E-Z-GO ST 480 manual

A T extron Company[...]

MANUAL INFORMATION For an y quest ions on m ateria l contained in this m anual, c ontact a rep resentativ e for c lar ific at ion. Read and understand all lab els locat ed on the vehicle . Always repl ace any dam - aged or m issing la bels. On stee p hills it is p ossible for v e hic les to coast at gre ater th an n orm a l speed s encoun tered on [...]

i OWNER’S MANUAL & SERVICE GUIDE ST 480 E-Z-G O Division of T e xtron Inc . reserve s the right to make des ign change s withou t obligat ion to make these ch anges on unit s pre viousl y sold and th e informa tion co ntained i n this manual is subject t o change w ithout not ice. E-Z-G O Division of T e xtron Inc. is not liab le for errors i[...]

ii NOTES T o obt ain a copy of the limited warran ty applicable to the vehicle, call or write a local Distributor , au thorized Branch or the W arranty Dep ar tment with v ehicle ser ial number and manufactur e date code. The use of non Orig inal Equipment Man ufacturer (OEM) approved pa rts may void the warranty . T amp e ring with or adjusting t [...]

TABLE OF CON TENTS 1-1 TITLE PAGE TITL E PAGE MANUAL INFORMATION .......................... Inside Fron t Cover NOTES ...... ........... ............ ................ ....................... ................. . i SAFETY INFORMAT ION ............ ............................ .............. 2-1 OPERATION AND SERVICE INFORMATION ............ .........[...]

1-2 TABLE OF CONTENTS TITLE PAGE TITL E PAGE TOWING .... ........... ................ .......... ................ .......... ................ ........... 3-22 NEUTRAL L OCK ............ ........... ................ ............... ........... ............... . 3-22 Fig. 20 Neutral Lock ................. ........... ................ .......... .....[...]

SAFETY INFORMATION Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s 2-1 The Ow ner ’s Man ua l and Se rv ice Gu ide h as bee n desi gne d to ass ist in ma in- taining the vehicle in acco rdance wi th procedu res develop ed by the ma nufac- turer . Adherenc e [...]

SAFETY INFORMATION Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s 2-2 MAINTENANCE The following information is very importan t in the maintenance of the vehicle. The p erso n per formi ng mainte nan ce p roce dures sho uld r ead , under stand and always observ[...]

OPERATION AND SERVICE INFORMATION 3-1 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s Thank y o u for pu rchasing a li ght duty util ity veh icle. Before dr iving th e vehicl e, we ask you to spend so me time reading th is Owne r ’s Ma nual and Servic e Gu[...]

OPERATION AND SERVICE INFORMA TIO N 3-2 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s lated (minimum of 5 air exchanges per hou r). To reduce t he ch ance o f b attery explo sion that could result in severe injury or d eath, never smoke around or char ge batt[...]

OPERATION AND SERVICE INFORMATION 3-3 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s MODIFICA TIONS TO VEHI CLE Chan ges to t he weig ht distri bution or the ce nter of gr avity may make it unst able or p ron e to roll over wh ich could result in in jury or d[...]

OPERATION AND SERVICE INFORMA TIO N 3-4 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s injury or death. Charging mu st take place in an area that is adequately ventilated (min imum of 5 air exchan ges per hour) . To reduce t he ch ance o f b attery explo sion [...]

OPERATION AND SERVICE INFORMATION 3-5 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s Before mov ing the wi nch, unplu g the winc h conne ctor from the wire harness . T o move the winch from one end of the v ehicle to the other , remov e the sprin g pin, pu ll[...]

OPERATION AND SERVICE INFORMA TIO N 3-6 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s The obj ect the winc h is att ache d to coul d fall on the veh icle and it’s occupants. If attaching the winch to a dead tree, a se ction could fall. When pul ling vehicle[...]

OPERATION AND SERVICE INFORMATION 3-7 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s To prevent d amage to t he wire cable, never ho ok the cable to itself. Always use a nylon sli ng (Ref Fig. 6 on page 3-7) (Ref Fig. 7 on page 3-7 ). Stay c lear of the wi nc[...]

OPERATION AND SERVICE INFORMA TIO N 3-8 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s 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 th e job. Do not apply shock loads [...]

OPERATION AND SERVICE INFORMATION 3-9 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s component damage, the vehicle must be com pletely stopped be fore moving the directio n selector. Located on the console be tween the seat s, this lever permits t he selec- t[...]

OPERATION AND SERVICE INFORMA TIO N 3-10 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s If oil leve l is bel ow ADD mark on dip stick , add oi l to bring level to FULL mark (R efer to p ag e 3- 29). Dr ive vehi cl e a sh ort dis tan ce an d chec k oil pressure[...]

