2002-2009 EZGO ST350 ST Sport Gas Utility Vehicle Service & Repair Manual

[I 4�•1] TECHNICIAN'S REPAIR AND SERVICE MANUAL GASOLINE POWERED UTILITY VEHICLES STARTING MODEL YEAR: 2000 REVISED: 9/2000

SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact an E-Z-GO representative for clarification. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground. (See vehicle specification.) Limit speed by applying the service brake. Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered abuse and will not be covered under warranty. If the vehicle is to be used in a commercial environment, signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe coasting condition. r WARNING  SHARP TURN APPLY BE  M SPEED \ � WARNING r SHARP TURN APPLY BE  LIM SPEED "   r " WARNING  STEEP HILL APPLY BE  LIM SPEED \ Be sure that this manual remains as part of the permanent service record should the vehicle be re-sold. NOTES, CAUTIONS AND WARNINGS T hroughout this guide NOTE, CAUTION and WARNING will be used. I N OTE I A NOTE indicates a condition that should be �- ---�- observed. CAUTION A CAUTION indicates a condition that may result in damage to the vehicle. AwARNINGA A WARNING indicates a hazardous condition that could result in severe injury or death. Please observe these NOTES, CAUTIONS and WARN- INGS; 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. AwARNINGA Engine exhaust from this product contains chemi- cals known, in certain quantities, to cause cancer, birth defects, or other re- productive harm. ! IMPORTANT ! The exhaust emissions of this vehicles engine is regulated by the Federal EPA. Significant fines could result from modifications or tampering with the engine, fuel, ignition or air intake systems. (NOTES, CAUTIONS AND WARNINGS CONTINUED ON INSIDE OF BACK COVER)

TECHNICIAN'S REPAIR AND SERVICE MANUAL GASOLINE POWERED UTILITY VEHICLES VEHICLES ST350 ST SPORT E-Z-GO Division of Textron reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388 , AUGUSTA, GEORGIA USA 30903-0388 Repair and Service Manual Page i

NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, E-Z-GO Branch or the E-Z-GO Warranty Department with vehicle serial number and manufacturer code. The use of non E-Z-GO parts may void the warranty. Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty. When servicing engines, all adjustments and replacement components must be per original vehicle specifications in order to maintain Federal and State emission certification. BATTERY PROLONGED STORAGE All batteries will self discharge over time. The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries. A fully charged battery will not freeze in winter temperatures unless the temperature falls below -75 ° F (-60 ° C). Page ii Repair and Service Manual

TABLE OF CONTENTS TITLE PAGE Safety ........................................................................................................................... Inside Covers Notes ................................................................................................................................................. ii Safety Information ............................................................................................................................ v TITLE SECTION General Information & Routine Maintenance ................................................................................... A Safety ............................................................................................................................................... B Body and Truckbeds ........................................................................................................................C Wheels and Tires ............................................................................................................................. D Front Suspension and Steering ........................................................................................................ E Electrical ........................................................................................................................................... F Accessory Wiring............................................................................................................................. G Engine .............................................................................................................................................. H Fuel System ..................................................................................................................................... J Speed Control .................................................................................................................................. K Mechanical Brakes ........................................................................................................................... L Continuously Variable Transmission (CVT) ..................................................................................... M Rear Suspension .............................................................................................................................. N Rear Axle.......................................................................................................................................... P Paint ................................................................................................................................................ Q Troubleshooting................................................................................................................................ R Limited Warranty .............................................................................................................................. S General Specifications ..................................................................................................................... T Repair and Service Manual Page iii

TABLE OF CONTENTS Notes: __________________________ _ Page iv Repair and Service Manual

SAFETY INFORMATION This manual has been designed to assist the owner-operator in maintaining the vehicle in accordance with procedures developed by E-Z-GO. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product. To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle; therefore it is impossible to anticipate and warn against every possible combination of circumstances that may occur. No warnings can take the place of 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 the owner-operator read this entire manual paying particular attention to the CAUTIONS and WARNINGS contained therein. It is further recommended that employees and other operators be encouraged to do the same. If you have any questions, contact your closest E-Z-GO representative or write to the address on the back cover of this publication, Attention: Product Service Department. E-Z-GO Division of Textron reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. This vehicle conforms to the current applicable standard for safety and performance requirements. These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards and are not equipped for operation on public streets. Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances. Refer to GENERAL SPECIFICAT IONS for vehicle seating capacity. 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 specification. Such modifications can cause serious personal injury or death. Modifications that increase the speed and/or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehicle. Do not make any such modifications or changes. E-Z-GO prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle. Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course environment. Additionally, speed should be further moderated by the environmental conditions, terrain and common sense. GENERAL OPERATION Always use the vehicle in a responsible manner and maintain the vehicle in safe operating condition. Always read and observe all warnings and operation instruction labels affixed to the vehicle. Always follow all safety rules established in the area where the vehicle is being operated. Always reduce speed to compensate for poor terrain or conditions. Always apply service brake to control speed on steep grades. Repair and Service Manual Page v

SAFETY INFORMATION Always maintain adequate distance between vehicles. Always reduce speed in wet areas. Always use extreme caution when approaching sharp or blind turns. Always use extreme caution when driving over loose terrain. Always use extreme caution in areas where pedestrians are present. MAINTENANCE Always maintain your vehicle in accordance with the manufacturer's periodic service schedule. Always ensure that mechanics performing repairs are trained and qualified to do so. Always follow the manufacturer's directions if you do any maintenance on your vehicle. Be sure to disable the vehicle before performing any maintenance. Disabling includes removing the key from the key switch and removal of a battery wire. Always insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by short- ing the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material. Always use specified replacement parts. Never use replacement parts of lesser quality. Always use recommended tools. Always 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. Always support the vehicle using wheel chocks and safety stands. Never get under a vehicle that is supported by a jack. Lift the vehicle in accordance with the manufacturer's instructions. Always empty the fuel tank or plug fuel hoses to prevent fuel leakage. Never attempt to maintain a vehicle in an area where exposed flame is present or persons are smoking. Always be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated. 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. Always test drive the vehicle after any repairs or maintenance. All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic. Always replace damaged or missing warning, caution or information labels. Always keep complete records of the maintenance history of the vehicle. Page vi Repair and Service Manual

SAFETY INFORMATION VENTILATION Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating. Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural or propane gas water heaters and furnaces. Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area. Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal. Repair and Service Manual Page vii

SAFETY INFORMATION Notes: _________________________ _ Page viii Repair and Service Manual

2002-2009 EZGO ST350 ST Sport Gas Utility Vehicle Service & Repair Manual

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