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OG INSTINCT.book - Bad Boy Buggies

1. A aii 31 Headlight Bulb einen aa q iq au 31 Phe ente ates Enters 31 Owner s Manual WHEELS ANDiTIRES is u usu amata iro tette e re teret 32 Tire RERA iint e ten e addi eee a es 32 Wheel Install amp tion e a e Re d ei d a 33 Unidirectional Tires uu ay eee De eee ree e ve 33 WHEEL APLIGNMENT nieht pee ree t ie ent he ne fedet 33 Wheel Aligritienit t rore aaa eter ee EEr oer rhet er meret 33 BRAKES uitium t nieder a us uei ies iid NE IS NEL 34 Master Cylinder 2m dp eee RU Ue Hd Eee e Po Pre eda 34 Bleeding Brakes i iet 34 Park Brake Adjustment 35 POWERTRAIN Zee ua ei aded erst tare adeat erede ties 35 REAR AXLE wees San Sta a eese a Su gen exp tae een ua 36 Checking the Lubricant Level enne 36 BATTERY CHARGING AND MAINTENANCE sess nnne 37 Battery Satelyi iioii bn eivai a Rb n te 37 Battery Disposal L s ua rel este dp edet Unas 37 BanG usata 38 Battery Maintenance sesei iner oriris peara EAEE nennen nennt nennen nennen nennen 38 At Each Charging Cycle ener nen 38 Monthly Ese 38 Temperature Affects Battery Capacity sss 39 Electrolyte Level and Water
2. 1 Park the vehicle on a level surface set the front wheels straight ahead Turn the key switch to OFF remove the key from switch and set the park brake With vehicle empty no passengers or payload measure distance between center of both the front and the rear sets of tires Measure both in front and behind each tire set keeping tape measure parallel to the ground The measurement behind the tires should be 1 4 more than the measurement taken at the front of the tires to produce a toe in condition wor Cas 33 Owner s Manual MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Adjust both tie rods equally to obtain the correct toe in Hold tie rod 2 with an open end wrench loosen the jam nut 1 and turn the adjustment shaft 3 to move the wheel in the desired direction Recheck the measurement at the front and at the rear of the front tires if the 1 4 toe in has been achieved tighten the lock nut 1 on each tie rod BRAKES This vehicle is equipped with four wheel hydraulic disc brakes and a hand operated park brake Check the fluid level at intervals specified in the PERIODIC SERVICE SCHEDULE if fluid leaks are noticed or the brake pedal seems soft check the fluid level immediately If the brake pedal is soft the brake system should be bled to remove air from the brake lines Refer to Bleeding
3. u u 39 Cleaning Batteries 41 Battery Removal and Installation seen 42 Prolonged Storage titt it eodd ig ie e E PL EE ada 42 Battery Chargiigk uu uuu eene 43 BATTERY TROUBLESHOOTING 43 HYBROMBETER 45 i Ee dd an a Q aep E dude eet edet 43 Using A Flydrometer ete rea eed 44 HARDWARE hunaq rape EUER TR ER RT GERA upas a tide 45 CAPACITIES AND REPLACEMENT PARTS sese enne 45 PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE I eee eee ener seer ener nennen 47 Owner s Manual TABLE OF CONTENTS Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers SAFETY GENERAL For any questions on material content in this manual contact an authorized representative for clarification Read all labels located on the vehicle Always replace any damaged or missing labels On steep hills it is possible for vehicle to obtain higher speeds than possible on flat ground To prevent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum level ground speed See GENERAL SPECIFICATIONS Limit speed by applying the brake Catastrophic damage to the drivetrain components due to excessive speed
4. INTRODUCTION FEATURES General Information If the vehicle is equipped with factory installed custom accessories some accessories remain operational with the key switch in the OFF position 1 Key Switch Direction Selector Located on the dash to the right of the steering wheel this four position switch allows the vehicle electrical system to be activated It also determines direction of travel It allows the operator to turn the electrical system off completely by mov ing the key to the OFF position or select Reverse Neutral or Forward by rotating key to the right 2 State of Charge Meter The illuminated state of charge meter is located on the dash It indicates the amount of usable power in the batteries with F indicating a full charge on the battery pack and E indicating the batteries are low 3 Park Brake Light The park brake light illuminates to indicate that the park brake is engaged 4 Light Switch Located on the left side of dash this ON OFF switch controls the lights In the ON position the headlights and taillights illuminate Owner s Manual 11 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 5 Max Speed Range Switch This is a two position switch located on the dash to the right of the key switch The top position is the Max Speed setting It allows the vehicle to travel up to
5. Locate the headlight bulb socket on the backside of the light assembly Headlight Bulb Turn bulb socket a quarter turn counterclockwise to unlock Pull out bulb and socket remove old bulb from the socket Insert new bulb in socket and position bulb socket into head light housing and rotate socket a quarter turn clockwise to secure Taillight Bulb The taillight contains an LED light board rather than a light bulb if the LEDs burn out the whole light will have to be replaced Owner s Manual 31 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers WHEELS AND TIRES A tire explosion can cause severe injury or death Never exceed the inflation pressure rating on the tire sidewall To reduce the possibility of tire explosion pressurize tire with small amounts of air applied inter mittently to seat beads Due to the low volume of the small tires overinflation can occur in sec onds Never exceed the tire manufacturer s recommendation when seating a bead Protect face and eyes from escaping air when removing a valve core Use caution when inflating tires Overinflation could cause the tire to separate from the wheel or cause the tire to explode either of which could cause severe injury To reduce the possibility of severe injury caused by a broken socket when removing wheels use only sockets designed for impact wrench use Tire
6. Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers LABELS AND PICTOGRAMS WARNING USE CAUTION IN OPERATE FROM NoPuBLic NCLEMENT WEATHER gpeRaTORMUST DRIVERSSIDE OCCUPANT MUST ROAD USE BE MIN 150 CM ONLY WEAR SEAT BELTS m FOR INFORMATION REFER TO OWNERS MANUAL OR WEBSITE NO UNATTENDED CHILDREN DRIVE IN ACCORDANCE A 638040 WITH LOCAL RULES AND REGULATIONS DO NOT OPERATE LEAVE VEHICLE REMAIN SEATED NO MORE THAN UNDER DRUG ALCOHOL IN THREAT OF KEEP ARMS LEGS TWO OCCUPANTS INFLUENCE LIGHTNING WITHIN VEHICLE PER SEAT ALWAYS remain PROPERLY SEATED with SEAT BELT FASTENED and HOLDING ON ONLY 2 occupants on bench seat Children may need assistance to remain PROPERLY SEATED with SEAT BELT FASTENED and HOLDING ON NEVER leave children unattended KEEP feet legs hands and arms inside the vehicle at all times NEVER attempt to enter or exit a moving vehicle AVOID standing in front of or behind vehicle 628943 628943 LOCATED ON UNDERSIDE OF SEAT BOTTOM LOAD DECK Maximum deck load is 400 Ibs 181 kg The center of gravity of the load must not exceed 12 inches 30 cm above the deck floor The load must be as far forward as possible and secured Top heavy loads may cause vehicle instability or tip over Drive slowly straight up or down slopes and in turns NEVER allow pass
7. nnns 4 To reduce the possibility of severe injury or death from a vehicle falling from a jack Always place chocks in front and behind the wheels not being raised Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is supported by a jack Use jack stands and test the stability of the vehi cle on the stands Use extreme care since the vehicle is very unsta ble during the lifting process When lifting the vehicle position the jacks and jack stands at the areas indicated Remove payload from vehicle before lifting No person s should be in or on the vehicle while lifting Lift Entire Vehicle 1 Place wheel chocks in front and behind each front wheel 2 Center jack under rear axle tube next to differential housing or under the skid plate 3 Raise vehicle and position jack stands under the frame where the leaf spring mounting bracket is welded to the frame 4 Lower the jack and test the stability of the vehicle on the two jack stands 5 Place the jack under the center front of the car just behind the bumper 6 Raise the vehicle and position the jack stands under the frame where the instrument panel support is attached to the frame 7 Lower the jack and test the stability of the vehicle on all four
8. BAD BOY OWNER S MANUAL INSTINCT 640690 ISSUED JULY 2014 REVISED APRIL 2015 Thank you for purchasing this vehicle Before driving the vehicle please take time to read and understand this entire Owner s Manual This manual contains important safety information as well as information that will assist in maintaining the vehicle for optimum performance This manual may cover the operation of several different models or show items that are optional therefore some illustra tions images may not be representative of all models Most service procedures can be accomplished using common tools Perform service procedures at intervals shown in the Periodic Service Schedule located elsewhere in this manual Repair or replacement parts are available through your BAD BOY BUGGIES retailer The following information is needed when contacting us concerning service or parts for your vehicle Vehicle Model PIN or Serial Number Manufacture Date Code OWNER S MANUAL ELECTRIC POWERED VEHICLE INSTINCT STARTING MODEL YEAR 2015 CALIFORNIA Proposition 65 Warning WARNING Motor vehicles may contain fuels oils and fluids battery posts terminals and related accessories which contain lead and lead compounds and other chemicals identified by the State of California to potentially cause cancer birth defects and other reproductive harm These chemicals are found in vehicles vehicle parts and accessories both new and replacements Durin
9. Pay particular attention to Notices Cautions Warnings and Dangers Key Switch Operation Wo sc Key Switch When the key is turned to the far left the vehicle electrical system is off and not operational Turn right to the first position labeled R for reverse The next posi tion to the right labeled N is neutral Rotate to the far right position labeled F for forward To prevent inadvertent operation of the vehicle when left unattended the key should be turned to the OFF position and removed from the switch To reduce the possibility of component damage the vehicle must be stopped completely before turning the key Max Range Speed Switch Max Speed Range Switch Press the top of the switch to select the Max Speed setting This setting allows the vehicle to travel up to 24 5 MPH diminishing distance capability for increased speed advantage Press the bottom of the two position switch to select the Max Range setting This setting limits top speed to 16 MPH which conserves battery power in order to extend the range of distance the vehicle is capable of traveling before the bat teries need to be recharged Light Switch Operation Press the top of the two position switch to activate the headlights and taillights Press the bottom of the switch to turn them off Light Switch Brake Operation This vehicle is equipped with four wheel hydraulic brakes Press the brake pedal to control speed or bring vehicle to a s