OPERATION AND SERVICE INFORMATION 3-11 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s differential lock may cause excess ive wear to t he rear tires. The vehicle must be completely stopped before engaging or disengaging the differential lock. Failure to stop [...]

OPERATION AND SERVICE INFORMA TIO N 3-12 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s OPERA TING THE VEHICLE Improper use of the vehi cle or the lack of pr oper main tena nce may result in dam age or decreased perform ance. Read an d underst and the follow i[...]

OPERATION AND SERVICE INFORMATION 3-13 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s is not designed t o comply with any DOT requir ements. The vehi cle shoul d be operated by person s with a valid driver’s license. Childr en should not oper ate this vehic[...]

OPERATION AND SERVICE INFORMA TIO N 3-14 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s The oil sho uld be ch anged i n accordan ce with the Periodic Service Schedule while th e engine is warm. See SERVICE AND MAINTE- NANCE for checkin g oil lev el and c hangi[...]

OPERATION AND SERVICE INFORMATION 3-15 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s above recommend ed speeds, limit speed with service bra ke. On stee p hil ls, i t is po ssibl e for the ve hicle t o coas t at great er th an nor - mal spe ed s en countered[...]

OPERATION AND SERVICE INFORMA TIO N 3-16 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s The vehi cle uses a combi nation st arter/gen erator to bo th start the engine an d charge the battery . The engine w ill not id le; therefore, the battery can not be charg[...]

OPERATION AND SERVICE INFORMATION 3-17 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s kg) an d no mor e than 50 lb s (23 kg ) tong ue weig ht may be attac hed to the hitc h. Rem ember that t he overal l capacity of the vehicle, operato r , pas s enger , c ont[...]

OPERATION AND SERVICE INFORMA TIO N 3-18 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s VEHICLE CARE PRODUCTS T o help maint ain the vehi cle there are severa l product s available through lo cal Distribut ors, autho rized Bra nches, o r the Service Part s Dep[...]

OPERATION AND SERVICE INFORMATION 3-19 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s Place the ja ck at the center of the f ront axle. Ra ise the vehicle and posi- tion jack s tands un der t he fr ame c rossm embe r as in dicat ed. Lower j ack and tes t the [...]

OPERATION AND SERVICE INFORMA TIO N 3-20 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s A tire explosion c an ca use s evere injur y or d eath. Nev er ex ceed in fla - tion pressure r ating on tire sidewall. To reduce the possibi lity of tire explosion, press [...]

OPERATION AND SERVICE INFORMATION 3-21 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s With the valve stem to the o utsid e, mount the w heel o nto the hu b with lug nut s. Be sure to pos ition t he wh eel on hub corre ctly with arrow ind i- cating d irection [...]

OPERATION AND SERVICE INFORMA TIO N 3-22 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s The vehi cle i s equipp ed with a st arter/generator and does not id le. When st artin g the e ngine, the st arter/generator fun ctions as a s tarte r and wit h the engi ne[...]

OPERATION AND SERVICE INFORMATION 3-23 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s Never ride on vehicle bein g transported. Always remove windshield befo re transportin g. Maximum speed with su n top installed is 50 mph ( 80 kph). If the vehi cle is to be[...]

OPERATION AND SERVICE INFORMA TIO N 3-24 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s Wrap wren ches wi th vinyl tape to reduce the possi bility o f a dropped wrench ‘shor ting out’ a bat tery, which could result in an exp losion. Reduce the p oss ibilit[...]

OPERATION AND SERVICE INFORMATION 3-25 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s of 4% hydrog en gas or more is explo sive. Engine exhaust gas (ca rbon monoxide) is deadly. Carbon monoxide is an odorless, colorless g as that is fo rmed as a natural part [...]

OPERATION AND SERVICE INFORMA TIO N 3-26 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s PERIODI C SERVICE SCHEDULE ✓ Che ck ♦ Clea n, Adjust, etc. ▲ Repla ce T o perform service that is liste d in this sch edule but not describ ed in thi s manual, contac[...]

OPERATION AND SERVICE INFORMATION 3-27 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s STEERING ASSEMBL Y ✓ Check for abnor mal play , tigh tness of all hardware TIE RODS/LINKAGES ✓ Check for excessive play, bent compone nts or loos e connection s REAR AXL[...]

OPERATION AND SERVICE INFORMA TIO N 3-28 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s Note 1 - Change o il after firs t 8 hours, the n after ev ery 50 hou rs. Note 2 - Chang e oil e very 25 h ours when oper ating under he avy l oad or in high temperatures . [...]

OPERATION AND SERVICE INFORMATION 3-29 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s REPLACING THE FUEL FIL TER To pr even t a po ssible exp losio n, d o not smoke near the fuel tank or in an area where gasoli ne is being h an- dled. Do no t perform proced u[...]

