602080 TM REVISED DATE: JAN.
SAFETY 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. See APPENDIX A. 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 be limited to no more than the maximum speed on level ground.
OWNER’S MANUAL AND SERVICE GUIDE GASOLINE POWERED UTILITY VEHICLE ST 4x4 STARTING MODEL YEAR 2005 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.
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.
TABLE OF CONTENTS SAFETY ................................................................................................................ inside covers GENERAL INFORMATION ....................................................................................................... ii SAFETY INFORMATION ......................................................................................................... vii WELCOME ................................................................................................
TABLE OF CONTENTS TOP AND WINDSHIELD .......................................................................................................... 12 TRANSPORTING VEHICLE .................................................................................................... 12 TOWING ........................................................................................................................................................... 12 HAULING .................................................................
TABLE OF CONTENTS LIGHT BULB REPLACEMENT ............................................................................................... 25 Fig. 35 Headlight Replacement ...............................................................................................25 FUSE REPLACEMENT ........................................................................................................... 25 SPARK ARRESTER ....................................................................................................
TABLE OF CONTENTS Notes: Page vi Owner’s Manual and Service Guide
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.
SAFETY INFORMATION • 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.
SAFETY INFORMATION 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.
SAFETY INFORMATION Notes: Page x Owner’s Manual and Service Guide
SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings GENERAL The following text is provided as recommended by part II of SAE J2258 DEC 2003. E-Z-GO strongly endorses the contents of this specification. B.1 PART II FOR THE CONTROLLING PARTY B.1.1 Maintenance and Operations B.1.1.1 Introduction B.1.1.1.1 Like other machines, light utility vehicles can cause injury if improperly used or maintained.
SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings B.1.1.4.2 The controlling party shall supervise the handling of liquefied petroleum gas fuels (when used) to be certain it is in accordance with appropriate sections of ANSI/NFPA 505 and ANSI/NFPA 58 or as required by local ordinance. B.1.1.5 Charging Storage Batteries B.1.1.5.
SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings B.2.3.4 Riding on the vehicle by persons other than the operator is authorized only on seat(s) provided by the vehicle manufacturer. All parts of each person's body shall remain within the plan view outline of the vehicle while the vehicle is in motion. B.2.3.
SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings equipped, is closed, following vehicle manufacturer's recommended practice. (e) Before disconnecting any part of the fuel system of LP/CNG powered vehicles, close the fuel cylinder valve and run the engine until fuel in the system is depleted, the engine stops running, and is allowed to cool (f) Disconnect battery(s).
OPERATION AND SERVICE INFORMATION 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. Before driving vehicle, we ask you to spend some time reading this Owner’s Manual and Service Guide and the Owner’s Manual provided by Honda Motor Co., Ltd. These manuals contain information to assist you in safe operation of vehicle. They will also assist you in maintaining vehicle.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ways the vehicle may be used, it is important the operator consider any potential hazards before use to prevent serious injury or death. Children may not have the skill, judgement or strength to operate this or similar vehicles and should not be permitted to do so. See GENERAL SPECIFICATIONS section of this manual for load and seating capacity.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CONTROLS & INDICATORS SERVICE BRAKE PEDAL Front of Vehicle HOURS P 8 16 0 4/4 Ref Pbh 2 Fig. 3 Park Brake and Indicator Ref Sbp 1 CHOKE Fig. 2 Service Brake Pedal The service brake is a hydraulic front disc/rear drum brake system. Push foot operated service brake pedal to activate wheel brakes, slowing or stopping vehicle (Ref. Fig.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings OFF Choke ON START 73767G01 Pull Out Ref Kes 5 Ref Chk 4 Fig. 5 Ignition Switch Fig. 4 Choke If vehicle is equipped with factory installed custom accessories, some accessories remain operational with key switch in ‘OFF’ position.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Place direction selector in forward and set park brake when leaving vehicle unattended. Engaged Rear Differential Lock Switch 2WD/4WD SELECTOR To reduce possibility of drivetrain damage, vehicle must completely stop before switching between two wheel and four wheel drive. This lever allows choice of two wheel or four wheel drive (Ref. Fig.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To prevent draining the battery, always place differential lock switches in the ‘unlocked’ position, turn the key switch to ‘off’ and remove the key. To engage rear differential lock, stop vehicle and push upper portion of rear differential lock switch.
