull at an angle. This will cause the wire cable to
pile up on one end of the winch. This may jam the winch
causing damage to the cable and/or the winch. Pulling the
vehicle at an angle can cause damage to the front suspen-
sion and may cause the vehicle to overturn. When pulling
vehicle, pull straight only (Ref Fig. 8 on page 3-7).
Fig. 6 Do Not Hook Cable to Itself
Fig. 7 Use a Nylon Sling and
Install a Damper when Winching
Nylon
Sling
Damper
Fig. 8 Do Not Pull at Angle
Correct
Incorrect

OPERATION AND SERVICE INFORMATION
3-8
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
If the vehicle is being used as an anchor to winch a load, it
should have the park brake set and chocks installed on all
wheels.
Never use the winch to lift people or other overhead loads.
Do not use the winch to secure loads. Use a tie down
designed for the job.
Do not apply shock loads to the winch.
Do not attempt to modify or weld the winch.
CONTROLS AND INDICATORS
Vehicle controls and indicators consistof:
• key/light switch
• direction selector
•choke
• fuel gauge
• low oil pressure indicator light
• accelerator pedal
• combination service and park brake pedal
•horn
KEY/LIGHT SWITCH
Located on the dash panel, this switch enables the basic electrical sys-
tem of the vehicle to beturned on and off by turningthe key. To prevent
inadvertent operation of the vehicle when left unattended, the key
should be turned to the ‘OFF’ position and removed (Ref Fig. 9 on page
3-8).
If the vehicle is equipped with lights, the key switch has a position to
operate them, indicated by the light icon.
If the vehicle is equipped with factory installed cus-
tom accessories, some accessories remain opera-
tional with the key switch in the ‘OFF’ position.
Fig. 9 Key/Light Switch, Low Oil Pressure Light and Fuel Gauge
OFF
OFF
ON
ON
FUEL
F
E
Low Oil Pressure
Indicator Light
Key/Light Switch
Fuel
Gauge

OPERATION AND SERVICE INFORMATION
3-9
Read all of manual to become thoroughly familiar with this vehicle. Payparticular attention to all Notes, Cautions and Warnings
DIRECTION SELECTOR
To reduce the possibility of
component damage, the vehicle
must be completely stopped before moving the
direction selector.
Located on the seat support panel, this lever permits the selection of
either ‘F’ (forward) or ‘R’ (reverse) (Ref Fig. 10 on page 3-9). Vehicle
should be left in ‘F’ when unattended.
CHOKE
The choke is used to aid cold starting (Ref Fig. 11 on page 3-9). See
‘Cold Starting’ (Refer to page 3-14) for instructions on using the
choke properly.
FUEL GAUGE
The fuel gauge (if equipped) will either be located on the dash panel
(electric) (Ref Fig. 9 on page 3-8) or directly on the fuel tank (mechani-
cal).
LOW OIL PRESSURE INDICATOR LIGHT
A low oil pressure indicator light is located on the dash panel (Ref Fig. 9
on page 3-8). The light illuminates when the oil pressure is low. Check
oil level. If oil level is between ADD and FULL mark on dipstick, a
mechanical problem exists within the engine and the vehicle must not
be driven.Contact a local distributor or authorized branch.
To prevent engine damage, do not
operate engine until oil pressure is
corrected. Do not overfill engine. Too much oil may
cause smoking or allow oil to enter the air filter
enclosure.
Fig. 10 Direction Selector
Forward
Reverse
Fig. 11 Choke
Choke

OPERATION AND SERVICE INFORMATION
3-10
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
If oil level is below ADD mark on dipstick, add oil to bring level to FULL
mark. Drive vehicle a short distance and check oil pressure. If oil light
does not come on, continueto use vehicle.
ACCELERATOR PEDAL
Unintentional movement of the
accelerator pedal will release the
park brake and may cause the vehi-
cle to move which could result in severe injury or death.
With the key switch ‘ON’, depressing the accelerator pedal starts the
engine. When the pedal is released, theengine will stop (RefFig. 12 on
page 3-10). To stop the vehicle more quickly, depress the service
brake.
If key switch is ‘ON’ and park brake is set, depressing the accelerator
inadvertently will release the park brake and will cause the vehicle to
move which could cause severe injury ordeath.
Depressing the accelerator pedal will release the park brake if it is
engaged. This is a feature to assure the vehicle is not driven with the
park brake engaged. Depressing the accelerator pedal is not the pre-
ferred method of releasing the park brake.
Depressing the lower section of the brake pedal
is the preferred method of releasing the park brake
to assure the longest service life of brake components.
COMBINATION BRAKE AND PARK BRAKE PEDAL
The brake pedal incorporates a park brake feature (Ref Fig. 12 on page
3-10). To engage, push down on the upper section of the pedal until it
locks in place. The park brake will release when the service brake
pedal is depressed. Use the lower section of the brake pedal to operate
the service brake system.
HORN
The horn is operated by pushing the horn button located on the floor to
the left of the brakepedal (Ref Fig. 13 on page 3-10).
Fig. 12 Accelerator and Brake Controls
! !
Park
Brake
Accelerator
PA R K
Service
Brake
Fig. 13 Horn Button
H
O
R
N
Horn
PA R K