OPERATION AND SERVICE INFORMA TIO N 3-30 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s If oil is required, rem ove oil fil l cap and ad d oil slowly to bring lev el to the FULL mark. Do not overfill. Replac e dipstick fully into dip stick tube a nd firmly r e[...]

OPERATION AND SERVICE INFORMATION 3-31 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s The oil mu st be high quali ty detergent oil c lassified ‘Fo r Servi ce SF , SG , SH, SJ’ or high er . Do not use spec ial add itives and do not mix oil wi th gasoli ne.[...]

OPERATION AND SERVICE INFORMA TIO N 3-32 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s CHANGING THE OIL FIL TER T ool L ist Qty . Requ ired Oil filt er wrench , to fit 3" (76 mm ) oil f ilter..................... ......... 1 Oil drai n pan ..............[...]

OPERATION AND SERVICE INFORMATION 3-33 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s AIR CLEANER INSPECTION AN D REPLACEMENT The air cle aner is a dual filter cl eaner , equi pped with a foam pre -cleaner over a con ventional pa per cartridge. The filt ers m[...]

OPERATION AND SERVICE INFORMA TIO N 3-34 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s Unscrew the knob s e curi ng the cartr idge to the air cleaner ba se and remo ve pla te. R emove cart ridg e and i nspec t. Replace if too dirty to clean or at the fir s t [...]

OPERATION AND SERVICE INFORMATION 3-35 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s The st arter/generator belt te nsion should be ch ecked afte r the first 15- 20 hours of operati on and se t to 75 - 80 lbs. (34 - 36 kg) . A loose belt can cause audible vi[...]

OPERATION AND SERVICE INFORMA TIO N 3-36 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s BA TTER Y CLEANIN G To reduce the po ssibility of damage to vehi cle or flo or, ne utral ize ac id before rinsing battery. To reduce the po ssibility of damage to electrica[...]

OPERATION AND SERVICE INFORMATION 3-37 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s After every of f road us e, al low to cool and then check for a build u p of dirt and debris in the air intak e and co oling fins. Dirt an d debri s ma y clog the en gine’[...]

OPERATION AND SERVICE INFORMA TIO N 3-38 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s After the v ehicl e has be en put into serv ice, it is rec omme nded t hat the brak es be checke d da ily by per formi ng th e foll owin g te st: Depress the bra ke pedal. [...]

OPERATION AND SERVICE INFORMATION 3-39 Read all of manual to be come thoroughly familiar with thi s v ehicle. P ay par ticular atten tion to all Notes, Caution s and W arning s General ly , thre e grades of hard ware are used in the vehicle. Gra de 5 hardwa re can be id entified by the th ree marks on t he hexago nal hea d and grade 8 ha rdware is [...]

OPERATION AND SERVICE INFORMA TIO N 3-40 Read all of manual to become thoroug hly familiar with this vehicle. P ay part icular attenti on to all Notes, Cautions and W ar ni ng s CAP ACITIES AND REPLACEMENT P ARTS Fig. 38 Cap acities and Replacement Parts Fuel T ank / Fuel Engine Oil Oil Filter Air Cleaner Filter Pre-Cleaner Filter Spark Plugs Star [...]

4-1 GENERAL SPECIFICATIONS ST 480 ST ANDARD EQUI PMENT : BA TTERY ........... .............. ............. ..One 12 Volt Maintenance Fre e (515 CCA, 82 Minute Reserv e) ENGINE ...... ............. ............. ........... 16 H.P . (11.9 k W) 29.2 ci (480 cc) T win Cylinder , Overhead Valve Pressuriz ed Lubricati on w ith Spin Off Filter Magnetron?[...]

4-2 GENERAL SPECIFICATIONS Fig. 1 V ehicle Dime ns ions 42.5 in (108 cm) 50 in (127 cc) 34 in (86 cm) 6 in (15 cm) Ground Clearance 110.5 in (281 cm) 15 in (38 cm) 49 in (125 cm) 77 in (196 cm) Rear 38 in (96 cm) F ront 38.5 in (97 cm) 78 in (198 cm) or 75 in (191 cm) with Brush Guard Cage 11.5 in (29 cm) 18 in (46 cm)[...]

4-3 GENERAL SPECIFICATIONS Fig. 2 V ehicle Incline Specifications Maximum Recommended Side Tilt 25% or 14˚ Max. Maximum Recommended Ramp Grade 25% or 14˚ Max.[...]

4-4 GENERAL SPECIFICATIONS Fig. 3 V ehicle T urning Clearance Diameter TURNING CLEARANCE DIAMETER Approx. 23.5 ft (7.2 m)[...]