10. 2 teaspoons 10 ml sodium bicarbonate baking soda dissolved in 1 quart 1 liter of water 2 In addition to the batteries pay special attention to metallic components adjacent to the batteries Spray these with the baking soda solution also 3 Allow the solution to set for at least three minutes then use a soft bristle brush or cloth to wipe the tops of the batter ies to remove any residue that could cause the batteries to self discharge 4 Rinse the entire area with low pressure clear water To prevent battery explosion that could result in severe personal injury or death use extreme care with aerosol containers of battery terminal protectant Insulate the metal container to prevent the metal can from contacting battery terminals 5 After batteries are clean and dry coat terminals with a commercially available protectant See previous WARNING Cleaning should take place once a month or more often under extreme conditions Owner s Manual 41 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Battery Removal and Installation Improper handling of high voltage wiring batter ies or control systems could result in serious or fatal injury by electric shock Only qualified techni cians should repair or access high voltage wiring battery packs and associated systems To prevent battery explosion that could result in severe personal inju
11. 24 5 MPH This setting diminishes distance capability for increased speed advantage The bottom position is the Max Range setting It limits the top speed of the vehicle to 16 MPH which conserves battery power in order to extend travel distance 6 Auxiliary Switch Positions There are three empty spaces on the dash to allow for additional switches to control added lights or accessories 7 12 Volt Power Outlet Located in the lower part of the dash above the cup holder the 12 volt outlet supplies constant power for additional equipment equipped with a 12 volt plug 8 Cupholder A cupholder is provided for convenience of vehicle occupants 9 Accelerator Pedal The accelerator pedal is located on the floorboard to the right of the brake pedal Its function is to accelerate and control the speed of the vehicle 10 Brake Pedal The brake pedal is located on the floor to the left of the accelerator pedal The brake pedal function is to slow or stop the moving vehicle 11 Park Brake The hand operated park brake is located in the middle of the floorboard The function of the park brake is to keep the vehicle from inadvertent movement when in a stationary position The brake is engaged when the handle is vertical and disengaged when the handle is almost parallel to the floor as shown 12 Charger Receptacle The polarized receptacle for the batteries is located on the panel below the drivers seat It is the receptacle for the ch
12. 25587 G01 1 Battery Protective 1 There is one battery under the cowl the remaining batteries are located under the seat The single battery under the cowl is equipped with a battery fill system tube that is located in the passenger side glove box The batteries under the seat can be accessed by raising and removing the seat bottom and battery cover At Each Charging Cycle To reduce the possibility of fire never attach a battery charger to a vehicle that is to be unattended beyond the normal charging cycle Overcharging could cause damage to the vehicle batteries and result in extreme overheating The charger should be checked after 24 hours and unplugged after the charge cycle is complete Before charging the batteries inspect the plug of the battery charger and vehicle receptacle housing for dirt or debris Charge the batteries after each days use Monthly Inspect all wiring for fraying loose terminations corrosion or deterioration of insulation e Check that the electrolyte level is correct and add suitable water as required Clean the batteries and wire terminations Torque battery terminal nuts to 95 105 in Ibs 11 12 Nm Coat battery terminals with commercially available protectant Replace all terminal covers Replace battery compartment cover and note service date on chart 38 Owner s Manual Read all of SAFETY and this
13. Brakes on page 34 for procedure Master Cylinder The master cylinder is located behind the driver side front wheel mounted to the frame Before removing the reservoir cap clean any dirt or debris from around the reservoir and cap Bleeding Brakes Tool List Qty Tool List Qty mE UIDI A R Clean Container sss 1 Brake Fluid DOT 3 eee A R Wrench 1 4 box end 1 The hydraulic brake system must be free of air to operate properly Air can enter the system when hydraulic parts are dis connected for servicing or replacement or when the fluid level in the master cylinder reservoir is very low Air in the sys tem will give the brake pedal a spongy feeling when pressed NOTICE An assistant is necessary to perform this procedure 1 Use a clean cloth to wipe off the master cylinder reservoir and wheel cylinder bleeder valves Clean each fitting before opening to prevent contaminating the system 2 Open the master cylinder reservoir and top off with standard automotive DOT brake fluid s XX a 34 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Never return brake fluid to the original container or reuse brake fluid due to the possibility of con tamination by dirt grease moisture C
14. Repair Tool List Qty Tool List Qty Lug Wrench 3 4 for steel 1 Impact Socket 3 4 for steel rims 1 Lug Wrench 17mm for aluminum rims 1 Impact Socket 17mm for aluminum rims 1 Impact Wrench ttt tee Rebels 1 Torque Wrench ft 168 1 Generally the most cost effective way to repair a flat tire resulting from a puncture in the tread portion is to use a com mercial tire plug If the tire is flat raise vehicle and remove wheel Refer to Lifting the Vehicle for proper lifting procedure and safety infor mation Inflate tire to the maximum recommended pressure immerse tire in water to locate the leak and mark the leak with chalk Insert tire plug in accordance with manufacturer s specifications Use caution when inflating tires Due to the low volume of the small tires overinflation can occur in seconds Overinfla tion could cause the tire to separate from the wheel or cause the tire to explode Recommended tire inflation pressure is 12 psi Under no condition should inflation pressure be higher than recom mended on tire sidewall All four tires should have the same pressure for optimum handling characteristics Be sure to install the valve stem dust cap after checking or inflating The vehicle is fitted with low volume tubeless tires mounted on one piece rims 32 Owner
15. are attached to the frame below the truck bed On some early model vehicles these labels are attached to the frame under the cowl on the driver s side Design changes take place on an ongoing basis In order to obtain correct components for the vehicle the PIN number manufacture date code serial number and vehicle model must be provided when ordering service parts Serial Number Serial Number PIN Label Part A Part B Front of Vehicle N ON Early Model Vehicle ar Wa Label gt Serial Number Part A Improper use of this vehicle could result in severe injury or death The buggy is a light duty utility vehicle NOT an All Terrain Vehicle ATV When driving vehicle consider the terrain traffic conditions and the environmental factors which affect the terrain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass or gravel Maintain a safe speed when driving up or down a hill Use brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of control To prevent loss of control do not move the direction selector while the vehicle is in motion Moving the direction selector will result in a sudden slowing of the vehicle Slow down before and during turns All turns should be made at reduced speed Do not drive through water that is more than 12 inches 30 cm deep Owner s Manua
16. attention to Notices Cautions Warnings and Dangers Cleaning Batteries When cleaning the outside of the batteries and terminals do not use a water hose without first spraying the batteries with a solution of baking soda sodium bicarbonate and water to neutralize any acid deposits Use of a water hose without first neutralizing the acid will move the acid from the top of the bat 2T teries to another area of the vehicle or storage facility where it 10 ml will attack the metal structure or the concrete asphalt floor ee Sodi Plastic After hosing down the batteries a residue will be left on the us batteries which is conductive and will contribute to the dis 1 Bottle charge of the batteries Clear Water Baking Soda To prevent battery damage be sure that all battery caps are tightly installed There is one battery under the cowl the remaining batteries are located under the seat The single battery under the cowl is equipped with a battery fill system tube that is located in the passenger side glove box To access the battery for clean ing remove the rivets from the access cover in the cowl and lift the cover The batteries under the seat can be accessed by raising and removing the seat bottom and battery cover Clean batteries 1 Use a plastic spray bottle to spray the top and sides of the batteries with a solution of baking soda and water The solution should consist of
17. driving vehicle consider the terrain traffic conditions and the environmental factors which effect the terrain 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 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 con trol 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 Do not permit more occupants on the vehicle than it is designed to carry Refer to GENERAL SPECIFICATIONS for seating capacity To reduce the possibility of severe injury or death resulting from improper vehicle operation the following warnings must be observed To prevent inadvertent movement when the vehicle is left unattended engage the park brake turn key to OFF position and remove key from switch Always bring the vehicle to a complete stop before shifting the direction selector Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operating in reverse All occupants must be seated with seat belts fastened and side nets latched Keep entire body inside vehicle and hold on while vehicle is in motion Owner s Manual 19 Read all of SAFETY and this section before attempting any procedure
18. environ mental officials regarding disposal information Owner s Manual 37 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Battery A battery is defined as two dissimilar metals immersed in an acid If the acid is absent or if the metals are not dissimilar a battery has not been created The batteries most commonly used in these vehicles are lead acid A battery does not store electricity but is able to produce electricity as the result of a chemical reaction which releases stored chemical energy in the form of electrical energy The chemical reaction takes place faster in warm conditions and slower in cold conditions Temperature is important when conducting tests on a battery and test results must be corrected to compensate for temperature differences As a battery ages it continues to perform adequately except that its capacity is diminished Capacity describes the time that a battery can continue to provide its design amperes from a full charge A battery has a maximum life therefore good maintenance is designed to maximize the available life and reduce the fac tors that can reduce the life of the battery Battery Maintenance Tool List Qty ToolList Qty Insulated Wrench 9 16 1 Battery Carrier a a rat 1 Hydtrotietlet 3 a 1 Battery Maintenance Kit P N
19. of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers e Maintain adequate distance between vehicles Reduce speed in wet areas Reduce speed and use extreme caution when approaching sharp or blind turns Reduce speed and use extreme caution when driving over loose terrain Reduce speed and use extreme caution in areas where pedestrians are present MAINTENANCE ALWAYS Replace damaged or missing warning caution or information labels e Maintain the vehicle in accordance with the manufacturer s periodic service schedule Ensure that repairs are performed by trained and qualified personnel Follow the manufacturer s maintenance procedures e Insulate any tools used within the battery area in order to prevent sparks or battery explosion Use specified replacement parts NEVER use replacement parts of lesser quality Use recommended tools Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle Support the vehicle using wheel chocks and jack stands NEVER get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions e Maintain the vehicle in an area away from exposed flame or persons who are smoking aware that a vehicle that is not performing as designed