OPERATION AND SERVICE INFORMATION 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 pressure light does not come on, continue to use vehicle. LIGHT SWITCHES Headlight switch is located to left of steering wheel on dash panel (Ref. Fig. 12 on page 7).
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Overuse of accessories may drain battery and leave insufficient reserve to start vehicle. A 12 volt power outlet, rated at 15 amps, is located left of ignition switch (Ref. Fig. 13 on page 7).
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Before operating, verify no one is behind vehicle. Always place a gas can on ground for filling. Never fill a gas can in load bed of vehicle. Built up static electricity could discharge during fueling process and ignite gasoline vapor.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Do not pull at an angle (Ref. Fig. 16 on page 10). This will cause cable to pile up on one end, jamming and damaging winch. The winch cable could also break from being overstressed and strike someone. Pulling vehicle at an angle can cause damage to front suspension and may cause vehicle to overturn. When pulling vehicle, pull straight only.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Winch shown mounted at front of vehicle Spring Pin Clevis Pin Damper Nylon Sling Ref Wmt 2 Ref Wca 3 Fig. 17 Mounting Winch Pull out desired amount of cable and secure. Engage drum by rotating knob until it snaps in place. Never operate winch unless clutch is engaged. To prevent damage to wire cable, never hook cable to itself.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings as possible from side of vehicle. Do not operate winch while sitting in passenger seat. Read ‘Winch Applications’ section before attempting to operate winch. The sun top has been designed to provide roll over protection and requires the ROPS system to be installed.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Vehicle may be equipped with a receiver that accepts a standard 2" ball hitch. Trailer range of motion is limited by the ball and hitch and should not be used on rough trails or over objects such as logs, large rocks, holes, etc. Latches Never install non-factory baskets or extensions in hitch receivers (front or rear).
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE ! ! To reduce possibility of severe injury or death from improper servicing techniques: Do not attempt any type of servicing operations before reading and understanding all notes, cautions and warnings in this manual. Wear eye protection when working on vehicle.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LIFTING THE VEHICLE Tool List Qty. Required Floor jack .................................................................... 1 Jack stands ................................................................. 4 Chocks ........................................................................
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings OIL LEVEL CHECK To reduce possibility of engine damage, do not run engine with oil level too low. Front of Vehicle Park vehicle on level surface, shut off engine and wait a minute for oil to settle. Lift seat, remove dipstick and wipe clean (Ref. Fig. 25 on page 18). Replace dipstick and remove again.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Front of Vehicle Inspect electrodes for wear and insulator for cracks or chips. Fouled spark plugs are indicated by a wet, black appearance. This could be caused by a dirty air filter element or other restrictions in air intake system.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Air Cleaner Cover Air Filter Element Air Cleaner Canister 3/8" (1 cm) Max. Deflection for New Belt 1/2" (1.3 cm) Max. Deflection for Existing Belt Clip Ref Air 4 Fig. 29 Air Cleaner FUEL FILTER Ref Abt 3 To reduce possibility of an explosion, do not smoke near fuel tank or in an area where gasoline is being handled.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Slip Joints & U-Joint Yokes View From Underside of Vehicle Ref Ffi 1 Ref Lub 5 Fig. 30 Fuel Filter Fig. 31 Lubrication Points LUBRICATION POINTS Do not use more than three (3) pumps of grease in any grease fitting at any one time. Excess grease may cause grease seals to fail or grease migration into areas that could damage components.