OPERATION AND SERVICE INFORMATION
3-11
Read all of manual to become thoroughly familiar with this vehicle. Payparticular attention to all Notes, Cautions and Warnings
LOAD BED
To reduce the possibility of severe
injury or death, read, understand
and follow the Danger label affixed
to the front of the load bed.
The electric lift bed is the standard bed for the ST350. A fixed bed is the
only bedfor the STSport.
A load bed warning label is affixed to the front of the bed. See Appendix
A. For safe operation of the vehicle, this label must be understood. See
the load bed warning label for maximum load. The load must be posi-
tioned in the bed as far forward as possible, distributed in such a way
that its center of gravity must not be higher than height noted on label,
and secured. Failure to follow these instructions may result in severe
injury, damage the vehicle and/or cause the vehicle to tip over. Use
extra care when operatingloaded vehicle.
Do not permit any one to ride in the bed.
Do not drive the vehicle with the load bed raised or with the tailgate
unsupported.
When using the electric lift on the ST 350, be sure to avoid backing up
to the edge of a drop off, such as a loading dock or ravine. A misjudg-
ment of distance or an unstable surface could result in the vehicle fall-
ing backwards.
Before operating load bed, check to ensure no one is behind the vehi-
cle.
Never fill a gas can in the bed of a
vehicle. Static discharge could ignite
gasoline vapor and cause an explo-
sion.
Always place a gas can on the ground before filling. Never fill a gas can
in the bed of the vehicle. Static electricity is built up during the fueling
process and could discharge causing the gasoline vapor to ignite.
ELECTRIC LIFT BED OPERATION (ST350 ONLY)
Exercise caution while operating the
electric lift bed to ensure clothing is
not caught during lifting or lowering
procedure. Severe injury could result if bed is lowered and
traps fingers or other body parts.
The electric lift switch is locatedon the driver sideof the front seatpanel
(Ref Fig. 14 on page 3-11). Move the toggle switch leverup toraise the
load bed and down to lower.
! !
Fig. 14 Electric Lift Switch
! !
! !
Raise
Lower

OPERATION AND SERVICE INFORMATION
3-12
Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings
OPERATING THE VEHICLE
Improper use of the vehicle or the
lack of proper maintenance may
result in damage or decreased performance.
Read and understand the following warnings before attempting to
operate the vehicle. To reduce the possibility of severe
injury or death resulting from loss of
vehicle control, the following warn-
ings must be observed:
When driving vehicle, consider the terrain, traffic condi-
tions and the environmental factors which effect the ter-
rain and the ability to control the vehicle.
Use extra care and reduced speed when driving on poor
surfaces, such as loose dirt, wet grass, gravel, etc.
Stay in areas suitable for a light duty utility vehicle. Avoid
rough, unimproved trails, areas with large rocks, stumps
or holes and avoid steep slopes.
Maintain a safe speed when driving down hill. Use service
brake to control speed when traveling down an incline. A
sudden stop or change of direction may result in loss of
control.
Slow down before and during turns. All turns should be
made at reduced speed.
Never drive vehicle up, down, or across an incline that
exceeds 14° (25% grade).
When driving the vehicle on unfamiliar terrain, drive the
vehicle slowly, especially when cresting a hill.
If the vehicle is unable to climb a hill, do NOT attempt to
turn it around. Turning the vehicle sideways on a hill could
result in the vehicle rolling over. Slowly back down the hill
using the service brake to control speed.
When operating the electric dump, do not back up to a
drop off, such as a loading dock or ravine. Misjudgment or
an unstable surface could cause the vehicle to fall back-
ward into the drop off.
To reduce the possibility of severe
injury or death resulting from
improper vehicle operation, the fol-
lowing warnings must be observed:
The vehicle is a light duty utility vehicle. It is not an ATV
(All Terrain Vehicle).
The vehicle is not a toy and engaging in horseplay is dan-
gerous.
The vehicle should not be operated on public highways. It
is not designed to comply with any DOT requirements.
The vehicle should be operated by persons with a valid
driver’s license. Children should not operate this vehicle.
Refer to GENERAL SPECIFICATIONS for seating capacity.
Use the park brake when the vehicle is parked.
Depressing accelerator pedal will release foot operated
park brake and may cause inadvertent vehicle movement.
Turn the key to the ‘OFF’ position whenever the vehicle is
parked.
To prevent inadvertent movement when the vehicle is to
be left unattended, engage the park brake, move direction
! ! ! !