20. section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Temperature Affects Battery Capacity E 11 Battery storage capacity is affected by the temperature the colder it is the less energy it is able to store as temperature 110 increases so does the storage capacity of the battery 105 The ideal battery temperature for deep cycle batteries is 100 77 F 25 C At 32 F 0 C the storage capacity of the bat 95 tery will be reduced by 2096 This means in cold weather the 90 vehicle will not travel as far as it would in warm weather gt m Electrolyte Level and Water Q 80 The correct level of the electrolyte is 1 2 13 mm above the 2 75 plates each cell 70 This level will leave approximately 1 4 3 8 6 10 mm of 65 space between the electrolyte and the vent tube The elec O 60 trolyte level is important since any portion of the plates x 55 exposed to air will be ruined beyond repair Also avoid filling with too much water which will result in electrolyte being 50 forced out of the battery due to gassing and a decrease in 45 volume of the electrolyte that results from the charging cycle 40 35 30 DO NOT overfill batteries The charging cycle will C 40 30 20 10 0 10 20 30 40 50 60 expel electrolyte and result in component damage TEMPERATURE If the battery electrolyte level is too high the electrolyte will block the ven
21. 0Hz unit U L Certified Electrical System 72 Volt DC six 12 volt deep cycle storage batteries Drive Train Direct motor shaft connected to transaxle pinion shaft Transaxle Differential with reverse helical gears Brakes 4 wheel hydraulic disc brakes and Induction motor Manual parking brake Body Protection Front Brush Guard PRODUCT OVERVIEW Ls Overall Length 111 0 in Seating Capacity amp Style 2 Persons Bench Seat Overall Width 52 0 in x cm Curb Weight 1 528 lb 693 kg Overall Height 76 5 in 194 cm Vehicle load capacity 840 Ib 381 kg Wheel Base 69 0 in 175 cm Towing capacity 1 000 Ib 454 kg coir Fane 185i a Gnd Clearance Differential 10 0 in 25 cm Outside Clearance Circle 24 ft 75m Speed Low Level Ground 16 0 mph 25 7 kph vnc Pover m Power Source 72 Volts DC 72 Volts AC Steering amp Suspension Horsepower kW 19 hp Steering Double Ended Rack amp Pinion 3 69 turns to lock Electrical System 72 Volt Front Suspension MacPherson Strut Six 12V Deep Cycle Rear Suspension MacPherson Strut mE Key or Pedal Start Key Start Service Brake 4 Wheel Hydraulic Disc with Motor Regen Speed Controller 300 amp Parking Brake Manual wicontroller cut out Front Tires Kenda 25x8 12 Uni Directional Drive Train Motor Shaft Direct Drive Rear Tires Kenda 25x11 12 Uni Directional Transaxle Hardened Helical Gears a Body amp Chassis Direction Selection Dash mounted Forward Neutral Reverse Frame Wel
22. Brake Light uuu dare te dne ier eed 11 Hie 11 Max Speed Range Switch essere 12 Auxiliary Switch Positions rr 12 12 Volt Power O tl t u u e Sau enne nnns nennen 12 u sus as C e Ree E et e ab retenti neo 12 Accelerator Pegal u u p ee u ee Me 12 Brake Podal 12 Park Brake uuu c 0 eal ae eu eae 12 Gharger Receptacle nete eee erae eet dte e tg 12 Tr ck Bed LatCli m i hr ons 13 Tr ck Beg ii eate dede e pne ia ed eher eio tein dose e rues 13 a cH 13 Head Protection x met eter teet ete recen ue rivo ince ette be Pp ees 13 Side Nets em E Pre UTE ERU ie eee an ruso Le ete 13 SeatBelIS 5 soie dette e Sau uk 13 Rear Seat Load Deck If Equipped 14 OPS Top Windshield ere Peer t Peter ane tees 14 OPERATING PROCEDURES Owner s Manual PIN AND SERIAL NUMBER LOCATION a 15 BEFORE INITIAL 1 2 u ate ce Mee e eee edd ane 16 PORTABLE CHAR GER ee Eo tee dtt dnd idet 17 Usirig the ChargeF e anan ede eee e e ee 18 iine erepto Pet Hb bieten ettet 19 Key Switch Operation nennen ennt nennen en 20 Max Speed Range Switch U enne
23. E Z GO manufactured vehicle is modified in any way by the Distributor Dealer or customer to operate at or in excess of 20mph UNDER FEDERAL LAW the modified product will be a Low Speed Vehicle LSV subject to the stric tures and requirements of Federal Motor Vehicle Safety Standard 571 500 In these instances pursuant to Federal law the Distributor or Dealer MUST equip the product with headlights rear lights turn signals seat belts top horn and all other modifications for LSV s mandated in FMVSS 571 500 and affix a Vehicle Identifi cation Number to the product in accordance with the requirements of FMVSS 571 565 Pursuant to FMVSS 571 500 and in accordance with the State laws applicable in the places of sale and use of the product the Distributor Dealer or customer modifying the vehicle also will be the Final Vehicle Manufacturer for the LSV and required to title or register the vehicle as mandated by State law Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers E Z GO will NOT approve Distributor Dealer or customer modifications converting E Z GO products into LSV s The Company recommends that all E Z GO products sold as personal transportation vehicles BE OPERATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND INACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION of the produ
24. OFF position and remove key from switch Drive vehicle only as fast as terrain and safety considerations allow Consider the terrain 2 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers and traffic conditions Consider environmental factors which affect the terrain and the abil ity to control the vehicle Avoid driving fast downhill Sudden stops or change of direction may result in a loss of control Use brake to control speed when traveling down an incline Use extra care and reduced speed when driving in poor conditions or on poor surfaces Stay in designated areas where provided and avoid steep slopes Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain Check area behind the vehicle before operating in reverse Ensure direction selector is in desired position before pressing the accelerator pedal Slow down before and during turns Always bring vehicle to a complete stop before changing direction See GENERAL SPECIFICATIONS for vehicle load and seating capacity NOTICE Read the following text and warnings before attempting to service vehicle In any product components may eventually fail to perform properly as the result of normal use age wear or abuse It is impossible to anticipate all possible component failures or the manner in which each component may fail A vehicle requi
25. ange without notice E Z GO IS NOT LIABLE FOR ERRORS IN THIS MANUAL E Z GO IS NOT LIABLE FOR INCIDENTAL OR CONSE QUENTIAL DAMAGES THAT RESULT FROM THE USE OF THE MATERIAL IN THIS MANUAL This vehicle conforms to the current applicable standard s for safety and performance requirements Vehicle is designed and manufactured for off road use It DOES NOT conform to Federal Motor Vehicle Safety Standards of the United States of America USA and is not equipped for operation on public streets Refer to GENERAL SPECIFICATIONS for vehicle seating capacity Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease it s stability or increase the speed or extend the stopping distance beyond the factory specifica tion Such modifications can result in serious personal injury or death Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease it s stability or increase the speed or extent the stopping distance beyond the factory specification E Z GO prohibits and disclaims responsibility for all such modifications which would adversely affect the safety of the vehicle Operation of the vehicle is limited to persons above the height of 59 inches 150 cm GENERAL OPERATION Read the following warnings before attempting to operate the vehicle To prevent personal injury or death observe the following When vehicle is to be left unattended turn key to
26. arger cord when the batteries need to be charged If vehicle is equipped with optional onboard charger receptacle is located on the back seat 12 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 13 Truck Bed Latch A truck bed latch is located at the front of the manual lift truck bed It is used to raise and lower the manual lift truck bed 14 Truck Bed The truck bed provides space to transport cargo A molded plastic bed is stan dard some vehicles may be equipped with an optional aluminum bed 15 Taillights The taillights are located at the rear of the truck below the truck bed 16 Head Protection Rubber pads provide head protection while driving over rough terrain They are a standard safety feature on the vehicle and should not be altered or removed 17 Side Nets Side nets are a standard safety feature provided with the vehicle and must be properly secured before operating vehicle 18 Seat Belts The vehicle is equipped with seat belts for the driver and front pas senger If vehicle has a rear seat it is equipped with seat belts for two rear facing passengers Seat belts must be worn at all times by all occupants when vehicle is in motion For more operational and safety information see Seat Belt Opera tion on page 21 Owner s Manual 13 Read all of SAFETY and this section before attemp
27. ath to operator occupants or bystanders consider the following when selecting an object to attach the cable to Make sure the object cannot be pulled over or otherwise damaged The object the winch cable is attached to could fall on the vehicle and it s occupants If attaching the winch to a dead tree a section could fall When pulling vehicle with winch pull straight ps Do not permit cable to contact the side of the rum Do not pull vehicle at an 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 The rear drive axle is equipped with a manually operated locking differential With the differential unlocked if one drive wheel looses traction all available power is transferred to that wheel until it regains traction In normal driving this is not a problem however if the vehicle becomes hung up on an object the vehicle will stop With the differential locked power is distributed to both drive wheels at all times If both drive wheels lose traction as a result of vehicle becoming hung up on an object the vehicle will stop If vehicle cannot be pushed off the obstruction it will have to be pulled off using the winch To prevent severe injury or death read and understand the following warnings before attempting to use the winch The winch is not intended
28. ct All customers should adhere to this SAFETY RESTRICTION in connection with the use of all E Z GO products new and used the Distributor or Dealer has reason to believe may be operated in personal transportation applications Information on FMVSS 571 500 can be obtained at Title 49 of the Code of Federal Regulations section 571 500 or through the Internet at the web site for the U S Department of Transportation at Dockets and Regulation then to Title 49 of the Code of Federal Regulations Transportation All vehicles can be used for a variety of tasks beyond the original intended use of the vehicle therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur No warning can replace good common sense and prudent driving practices Good common sense and prudent driving practices do more to prevent accidents and injury than all of the warnings and instructions combined E Z GO strongly suggests that all users and maintenance personnel read this entire manual pay ing particular attention to the CAUTIONS WARNINGS and DANGERS contained therein For questions regarding this vehicle contact your BAD BOY BUGGIES dealer or write to the address on the back cover of this publication Attention Customer Care Department E Z GO reserves the right to make design changes without obligation to make these changes on units previously sold The information contained in this manual is subject to ch