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings BATTERY CLEANING To reduce possibility of damage to vehicle or floor, neutralize acid before 1 1/2 gallons (6 liters) Clear Water rinsing battery. 1 quart (1 liter) Clear Water To reduce possibility of damage to electrical components while cleaning, do not use a pressure washer.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings If engine does not start or runs improperly after washing, remove spark plug wires (by pulling the spark plug boots, never the wires). Dry all connections with forced air. Reinstall wires. CARE PRODUCTS + Weak Battery - Front of Vehicle Strong Battery + Ref Jmp 1 Fig. 33 Jump Starting tem.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings WHEELS AND TIRES Remove lug nuts and wheel. To reduce possibility of damage, tighten lug nuts to no more than 85 ft. lbs. Tires are uni-directional and should never be moved from one side of vehicle to the other. This vehicle comes standard with low pressure, tubeless, uni-directional tires mounted on one piece wheels (Ref. Fig.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LIGHT BULB REPLACEMENT Inside of Cowl Brush off carbon deposits from arrester screen without damaging screen. Screen must be intact. Replace spark arrester if screen is breached. Install arrester on muffler and secure with screw. Headlight Bulb Ref Hdr 4 Ref Csa 1 Fig. 35 Headlight Replacement Fig.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • Add fuel stabilizer to fuel tank following instruc• • • tions on stabilizer container. Attach fuel line to tank and drive vehicle for several minutes to circulate fuel stabilizer through carburetor. While engine is still warm, change oil (Ref. OIL CHANGE on page 18). Remove spark plugs (Ref. SPARK PLUGS on page 19) and pour about 1 oz.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CAPACITIES Cooling Fins Fuel Tank Air Intake 6.7 gal (25.4 liters) unleaded, 87 octane or higher 1.59 quarts (1.5 liters) crankcase only Engine Oil 1.90 quarts (1.8 liters) crankcase and filter 10W30 usually. See OIL on page 17. Front Differential 15.2 ± 1 oz. (450 ml) of 80 - 90W GL5 Rear Axle 15.2 ± 1 oz.
OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HARDWARE Periodically, vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref. Fig. 41 on page 28). Generally, three grades of hardware are used in vehicle. Grade 5 hardware can be identified by three marks on the hexagonal bolt head and grade 8 by six marks.
GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Owner’s Manual and Service Guide Page 29
GENERAL SPECIFICATIONS ST 4X4 STANDARD EQUIPMENT: CHASSIS BODY (Front) Welded steel, hot-dip galvanized, front hitch receiver Flexible, Impact Resistant DuraShield™ Injection Molded TPE (Thermoplastic Elastomer) with Base Coat/Clear Coat BODY (Rear) Lightweight, replaceable steel panels, plastic rear fenders BATTERY One 12 Volt Maintenance Free (340 CCA, 38 Minute Reserve) ENGINE Honda 18 H.P. (13.4 kW) 37.
GENERAL SPECIFICATIONS 50" (127 cm) 54" * (137 cm) 11 1/2" (29 cm) 12 3/4" * (32 cm) 112" (285 cm) 18 1/4" (46 cm) 50" (127 cm) 11" (28 cm) (Inside) 31.5" (80 cm) 16" (40.6 cm) Front 43 3/8" (110 cm) Rear 43 3/4" (111 cm) Ref Dim 3-1 9 1/2" (24 cm) Clearance At Lowest Point On Frame 76" (193 cm) 8 3/8" (21.3 cm) Clearance At Lowest Point Of Vehicle (On Rear Axle) Late 2005 Production Loadbed shown. Early Production Similar * Indicates Late 2005 Production Dimension Fig.
GENERAL SPECIFICATIONS TURNING CLEARANCE DIAMETER Approx. 25'-6" (7.8 m) Ref Dim 3-3 Fig.
VEHICLE WARRANTIES VEHICLE WARRANTIES Owner’s Manual and Service Guide Page 33
VEHICLE WARRANTIES Page 34 Owner’s Manual and Service Guide
VEHICLE WARRANTIES EMISSION CONTROL SYSTEM WARRANTY STATEMENT (Owner’s Defect Warranty Rights and Obligations) Refer to the HONDA Emission Control System Warranty sheet, provided with vehicle, for information. ENGINE OWNER WARRANTY POLICY Refer to the Warranty sheet, provided with vehicle, for Engine Warranty information. INTERNATIONAL WARRANTY STATEMENT Refer to the International Warranty sheet, provided with vehicle, for information.
VEHICLE WARRANTIES Notes: Page 36 Owner’s Manual and Service Guide
DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY (EUROPE ONLY) Declaration of Conformity is packaged with vehicle.