5-1 LIMITED WARRANTY EMISSION CONTROL SYSTEM W ARRANTY ST A TEMENT (Owner ’ s Defect W arranty Rights and Obligations) Refer to the Briggs & S tr atton ® Operating & Ma intenance Instructions, provided with vehicle, for Emission C ontrol System Warranty information. ENGINE OWNER W ARR ANTY POLICY Refer to the Briggs & S tratton ® Op[...]

5-2 LIMITED WARRANTY Notes:[...]

6-1 DECLARATION OF CONFORMITY NO T A V AILABLE A T TIME OF PUBLICA TION[...]

6-2 DECLARATION OF CONFORMITY Notes:[...]

Appendix A-1 LABELS AND PICTOGRAMS Fig. 1 La be l Loca t i on s 35962G01 ! ! R F < 14 ˚ 25 % P F ! < 14 ˚ 25 % 35962-G01 See Following Pages For Explanation Of These Pictograms: (2,3,4,6,9,36,37, 38,39,40,29) See Following Pages For Explanation Of These Pictograms: (19,43,44,45) 75808G01 OFF ON 75808-G01 H O 2 1 2 3 P P P P P P 74093-G01 74[...]

Appendix A-2 LABELS AND PICTOGRAMS Fig. 2 Lab el Loc ation s (Conti nued) WARNING Keep entire body inside car. 27653G01 See Following Pages For Explanation Of Pictogram: (49) P P MA X 250 l b s. 114 k g MA X 4 i n . 10 c m MA X 14 o / 25 % ! 35980G01 35980G02 See Following Pages For Explanation Of These Pictograms: (1,2,12,10,8, 7,5,11) WARNING Win[...]

Appendix A-3 LABELS AND PICTOGRAMS Fig. 3 Pi ctogra m Defi nitions WARNING READ MANUAL ! WARNING USE CAUTION IN INCLEMENT WEATHER WARNING DO NOT OPERATE IF USING ALCOHOL OR DRUGS M A X 14 ˚ / 25 % MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED ! < 14 ˚ 25 % WARNING MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED LOAD WITH HIGH CENTER OF GRAVITY COULD R[...]

Appendix A-4 LABELS AND PICTOGRAMS Fig. 4 Picto gr a m Defin itions (Continu ed) ! < 14 ˚ 25 % WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL M A X xxx l b s . xxx k g SECURE LOAD AS FAR FORWARD AS POSSIBLE. MAXIMUM LOAD BED CAPACITY DO NOT RIDE IN LOAD BED P P DANGER OF EXPLOSION DO NOT FILL GAS CAN IN LOAD BED x in xi n [...]

Appendix A-5 LABELS AND PICTOGRAMS Fig. 5 Pictogr a m Defini tions ( C ont in ued) 1 3 H O 2 P P CLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE P P UNLEADED GASOLINE P P GROUND FUEL PUMP P P DO NOT SPILL FUEL ON A HOT ENGINE NO TAMPERING. KEEP HANDS OUT NEGATIVE GROUND BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND SHORTING [...]

Appendix A-6 LABELS AND PICTOGRAMS Fig. 6 Picto gr a m Defin itions (Continu ed) DO NOT DISPOSE OF BATTERIES IN LANDFILL DO NOT DRIVE ON HIGHWAY WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS BATTERIES ARE HEAVY. USE CARE LIFTING USE INSULATED TOOLS WEAR EYE PROTECTION NO SMOKING HOT SURFACE 28. 29. 30. 31. 32. 33. 34. 35. OPERATE FROM D[...]

Appendix A-7 LABELS AND PICTOGRAMS Fig. 7 Pictogr a m Defini tions ( C ont in ued) KEEP ARMS AND LEGS WITHIN VEHICLE F TO OPERATE VEHICLE IN FORWARD: ✱ TURN KEY TO ON ✱ MOVE DIRECTION SELECTOR TO FORWARD ✱ DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY KEEP CLEAR HAND OR FINGERS CAN BE TRAPPED 37. 38. 42. P F R TO OPERATE VEHICLE IN REVERS[...]

Appendix A-8 LABELS AND PICTOGRAMS Fig. 8 Picto gr a m Defin itions (Continu ed) ON OFF ON POSITION OFF POSITION HEADLIGHTS UNLOCKED 43. 44. 45. 46. LOCKED DIFFERENTIAL LOCKED 47. 48. 49. WARNING KEEP ENTIRE BODY INSIDE CAR[...]

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Starting Model Y ear 2004 P . O . B o x 3 88 A ugu s t a , G eor g ia 309 03- 0 388 US A I ns id e US A Ph one : 1- 8 00- 2 41-5 855 , F A X: 1- 80 0- 44 8-81 24 O ut s id e US A P h one : 01 0-1- 7 06-7 98- 4 311 , F A X : 010 -1- 70 6-77 1- 46 09 Cop yrighted Mater ial This manual ma y not be reproduced in whole or in par t without the express pe[...]