29. ct the DC supply before making or breaking the connections to the battery while charging Do not open or disassemble charger Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow been dropped or otherwise damaged in any way refer all repair work to qualified personnel Not for use by children The portable charger is shipped with the vehicle Prior to vehicle or charger operation the charger must be removed from the vehicle A dedicated circuit is required for the charger Refer to the charger manual for appropriate circuit protection For optimum performance and shortest charge times place the charger in an area with adequate ventila tion and relatively free of dirt mud or dust If the charger is operated in an outdoor location rain and sun protection must be provided The charger may get hot during operation and must be placed such that risk of contact by people is reduced Owner s Manual 17 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTICE Looping the DC cord through the steering wheel when charging serves as a good reminder to store the cord out of the way when finished with charging The DC plug can be damaged by driving over or catching the cord on the vehicle when driving away To reduce the possibility of a physical hazard that could result in an electrical shock or electrocu tion be su
30. ctured in the United States of America USA 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 BATTERY PROLONGED STORAGE Batteries self discharge over time The rate of self discharge varies depending on the ambient temperature the age and condition of the batteries Fully charged batteries will not freeze in winter temperatures unless the temperature falls below 75 F 60 C For winter storage the batteries must be clean fully charged and disconnected from any source of electrical drain The battery charger may be left connected to the vehicle to maintain a full charge on the batteries provided the charger is plugged into an active electrical source If power to the electrical source is disconnected or interrupted the battery charger will continue to check the charge on the battery pack This will draw power from the battery pack and eventually drain the batteries if power is not restored in a timely manner As with all electric vehicles the batteries must be checked and recharged as required or ata minimum of 30 day intervals Check and maintain the proper fluid level in all battery cells during the storage period Proper fluid level is required for maximum battery performance BATTERY DISPOSAL Lead acid batteries are recyclable Return whole scrap batteries to distributo
31. ded Steel with DuraShield powder coat Speed Selection Dash mounted Speed Range switch amp Finish Injection Molded TPO amp Automotive Style Paint Rear Axle Ratio 12491 Standard Color Matte Black Cargo Bed 9 7 Cu Ft Polyethelyne Bed Some items shown may be optional equipment Batteries Qty Type Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers VEHICLE DIMENSIONS AND INCLINE INFORMATION m 112 43 75 111 cm 285 cm 113 287 P Maximum Recommended Ramp Grade Maximum Recommended Side Tilt 25 or 14 Max 25 or 14 Max 8 Owner s Manual GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Manual GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 10 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers
32. e release the service brake and check to see if the park brake holds Z gt Knob Repeat the process if necessary X iS M POWERTRAIN To reduce the possibility of severe injury or death from improper servicing techniques DO NOT attempt any type of servicing operations before reading all notes cautions and warnings in this manual Never press the accelerator pedal with drive wheels off the ground Any servicing requiring adjustments to the powertrain while the motor is running must be made with all four drive wheels raised and vehicle properly supported on jack stands To reduce the possibility of motor damage never operate vehicle at full throttle for more than 4 5 seconds while vehicle is in a no load condition Reduce the possibility of accidental starting by disconnecting battery at negative terminal before servicing Owner s Manual 35 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Wear eye protection when working on the vehicle Use extra care when working around batteries or using solvents or compressed air To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all electrical loads from the battery before removing battery wires gt Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench shorting out a battery which could res
33. e in good condition and free from dirt or debris The charger connector must be fully inserted into the vehicle receptacle The charger connector cord set must be protected from damage and is located in an area to prevent injury that may result from personnel running over or tripping over the cord set The charger is automatically turned off during the connect disconnect cycle and therefore no electrical arc is gener ated at the DC plug receptacle contacts BATTERY TROUBLESHOOTING In general troubleshooting will be done for two distinct reasons A battery that performs poorly and is outside of the manufacturers specification should be identified in order to replace it under the terms of the manufacturer s warranty Different manufacturers have different requirements Con sult the battery manufacturer or the manufacturer s representative for specific requirements Determine why a particular vehicle does not perform adequately Performance problems may result a vehicle that runs slowly or in a vehicle that is unable to operate for the time required A new battery must mature before it will develop its maximum capacity Maturing may take up to 100 charge discharge cycles Cylinder Bulb After the maturing phase as the battery ages its capacity dimin ishes The only way to determine the capacity of a battery is to perform a load test using a discharge machine following manufac i Thermometer turer s r
34. ecommendations A cost effective way to identify a poorly performing battery is to Add to Float use a hydrometer to identify a battery in a set with a lower than di di normal specific gravity Once the problematic cell or cells are identified the suspect battery can be removed and replaced At this point there is nothing that can be done to salvage the battery i however the individual battery should be replaced with a good battery of the same brand type and approximate age Subtract from Float Reading HYDROMETER A hydrometer is used to test the state of charge of a battery cell This is performed by measuring the density of the electrolyte which is accomplished by measuring the specific gravity of the electrolyte The greater the concentration of sulfuric acid the more dense the electrolyte becomes The higher the density the higher the state of charge Hydrometer Weight Owner s Manual 43 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers To prevent battery explosion that could result in severe personal injury or death never insert a metal thermometer into a battery Use a hydrometer with a built in thermometer that is designed for testing batteries Specific gravity is the measurement of a liquid that is com pared to a baseline The baseline is water which is assigned a base number of 1 000 The concentration of sulfuric acid to
35. engers to ride on load deck 630398 WEAR SAFETY RECYCLE GLASSES BATTERIES LOCATED ON BATTERY HOLD DOWN INFORMATION FOUND IN M 2 WARNING OWNERS MANUAL CORROSIVE a is is 640561 DONOTEXPOSE DONOTDISPOSE DANGER WARNING WARNING TO OPEN FLAME OF BATTERIES LETHAL ELECTRIC EXPLOSIVE LANDFILL VOLTAGE SHOCK 6 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers GENERAL SPECIFICATIONS A Textron Company MODEL INSTINCT TYPE ELECTRIC OFF ROAD VEHICLE MODEL YEAR 2015 Part No 640371G01 PRODUCT SPECIFICATION CONFIGURATION HIGHLIGHTS Programmable AC Drive System Factory programmable to application Solid State variable frequency AC speed controller 300 Amp AC Controller Drive by wire electronic throttle control Full torque reduced speed reverse e Dash mounted direction selector switch Forward Neutral Reverse Sealed Hall effect throttle sensor e Descent speed control e Full diagnostic capability Hand held diagnostic unit Full time regenerative braking Dash mounted Max Speed Max Range speed selector switch Motor One 72 Volt AC induction motor solid copper windings 19 hp 12 4 kW peak AC system reads motor speed for accurate speed control in all conditions Regenerative braking for maximum economy Battery Charger Remote 72 VDC DPI Charger 120 VAC 60 Hz or optional 230VAC 5
36. ercially available vinyl rubber cleaner The painted surfaces of the vehicle provide attractive appearance as well as durable protection Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surfaces Occasional cleaning and waxing with non abrasive products designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or dust control can collect on the underbody of the vehicle These materials will cause corrosion of underbody parts unless flushed occasionally with plain water Thoroughly clean any areas where mud or other debris can collect Sediment packed in closed areas should be loosened to ease its removal taking care not to chip or otherwise damage paint ROUTINE MAINTENANCE Preventive maintenance applied at recommended intervals is the best guarantee for keeping the vehicle dependable This vehicle will give years of satisfactory service providing it receives regular maintenance Refer to the PERIODIC SERVICE SCHEDULE for appropriate service intervals Owner s Manual 29 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers LIFTING THE VEHICLE Tool List Qty misleui emt 1 Jack Stands ecce ee teste ibat ecu Reno Rees 4 Wheel Chocks
37. etermined level Se Electrolyte Level ___ Pure Water Single Battery Cell Automatic Watering Gun Impurity Parts Per Million Colora Clear Suspended sdas dud anh ee ee lc Trace Total Solids 2 ee 100 Calcium amp Magnesium Oxides _____________ 40 rej sep CE 5 Ammonia 2222222222nn 8 Organic amp Volatile Matter _________________ 50 Nitriles 2 lt 222242 oe eh bee Gk Sao ee 5 Nitrates ou Sooo Soe oe 10 G o rTo ae eee Se 5 Water Purity Table Hand Held Watering Device Distilled Water Valve consistently fills to a predetermined level Electrolyte Level NOTICE The watering device should only be used if the electrolyte level is less than 1 2 13 mm above top of plates Electrolyte in a storage battery is an acid solution which can cause severe burns to the skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Con tact a physician immediately flushed with water charging batteries 40 Owner s Manual Single Battery Cell Any electrolyte spills should be neutralized with a solution of 2 teaspoons 10 ml sodium bicarbonate baking soda dissolved in 1 quart 1 liter of water and Always wear a safety shield or approved safety goggles when adding water or Read all of SAFETY and this section before attempting any procedure Pay particular
38. f vehicle is involved in an accident or if vehicle makes a sudden maneuver The rear facing seat will accommodate two passengers with a combined weight of less than 400 Ibs 181 kg The seat bottom can be folded out to form a load deck When using the load deck position the load as far forward as possible and securely fasten it down The maximum load is 250 Ibs 113 kg and the center of gravity must not be higher than 12 30 cm above the load deck WINCH OPERATION IF EQUIPPED WITH WINCH This vehicle may be equipped with an optional winch Read understand and follow all of the information supplied with the winch on the operation and use of the winch before attempting to operate it Winch Application A winch may be used for a number of purposes including pulling the vehicle if it loses traction on unsuitable 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 therefore the following warnings should not be con sidered as complete Before operating the winch consider the possible dangers and take precautions to protect yourself your passenger and any bystanders 24 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers To prevent severe injury or de