DECLARATION OF CONFORMITY Notes: Page 38 Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS LABELS AND PICTOGRAMS Owner’s Manual and Service Guide Appendix A - 1
LABELS AND PICTOGRAMS Notes: Appendix A - 2 Owner’s Manual and Service Guide
LABELS AND PICTOGRAMS See Following Pages For Explanation Of These Pictograms: (56,57,58,59,60) OFF See Following Pages For Explanation Of These Pictograms: (43,44,51) ON START 73767G01 73767G01 73777G01 See Following Pages For Explanation Of This Pictogram: (28) 73777G01 (Lift Pb Cow l) 35493-G01 35493G01 See Following Pages For Explanation Of These Pictograms: (1,2) 71489G01 MAX 1100lbs.
LABELS AND PICTOGRAMS ! 1. WARNING 9. 2. < 14 ° 25 % READ MANUAL MAX MA X xxx lbs. xxx kg 10. WARNING USE CAUTION IN INCLEMENT WEATHER 3. ! WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. MAXIMUM RAMP/HILL 11. SECURE LOAD AS FAR FORWARD AS POSSIBLE MAXIMUM LOAD BED CAPACITY DO NOT RIDE IN LOAD BED WARNING DO NOT OPERATE UNDER THE INFLUENCE OF DRUGS OR ALCOHOL 4. 5. MAX M AX 14 ° / 25 % MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED 12.
LABELS AND PICTOGRAMS 1 15. 3 2 PP H 2O 26. WARNING LETHAL VOLTAGE 27. DO NOT EXPOSE TO FLAME 28. DO NOT DISPOSE OF BATTERIES IN LANDFILL 29. DO NOT DRIVE ON HIGHWAY 30. WINDSHIELDS DO NOT PROVIDE PROTECTION FROM FLYING OBJECTS 31. BATTERIES ARE HEAVY. USE CARE LIFTING CLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE 16. 17. 18. 19. PP UNLEAD GASOLINE PP DO NOT SPILL FUEL ON A HOT ENGINE PP GROUND FUEL PUMP LOW OIL PRESSURE 20. NEGATIVE GROUND BATTERY 21.
LABELS AND PICTOGRAMS 36. OPERATE FROM DRIVER’S SIDE ONLY 37. KEEP ARMS AND LEGS WITHIN VEHICLE TO OPERATE VEHICLE IN FORWARD: * TURN KEY TO ON * MOVE DIRECTION SELECTOR TO FORWARD * DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY 38. F TO OPERATE VEHICLE IN REVERSE: * TURN KEY TO ON * MOVE DIRECTION SELECTOR TO REVERSE * AN AUDIBLE DEVICE WILL SOUND * DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY 39. R P 40.
LABELS AND PICTOGRAMS 54. WARNING READ OWNER’S MANUL BEFORE OPERATING VEHICLE IN FORWARD OR REVERSE 55. WARNING READ OWNER’S MANUAL BEFORE PARKING VEHICLE AND LEAVING IT UNATTENDED 62. AUXILIARY LIGHTS 63. HORN BUTTON FORWARD 56. NEUTRAL REVERSE 57. WARNING READ OWNER’S MANUAL BEFORE ENGAGING TWO OR FOUR WHEEL DRIVE PUSH TOP OF SWITCH TO LOCK DIFFERENTIAL 58. PUSH BOTTOM OF SWITCH TO UNLOCK DIFFERENTIAL 59. REAR DIFFERENTIAL LOCK SWITCH 60. FRONT DIFFERENTIAL LOCK SWITCH.
LABELS AND PICTOGRAMS Notes: Appendix A - 8 Owner’s Manual and Service Guide
Check area behind the vehicle before operating in reverse. area that is being used for charging batteries. A concentration of 4% hydrogen gas or more is explosive. Make sure the direction selector is in correct position before attempting to start the vehicle. Engine exhaust gas (carbon monoxide) is deadly. Carbon monoxide is an odorless, colorless gas that is formed as a natural part of incomplete combustion of hydrocarbon fuels.
E-Z-GO Division Of Textron, Inc., 1451 Marvin Griffin Road, Augusta, Georgia USA 30906-3852 TO CONTACT US North America: Technical Assistance & Warranty Phone: 1-800-774-3946, FAX: 1-800-448-8124 Service Parts Phone: 1-888-GET-EZGO (1-888-438-3946), FAX: 1-800-752-6175 International: Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron, Inc.