39. fely Read understand and follow the safety and operation label on the dash panel Although the vehicle has been designed to provide safe and reliable operation maintaining good performance depends to a large extent on the operator Before a new vehicle is put into operation the items shown in the INITIAL SERVICE CHART must be performed MUT S MN Uum LIE LAPIS EE INITIAL SERVICE CHART Service Operation Battery Charger Remove from vehicle and read operating instructions Batteries Charge Batteries must be fully charged before initial use Seats Remove protective plastic covering Brakes Check operation adjust if necessary Check hydraulic fluid level add if necessary Tires Check air pressure adjust if necessary See WHEELS AND TIRES on page 32 for tire pressure Vehicle Inspection Visually inspect overall vehicle for leaks or damage that may have developed in shipping Inspect for loose hardware tighten if necessary 16 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Hydrogen gas is generated as a natural part of the lead acid battery charging process A 4 con centration 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 res
40. g maintenance these vehicles generate used oil waste fluids grease fumes and partic ulates all identified by the State of California to potentially cause cancer birth defects and other reproductive harm Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease its stability or increase the speed beyond the factory specifications Such modifications can cause serious personal injury or death Bad Boy Buggies prohibits and dis claims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle Bad Boy Buggies reserves the right to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may be revised periodically by Bad Boy Buggies and therefore is subject to change without notice Bad Boy Buggies DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this manual These are the original instructions as defined by 2006 42 EC CONTACT US Bad Boy Buggies 1451 Marvin Griffin Rd Augusta GA USA 30906 FAX 855 256 9900 E mail info badboybuggies com For parts and repair contact local dealer Dealers can be located at www BADBOYBUGGIES com This vehicle has been designed and manufa
41. ghly corrosive explosive may produce high amperage or reach high temper atures Battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unexpected situation occur Always use the appropriate tools listed in the tool list and wear approved safety equipment Before working on vehicle remove all jew elry rings watches necklaces etc Be sure no loose clothing or hair can contact moving parts Use care not to touch hot objects Raise rear of vehicle and support on jack stands before running or adjusting power train Wear eye protection when working on or around the vehicle In particular use care when working around batteries using sol vents or compressed air Hydrogen gas forms when charging batteries Do not charge batteries without adequate ventilation Do no permit open flame or smokers in an area being used for charging batteries A concentration of 496 hydrogen gas or more is explosive CONTACT US Bad Boy Buggies 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA FAX 855 256 9900 E mail info badboybuggies com UE 5 Em BAD BUY uU c S For parts and repair contact local dealer Dealers can be located at www BADBOYBUGGIES com Copyrighted Material This manual may not be reproduced i
42. iles 1250 kms ANNUAL 250 miles 415 kms QUARTERLY Before each use MONTHLY SEMI ANNUAL REPLACE AFTER Tires pressure condition of tires amp rims Hardware loose or missing Overall Vehicle Condition Seat Belts Inspect webbing for cuts frays or any kind of damage or wear that could weaken the belt Check latch mechanism for proper operation Batteries state of charge condition loose terminals corrosion hold downs amp hardware Batteries check electrolyte level fill after charging if required if plates are exposed before charging add only enough water to cover any exposed plates and fill after amp amp amp amp CH charging a Brakes Check fluid level in master cylinder cH on 3000 miles 5000 kms Brakes smooth operation of pedal stopping distance Park Brake ability to hold on a Pil GA G A Accelerator smooth operation Wiring loose connections broken or missing insulation CH CH CH CH Charger Receptacle inspect and clean receptacle at each CL CL CL CL charge Direction Selector attachment and mechanism 8A C amp A C amp A CBA Steering Assembly excessive play loose or missing hard CH CH CH CH ware Tie Rods excessive play bent rods loose or missing hard aa a ae ware Rear Axle oil leakage noise loose or missing hardware CH CH CH Rear Ax
43. is a potential hazard and must not be operated Test drive the vehicle after any repairs or maintenance in a safe area that is free of both vehicular and pedestrian traffic Keep complete records of the maintenance history of the vehicle The manufacturer cannot anticipate all situations therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic VENTILATION Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 496 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating proper ventilation Five air exchanges per hour is considered the minimum requirement NEVER charge a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane gas water heaters and furnaces Operate charger in accordance with charger manufacturers recommendations or applicable electrical code whichever is higher ALWAYS Use a dedicated circuit for battery charger Do not permit other appliances to be plugged into the receptacle when the charger is in operation Charge vehicle in an area free of flames or sparks Ope
44. is evi dent the lubricant need only be replaced after five years Refer to the Service and Repair Manual for the fluid replacement procedure Checking the Lubricant Level Clean the area around the check fill plug and remove the plug The correct lubricant level is just below the bottom of the threaded hole If lubricant is low add lubricant as required Add lubricant slowly until it starts to seep from the hole Install the check fill plug 36 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers BATTERY CHARGING AND MAINTENANCE Battery Safety Always observe the following warnings when working on or near batteries To prevent battery explosion that could result in severe personal injury or death keep all smoking materials open flames or sparks away from the batteries Hydrogen gas is formed when charging batteries Do not charge batteries without adequate venti lation A 4 concentration of hydrogen gas is explosive Be sure that the key switch is off and all electrical accessories are turned off before starting work on the vehicle Never disconnect a circuit under load at a battery terminal Batteries are heavy Use proper lifting techniques to move them Always lift S AFETY FIRST the battery with a commercially available battery lifting device Use care not to tip batteries when removing or installing them spilled electrol
45. jack stands Lift Front of Vehicle 1 Place wheel chocks in front and behind rear wheels 2 Place the jack under the center front of the car just behind the bumper 30 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 3 Raise the vehicle with jack and position the jack stands under the frame where the instrument panel support is attached to the frame 4 Lower the jack and test the stability of the vehicle on jack stands 5 The jack may be left under the center front of the frame while the front end of the vehicle is on the jackstands Lift Rear of Vehicle 1 Place wheel chocks in front and behind front wheels 2 Center jack under rear axle tube next to differential housing or under the skid plate 3 Raise vehicle with jack and position jack stands under the frame where the leaf spring mounting bracket is welded to the frame 4 Lower the jack and test the stability of the vehicle on the two jack stands 5 The jack may be left under rear axle tube while the rear end of the vehicle is on the jackstands Lower Vehicle Lower the vehicle by reversing the lifting sequence LIGHT BULB REPLACEMENT To reduce the possibility of premature bulb failure do not touch new bulbs with bare fingers Use clean dry tissue or paper towel to handle the glass portion of the bulb Headlight Bulb Turn key switch to OFF and remove key from switch
46. l 15 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers To prevent inadvertent movement when the vehicle is left unattended engage the parking brake turn key to OFF position and remove key from switch Always bring the vehicle to a complete stop before shifting the direction selector Do not take vehicle out of gear while in motion coast Check area behind vehicle before operating in reverse All occupants must be seated with seat belts fastened and side nets latched Keep entire body inside vehicle and hold on while vehicle is in motion This vehicle is not a toy and using it while engaging in horseplay is dangerous Plan carefully before using the vehicle to go significant distances over unfamiliar terrain Remem ber that a one hour drive may take many hours to walk back should the batteries become dis charged or vehicle become stuck on unsuitable terrain BEFORE INITIAL USE NOTICE Record the four digit key number and store in a safe place Individual keys can only be replaced if the key number is known Without a key number the entire ignition switch will have to be replaced if keys are lost Make a note of the key number in the event that new keys must be ordered The key number is stamped into the key and into the face of the ignition switch Both numbers must match Be sure you understand the vehicle its equipment and how to use it sa
47. l and note the reading where the electrolyte meets the scale on the float 4 Add or subtract four points 004 to the reading for every 10 F 6 C the electrolyte temperature is above or below 80 F 27 C Adjust the reading to conform with the electrolyte temperature e g if the reading indicates ELECTROLYTE TEMPERATURE wo nl 160 71 ail 032 FH 030 EXAMPLE 1 150 65 B H 028 ELECTROLYTE TEMPERATURE L H 026 Above 80 F 27 C 140 60 024 AMBIENT TEMPERATURE Above 80 F 27 C a Sl i0 49 1018 ELECTROLYTE TEMPERATURE Above 90 F 32 C 410 o12 HYDROMETER READING 1 250 H 1 250 004 1 254 ido H CORRECTED SPECIFIC GRAVITY H READING 90 004 2 002 80 002 70 004 006 EXAMPLE 2 60 008 ELECTROLYTE TEMPERATURE n 010 Above 80 F 27 C 7014 AMBIENT TEMPERATURE 2 oig Above 80 F 27 C T po ELECTROLYTE TEMPERATURE 022 Above 70 F 21 C 5 7024 READING 1 250 026 1 250 004 1 246 40 028 CORRECTED SPECIFIC GRAVITY READING Hydrometer Temperature Correction a specific gravity of 1 250 and the electrolyte temperature is 90 F 32 C add four points 004 to the 1 250 which gives a corrected reading of 1 254 Similarly if the temperature was 70 F 21 C subtract four points 004 from the 1 250 to give a corrected reading of 1 246 5 Test each ce
48. l ground see GENERAL SPECIFICATIONS Limit speed by applying pressure to the brake pedal TOWING A TRAILER The vehicle is equipped with a 2 inch receiver The trailer and its load must not exceed 1000 Ibs 453 kg and no more than 100 Ibs 45 kg tongue weight may be attached to the hitch Remember that the overall capacity of the vehicle oper ator passenger contents of load bed and accessories must be reduced to compensate for the trailer and load The range of motion of the trailer is limited by the ball and hitch The trailer should not be used on rough trails or over objects such as logs large rocks holes etc Never install baskets or extensions using the hitch receivers Such items will change the performance characteristics of vehicle and result in unsafe handling possible roll over or vehicle damage TERRAIN The vehicle is NOT designed for use on public roads The vehicle may 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 that is more than 12 inches 30 cm deep or fast moving water Be aware of steep slopes and overhanging limbs When traveling up or down steep slopes do not attempt to turn the vehicle around on the slope Be aware that vehicle stopping distance increases when driving on wet grass dirt roads or loose surfaces Owner s Manual 23 Read all of SAFETY and this section before attempting any procedure Pay particular a
49. le drain and replace fluid S000 miles 8000 kms Front Suspension strut oil leakage excessive play in hubs CH CH CH CH or kingpins worn bushings loose or missing hardware Rear Suspension strut oil leakage worn bushings loose or CH CH CH missing hardware O go gt O go gt O go gt Front Wheel Alignment unusual tire wear Use only distilled or purified water that is free from contaminates to fill batteries NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions Owner s Manual 47 PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 48 Owner s Manual NOTICE Read the following warnings before operating vehicle To prevent personal injury or death observe the following When vehicle is to be left unattended engage park brake move direction selector to neutral turn key to OFF position and remove from key switch Drive vehicle only as fast as terrain and safety considerations allow Con sider environmental factors which effect the terrain and the ability to control the vehicle Avoid driving fast down hill Sudden stops or change of direction may result in loss of control Use service brake to control speed when traveling down an incline Use extra care and reduced speed when driving on poor surfaces such a
50. ll and note the readings corrected to 80 F or 27 C A variation of fifty points between any two cell readings example 1 250 1 200 indicates a problem with the low reading cell s 44 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers As a battery ages the specific gravity of the electrolyte will decrease at full charge This is not a reason to replace the bat tery providing all cells are within fifty points of each other Since the hydrometer test is in response to a vehicle exhibiting a performance problem the vehicle should be recharged and the test repeated If the results indicate a weak cell the battery or batteries should be removed and replaced with a good battery of the same brand type and approximate age HARDWARE Periodically the vehicle should be inspected for loose fasteners Use care when tightening fasteners refer to the Techni cian s Repair and Service Manual for specific torque values Generally three classes of standard hardware and two classes of metric hardware are used in the vehicle Grade 5 hard ware can be identified by the three marks on the hex head and grade 8 hardware is identified by six marks on the head metric hardware is marked on the head with 8 8 or 10 9 Unmarked hardware is Grade 2 ALL TORQUE FIGURES ARE IN FT LBS Nm Unless otherwise noted in text tighten all hardware in accordance
51. 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 NOTICES CAUTIONS WARNINGS AND DANGERS Throughout this guide NOTICE CAUTION WARNING and DANGER will be used Please observe these NOTICES CAUTIONS WARNINGS and DANGERS be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous Improper service or repair may damage the vehicle or render it unsafe NOTICE Address practices not related to personal injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Indicates a hazardous situation which if not avoided could result in death or serious injury DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product To reduce the chance of personal injury or property damage the following must be carefully observed Certain replacement parts can be used independently and or in combination with other accessories to modify an E Z GO manufactured vehicle to permit the vehicle to operate at or in excess of 20 mph When an
52. n before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 28 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers MAINTENANCE VEHICLE CLEANING AND CARE To reduce the possibility of severe injury or vehicle damage read and understand all instructions supplied by manufacturer of pressure washer When pressure washing exterior of vehicle do not use pressure in excess of 700 psi and maintain a 12 mini mum distance from spray nozzle to painted surface To reduce the possibility of cosmetic damage do not use any abrasive or reactive solvents to clean plastic parts It is important that proper techniques and cleaning materials be used Using excessive water pressure may cause severe injury to operator or bystander damage to seals plastics seat material body finish or electrical system Do not use pres sure in excess of 700 psi to wash exterior of vehicle Clean windshield with lots of water and a clean cloth Minor scratches may be removed using a commercial plastic polish or Plexus plastic cleaner available from the service parts department Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the use of a comm
53. n whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department
54. nennen 20 Light Switch Operation I 20 Brake Operation x cedit d e tle ure ie D eh Laus 20 Park Brake Operation 20 Accelerator Operation esee entree nnne nnns sinn 20 Truck Bed Latch Operation a 21 Seat Belt Operations eet etait edes 21 COMMON SENSE OPERATION sessi 22 ENVIRONMENTAL CONCERNS nennen nennen snnt enn sn nnns 22 STARTING AND DRIVING roiie aa ea aa 22 Starting the Vehicle on a Hill 23 COASTING 2 ed o federe Ret rr fer el aie eet Se 23 OWING A TRAIDER ainoudaten ies a ust etse 23 TERRAIN i oa oett OA etc eet rp eec Qe ie et vede VERA dava doe qaa hk 23 TRUCK BED 3e tiim oie quts ti 24 REAR FACING SEAT LOAD DECK 24 WINCH OPERATION IF EQUIPPED WITH WINCH 24 Winch Application uuu ei ie deca ecce loan dvi eee tide ee ene 24 MAINTENANCE VEHICLE CLEANING AND CARE uu L n u aa 29 ROUTINE MAINTENANGE i er erede 29 LIFTING THE VEHIGEE ORIS ete e oe et IH e lage 30 Lit Eniro Vehicle uiii e Ri e ve ute e s reet 30 Litt Front of Vehicle uu e el a eri eee Yee i Sega kr 30 Eit Rear af Vehicle uie ei ee edt di e n uet 31 Lower Vehicle asirar ia eda e dd edt di d 31
55. omr m Owner s Manual To Solenoid To Controller B S OF oc 15 9 1 100 1 140 1 180 1 220 1 260 1 300 1 120 1 160 1 200 1 240 1 280 SPECIFIC GRAVITY ELECTROLYTE FREEZING POINT Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Battery Charging The battery charger is designed to fully charge the battery set If the batteries are severely deep cycled some automatic battery chargers contain an electronic module that may not activate and the battery charger will not function Automatic chargers will determine the correct duration of charge to the battery set and will shut off when the battery set is fully charged Always refer to the instructions of the specific charger being used Before charging the following should be observed Do not overfill batteries The charging cycle will expel electrolyte and result in component damage The electrolyte level in all cells must be at the recommended level and cover the plates The charging must take place in an area that is well ventilated and capable of removing the hydrogen gas that is generated by the charging process A minimum of five air exchanges per hour is recommended The charging connector components must b
56. ontaminated brake fluid could cause failure of the braking system Dispose of brake fluid in accordance with Federal state and local codes 3 Attach a short length of clear hose to the caliper bleed valve and insert the other end into a suitable clean container containing fresh clean brake fluid Check the fluid level in the master cylinder frequently during this opera tion to prevent air from entering the lines Bleeder 4 Start with the passenger side rear brake then driver side rear brake passenger side front brake and finish with driver side front brake Bleed ing the brakes requires an assistant to pump the brake pedal and keep pressure on the pedal Bleed the brakes using the following procedure a Build pressure in the brake system if possible by slowly pumping the brake pedal b Open the bleeder valve while an assistant holds pressure on the brake pedal as the pedal slowly goes through the full stroke c Close the bleeder valve and have the assistant slowly release the brake pedal Repeat the process until no bubbles can be seen leaving the bleeder valve Close the valve and move to the next brake Park Brake Adjustment The floor mounted park brake has an adjustment knob on the end of the handle If the vehicle starts to roll when the park brake is engaged on a hill place one foot on 22 Was the service brake pedal turn the adjustment knob clockwise to increase tension 4J f Adjustment the brak
57. r manufacturer or lead smelter for recycling For neutralized spills place residue in acid resistant containers with absorbent material sand or earth and dispose of in accordance with local state and federal regulations for acid and lead compounds Contact local and or state envi ronmental officials regarding disposal information WARRANTY Separate inserts supplied in packaging with the vehicle provide information on Product Warranty and Emissions Warranty Failure to follow instructions for emission parts replace ment may violate Federal Law 40 CFR part 1068 105 b and be subject to fines and other penalties as described in the Clean Air Act ii Owner s Manual SAFETY GENERAL uyan kn tees e RU ee Coda tu ie amem 1 NOTICES CAUTIONS WARNINGS AND DANGERS 1 GENERAL OPERATION ease EV o u da RU vee 2 MAINTENANGE I ner eee Ee RD Pe e t A ec ai e aee 4 Menag spem 4 LABELS AND PIGCTIOGRANMS u spa un au a uq ahua Nu sinn nenas 5 LABELS AND PICTOGRAMS u u 2 an p ed hace a sS ha aa eee 6 GENERAL SPECIFICATIONS VEHICLE DIMENSIONS AND INCLINE INFORMATION eene 8 INTRODUCTION FEATURES edm tdi Mateo d nile Ed Eee poco 11 General Information narret oe bit niea de 11 Key Switch Direction Selector L 11 State of Charge Meter esent nennen nnns 11 Park
58. rate battery charger in accordance with manufacturers recommendations 4 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers LABELS AND PICTOGRAMS FOR INFORMATION REFER TO Lor Nf MANUAL OR WEBSITE DRIVE IN ee WARNING USE CAUTION IN NO PUBLIC INCLEMENT WEATHER ROAD OPERATE FROM DRIVERS SIDE OCCUPANT MUST ONLY WEAR SEAT BELTS OPERATOR MUST BE MIN 150 CM MN 150 m p NO UNATTENDED E CHILDREN LRN 638040 WITH LOCAL RULES AND REGULATIONS DO NOT OPERATE LEAVE VEHICLE REMAIN SEATED NO MORE THAN UNDER DRUG ALCOHOL IN THREAT OF KEEP ARMS LEGS TWO OCCUPANTS INFLUENCE LIGHTNING WITHIN VEHICLE PER SEAT MAY CAUSE EXPLOSION SECURE LOAD HIGH CENTER OF DO NOT FILL FUEL MAX BED WEIGHT GRAVITY MAY CAUSE CONTAINERS IN BED 500 LBS or 255 KG TIP OVER 35980G02 3 NO PASSENGERS aw r IN TRUCK BED ax WARNING MAX CENTER OF MAX SIDE READ THE GRAVITY HEIGHT SLOPE 14 MANUAL 5 OR 12 CM ABOVE FLOOR DO NOT RELEASE BED LATCH WITH ANYONE STANDING BEHIND BED 74099G01 WEAR SAFETY RECYCLE GLASSES BATTERIES LOCATED ON BATTERY HOLD DOWN INFORMATION OWNERS MANUAL CORROSIVE NC 7 640561 DONOTEXPOSE DONOTDISPOSE DANGER WARNING WARNING TOOPENFLAME LETHAL ELECTRIC EXPLOSIVE LANDFILL VOLTAGE SHOCK Owner s Manual
59. re Pay particular attention to Notices Cautions Warnings and Dangers COMMON SENSE OPERATION Never transport loaded firearms on or in vehicle Check that firearms are unloaded with the safety engaged and are properly secured with muzzle pointing in a safe direction before operating vehicle Be aware of other firearms in proximity to operator and passengers This vehicle is not a toy If not operated properly and responsibly it can cause severe injury or death to the operator passengers or bystanders All operators should possess a valid driver s license Children should not be permitted to operate the vehicle Children may not have the skill judgment or strength to operate this or similar vehicles Alcohol drugs and many over the counter medications reduce the ability of the driver to operate the vehicle safely Always review side effects of any medication with a doctor or pharmacist before operating vehicle Protective clothing and an approved motorcycle helmet are recommended for operator and passengers when operating vehicle in rough or densely wooded terrain When driving at full speed on a dirt road loose surfaces or wet grass vehicle stopping distance will increase If the vehi cle is fully loaded it requires longer to stop than with no load When operating vehicle in wet weather conditions remem ber that the brakes may need to be lightly applied in order to provide enough friction to dry the brake unit If wet the brakes lo
60. re that the charger plug is not damaged and is inserted into a grounded receptacle An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution Using the Charger Before use read the charger manufacturer s operation manual that is supplied with the charger To prevent a physical hazard that could result in an electrical shock or electrocution be sure that the charger plug is not damaged and is inserted into a grounded receptacle An ungrounded electrical device may become a physical hazard that could result in an electrical shock or electrocution The charger DC cord is equipped with a polarized connector that fits into a matching receptacle on the vehicle The receptacle is located in the seat panel below the seat on the driver side of the vehicle Always check to be sure the receptacle is free from dirt and debris before inserting the charger cord Charger Receptacle 18 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers OPERATING THE VEHICLE Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance Read 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 follow ing warnings must be observed When
61. ring repair is no longer functioning as designed and therefore could be potentially hazardous Therefore use extreme care when working on any vehicle When diagnosing removing or replacing any components that are not operating correctly take time to consider the safety of yourself and others around you Some components are heavy spring loaded highly corrosive explosive may produce high amperage or reach high temperatures Exposure to battery acid and hydrogen gas could result in serious bodily injury Be careful to protect hands face feet and body from injury Always use the appropriate tools listed in the tool list and wear approved safety equipment Before working on the vehicle remove all jewelry Be sure no loose clothing or hair can contact moving parts Use care not to touch hot objects Wear eye protection when working on or around the vehicle In particular use care when working around batteries using solvents or compressed air ALWAYS Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition Read and observe all warnings and operation instruction labels affixed to the vehicle Follow all safety rules established in the area where the vehicle is being operated Leave the vehicle and seek shelter when there is a risk of lightning Reduce speed to compensate for poor terrain or conditions Apply service brake to control speed on steep grades Owner s Manual Read all
62. ry or death use extreme care with aerosol containers of battery terminal pro tectant Insulate the metal container to prevent the metal can from contacting battery terminals which could result in an explosion If the batteries are replaced make sure they are the exact type and model originally supplied with the vehi cle Failure to follow this caution can result in damage to the vehicles electrical system Prolonged Storage During periods of storage the batteries must be maintained to prevent discharge In winter conditions the batteries must be fully charged to prevent the possibility of freezing A fully charged battery will not freeze in temperatures above 75 F 60 C Although the chemical reaction is slowed in cold temperatures the bat tery must be stored fully charged and disconnected from any circuit that could discharge the battery The batteries must be cleaned and all deposits neutralized and removed from the battery case to prevent self discharge The battery charger may be left connected to the vehicle to maintain a full charge on the batteries provided the charger is plugged into an active electrical source If power to the electri cal source is disconnected or interrupted the battery charger will continue to check the charge on the battery pack This will draw power from the battery pack and eventually drain the batteries if power is not restored in a timely manner 42 Im2Z0Cc 220m Uzm rmm X r O2
63. s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Wheel Installation To reduce the possibility of component damage do not tighten lug nuts to more than 85 ft Ibs 115 Nm torque NOTICE It is important to follow the cross sequence pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Finger tighten the lug nuts 1 in a cross Tire stvle var sequence pattern Tighten the lug nuts to 50 to 85 ft Ibs 68 T aii to 115 Nm torque in 20 ft 165 27 Nm increments following Cross Sequence the cross sequence pattern Unidirectional Tires Unidirectional tires may be identified by a directional arrow on the sidewall Be sure to position the wheel on the hub cor rectly with the arrow indicating the direction of rotation when moving forward WHEEL ALIGNMENT Driving over rough terrain may cause misalignment of the wheels With four wheel independent suspension both front and rear wheels may need to be aligned Wheel Alignment Tool List Qty Tool List Qty Tape Measure 1 Open End Wrench 12 mm 1 Open End Wrench 17 mm sess 1 Open End Wrench 19 mm
64. s loose dirt wet grass gravel etc All travel should be directly up or down hills use extra care if ever forced to drive across an incline Stay in designated areas and avoid steep slopes Activate the park brake when the vehicle is parked Keep feet legs hands and arms inside vehicle at all times Avoid extremely rough terrain Check area behind the vehicle before operating in reverse Make sure direction selector is in desired position before starting the vehicle Slow down before and during turns All turns should be executed at reduced speed Always bring vehicle to a complete stop before shifting direction selector See GENERAL SPECIFICATIONS for vehicle load and seating capacity NOTICE Read the following information and warnings before operating vehicle In any product components will eventually fail to perform prop erly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible component failures or the manner in which they may fail A vehicle requiring repair indicates that it is no longer function ing as designed and therefore should be considered poten tially hazardous Use extreme care when working on vehicle When diagnosing removing or replacing any components that are not operating properly take time to consider the safety of yourself and others around you should the component move unexpectedly Some components are heavy spring loaded hi
65. s section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers On a downhill slope it is possible for the vehicle to achieve speeds greater than if it were operating on flat terrain Limit downhill speed to 5 mph 8 kph with use of the service brake Caution must also be used on an uphill slope and speed should be limited to no more than 5 mph 8 kph If allowed to travel too fast on an uphill or downhill slope loss of control may occur possibly causing serious injury or death Use caution when traveling through water and never operate vehicle in water over 12 inches 30 cm deep Starting the Vehicle on a Hill Do not hold vehicle on hill by using accelerator and motor This will cause premature and excessive wear to drive train components To reduce the possibility of permanent damage to the drive system it is important to prevent excessive roll back when starting the vehicle on a hill Place left foot on brake pedal and disengage park brake Press accelerator with right foot while releasing brake pedal COASTING To reduce the possibility of severe injury or death from coasting at above recommended speeds limit speed with brake pedal On steep hills it is possible for the vehicle to coast at greater speeds than possible on a flat surface To reduce possible loss of vehicle control and severe drivetrain damage speeds should be limited to no more than the maximum governed speed on leve
66. se much of their effect Slow down when on unfamiliar terrain Slow down when cresting a hill in an area that is not familiar Some hills are too steep to climb If attempting to climb a hill that is too steep or if unable to achieve adequate traction do not attempt to turn around on the hill Slowly back straight down the hill using the brake pedal to control speed 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 To prevent severe injury or death while driving be aware of environmental hazards such as steep slopes overhanging limbs etc STARTING AND DRIVING Make sure that the park brake is engaged Make sure that the accelerator pedal is NOT pressed no pressure on it Place key in switch and turn to desired position Release parking brake Press the accelerator pedal to move the vehicle Make sure the park brake is engaged the key switch is in the OFF position and the key is removed from the switch before exiting the vehicle This vehicle is to be operated by licensed drivers only Do not attempt to operate the buggy while under the influence of drugs or alcohol Never turn the key switch to OFF while the buggy is in motion doing so can cause loss of control and lead to serious injury or death 22 Owner s Manual Read all of SAFETY and thi
67. secure more than one person in a seat belt Seat belts must be worn at all times by all occupants when vehicle is in motion To keep seat belts in proper working condition do the following Inspect the seat belt webbing and hardware periodically Check for cuts frays or loose parts Replace components if excessive wear or damage is noticed Keep seat belts clean and dry To clean use mild soap and warm water Do not use bleach dye or abrasive cleaners as this will weaken the belt webbing material Do not insert any foreign objects into the retractor mechanism e Periodically check for smooth operation and replace if the mechanism is not operating properly To properly secure the seat belts 1 Pull the metal tab on the seat belt across the body toward the appropriate buckle located near the center of the seat 2 Insert tab into buckle A click will be heard when the tab is securely latched 3 Position the lap belt as low as possible on the hips not at the waist 4 Adjust to ensure a snug fit by pulling the shoulder portion upward The retractor will lock the belt during sudden stops It may also lock if occupant leans forward quickly Slow easy motions allow the belt to travel freely To release the safety belt press the buckle release button and allow the belt to retract If the belt does not retract check for twisted straps Owner s Manual 21 Read all of SAFETY and this section before attempting any procedu
68. t tube and the gas will force it out of the vent tube and battery cap The water will evaporate but the sulfuric acid will remain where it can damage vehicle components and the storage facility floor Sulfuric acid loss will weaken the concentration of acid within the electrolyte and reduce the life of the battery Gas Vent Expansion Space B 1 4 to 3 8 inch 6 mm to 10 mm Electrolyte level should be at least 1 2 13 mm above the plates and 1 4 to 3 8 6 to 10 mm below vent Owner s Manual 39 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Over the life of the battery a considerable amount of water is consumed It is important that the water used be pure and free of contaminants that could reduce the life of the battery by reducing the chemical reaction The water must be distilled or purified by an efficient filtration system Even if the water is colorless odorless tasteless and fit for drinking the water should be analyzed to see that it does not exceed the impurity levels specified in the table An automatic watering gun or a battery watering jug available from many auto parts stores may be used to fill the batteries These watering devices are accurate easy to use and allow for rapid filling They also maintain the correct electrolyte level within the battery cells Valve consistently fills to a pred
69. the free spool clutch while the cable is under load 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 connec tions 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 suspension and may cause the vehicle to overturn When pulling vehicle pull straight only Incorrect Correct Do Not Pull at Angle If the vehicle is being used as an anchor to winch a load it should have the parking brake applied 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 26 Owner s Manual OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes Owner s Manual 27 OPERATING PROCEDURES Read all of SAFETY and this sectio
70. ting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 19 Rear Seat Load Deck If Equipped The rear facing seat is designed for two occupants The rear seat can be converted to a load deck by unfolding the seat bottom 20 OPS Top Windshield The standard vehicle is equipped with an OPS Operator Protection System vehicle may be equipped with an optional top and or windshield The OPS and top provide some protection from smaller falling objects but will not protect against large falling objects such as trees or heavy limbs The windshield deflects oncoming wind from occupants but will not protect against flying objects and tree limbs The top and windshield provide some protection from the elements however they will not keep occupants dry in a down pour The OPS and top do not provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects Remove windshield and store securely before transporting this vehicle on a trailer The windshield is not designed to withstand highway speeds 14 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers OPERATING PROCEDURES PIN AND SERIAL NUMBER LOCATION The PIN plate is riveted to the frame below the seat wrap panel Two serial number labels Part A and Part B and a PIN label
71. to be used in any hoisting operation The rolling load capacity of the winch decreases with the steepness of the slope The winch is designed for intermittent duty only The electric 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 replacement only Never operate the winch with less than five 5 full turns of cable around the drum 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 the manufacturers maximum load rating 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 Owner s Manual 25 Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Do Not Hook Cable to Itself Use a Nylon Sling and Install a Damper when Winching 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 When operating the winch keep the entire area in view Never release
72. top Park Brake Operation The park brake should be engaged whenever the vehicle is in a stationary position or left unattended Pull the hand operated park brake handle up until it stops in a vertical position to engage the park brake Push the handle down to disengage Accelerator Operation With the key switch ON pressing the accelerator pedal starts the electric motor and activates the vehicle When the pedal is released the motor deactivates and the vehicle will decelerate To stop the vehicle more quickly press the brake pedal 20 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Truck Bed Latch Operation Pull upward on the handle to release the truck bed latching mechanism allow _ ing the front of the bed to be raised Bed Latch Handle Seat Belt Operation Seat belts must be worn by all occupants whenever vehicle is in motion Ensure seat belts are free from twists and latch securely Position shoulder belt across the top of the shoulder do not place shoulder belt under the arm Keep belts snug and positioned low on hips Loose fitting belts significantly reduce protection The vehicle is equipped with seat belts for the number of occupants it is designed to carry do not exceed the recommended number of occupants for the vehicle Seat belts are designed for one occupant per belt Do not attempt to
73. ttention to Notices Cautions Warnings and Dangers TRUCK BED Do not allow passengers to ride in truck bed Severe injury or death could result if a passenger should fall out if vehicle is involved in an accident or if vehicle makes a sudden maneuver Use caution when loading the vehicle Secure loads to prevent shifting Do not overload vehicle A bed warning label is affixed to the inside of the bed on the front panel This label must be understood and observed at all times for safe use of the bed The bed is limited to a maximum load of 500 Ibs Position load in the bed as far forward as possible Its center of gravity must not be higher than 12 80 cm above the bed floor and it must be securely fastened down Failure to follow these instructions could cause personal injury damage to the vehicle and or cause the vehicle to tip over Operate the vehicle with awareness of the load Do not drive the vehicle with the truck bed raised or with the tailgate unsupported When using the optional electric dump be sure to avoid backing up to the edge of a drop off such as a loading dock or ravine A misjudgment of distance or an unstable surface could result in the vehicle falling backwards Always ensure that no one is behind or close to the bed while the electric dump mechanism is being operated REAR FACING SEAT LOAD DECK Do not allow passengers to ride on load deck Severe injury or death could result if a passenger should fall out i
74. ult explosion The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes Treat all electro lyte spills to the body and eyes with extended flushing with clear water Contact a physi cian immediately Any electrolyte spills should be neutralized with a solution of 2 teaspoons 10 ml sodium bicarbonate baking soda dissolved in 1 quart 1 liter of water and flushed with water Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal container to reduce the possibility of can contacting battery terminals which could result in an explosion It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual Preventative maintenance applied at recommended intervals is the best guarantee for keeping the vehicle both dependable and economical This vehicle will give years of satisfactory service providing it receives regular maintenance Refer to the PERIODIC SERVICE SCHEDULE for appropriate service intervals To prolong vehicle life some maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures extreme dust debris conditions or frequent use with maximum load REAR AXLE The only maintenance required for the first five years is the periodic inspection of the axles for lubricant leakage Unless leakage
75. ult in severe injury or death never smoke around or charge batteries in an area that has open flame or electrical equipment that could cause an electrical arc Hydrogen gas is generated in the charging cycle of batteries and is explosive in concentrations as low as 4 Because hydrogen gas is lighter than air it will collect in the ceiling of buildings necessitating proper ventilation Five air exchanges per hour is considered the minimum requirement Never charge a vehicle in an area that is subject to flame or spark Pay particular attention to natural gas or propane water heaters and furnaces PORTABLE CHARGER Use charger ONLY on 72 volt battery systems Other usage may cause personal injury and dam age Lead acid batteries may generate explosive hydrogen gas during normal operation Keep sparks flames and smoking materials away from batteries Provide adequate ventilation during charging Never charge a frozen battery Study all battery manufacturers specific precautions such as recommended rates of charge and removing or not removing cell caps while charging DANGER Risk of electric shock Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances A grounded out let is required to reduce risk of electric shock do not use ground adapters or modify plug Do not touch uninsulated portion of opn connector or uninsulated battery terminal Disconne
76. water in a new golf car battery is 1 280 which means that the electrolyte weighs 1 280 times the weight of the same volume of water A fully charged battery will test at 1 275 1 280 while a discharged battery will read in the 1 140 range NOTICE Do not perform a hydrometer test on a battery that has just been watered The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte The temperature of the electrolyte is important since the hydrometer reading must be corrected to 80 F 27 C High quality hydrometers are equipped with an internal thermome ter that will measure the temperature of the electrolyte and will include a conversion scale to correct the float reading It is important to recognize that the electrolyte temperature is sig nificantly different from the ambient temperature if the vehicle has been operated Using A Hydrometer 1 Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte tem perature and note the reading Examine the color of the electrolyte A brown or gray coloration indicates a prob lem with the battery and is a sign that the battery is near ing the end of its life 2 Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without con tacting the top or bottom of the cylinder 3 Holdthe hydrometer in a vertical position at eye leve
77. with this chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque required for dry fasteners BOLT SIZE 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 4 8 15 24 35 55 75 130 125 11 20 33 47 75 102 176 169 13 23 35 55 80 110 200 320 18 31 47 75 108 149 271 434 18 35 55 80 110 170 280 460 75 108 149 23 880 624 M12 35 47 1 8 8 83 Class 10 9 86 Grade 8 o9 117 Torque Specifications and Bolt Grades CAPACITIES AND REPLACEMENT PARTS CAPACITIES REPLACEMENT PARTS 13 8 oz 90 wt Gear Oil LED Headlight Bulb P N 619101 Brake Fluid DOT3 Headlight Bulb P N 619100 ATC Type Fuse 10 Amp P N 35212G07 ATC Type Fuse 15 Amp P N 35212G01 ATC Type Fuse 20 Amp P N 35212G02 Owner s Manual 45 MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes 46 Owner s Manual Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers PERIODIC SERVICE SCHEDULE PERIODIC SERVICE SCHEDULE CH CHECK C amp A CHECK amp ADJUST CL CLEAN a E x a Ex 9 o tO ral 3000 miles 5000 kms 750 m
78. yte can cause burns and damage Ke Electrolyte in a storage battery is an acid solution which can cause severe burns to skin and eyes Treat all electrolyte spills to the body and eyes with extended flushing with clear water Contact a physician immediately Always wear a safety shield or approved safety goggles when adding water or charging batteries Neutralize electrolyte spills with a solution of 1 4 cup 60 ml sodium bicarbon ate baking soda dissolved in 1 1 2 gallons 6 liters of water and flush with water Overfilling batteries may result in electrolyte being spilled from the battery during the charge cycle Expelled electrolyte may cause damage to the vehicle and storage facility Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal container to prevent can from contacting battery terminals which could result in an explosion D Wrap wrenches with vinyl tape to prevent the possibility of a dropped wrench from shorting out a battery which could result in explosion and severe personal injury or death Battery Disposal Lead acid batteries are recyclable Return whole scrap batteries to distributor manufacturer or lead smelter for recycling For neutralized spells place residue in acid resistant containers with absorbent material sand or earth and dispose of in accordance with local state and federal regulations for acid and lead compounds Contact local and or state

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