EZ GO 480 GOLF CART Service Parts Manual

OWNER'S MANUAL & SERVICE GUIDE R ST 480 Starting Model Year 2003

MANUAL INFORMATION For any questions on material contained in this manual, contact a representative for clarification. Read and understand all labels located on the vehicle. Always replace any dam- aged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To prevent loss of vehicle control and possible serious injury, speeds should 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. Be sure that this manual remains as part of the permanent service record should the vehicle be re-sold. Throughout this guide, NOTE, CAUTION and WARNING will be used. A NOTE indicates a condition that should be observed. A CAUTION indicates a condition that may result in damage to the vehicle. A WARNING indicates a hazardous condition which could result in severe injury or death. Please observe these notes, cautions, and warnings; be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be hazardous. Improper service or repair may damage the vehicle or render it unsafe. Engine exhaust from this product contains chemicals known, in certain quanti- ties, to cause cancer, birth defects, or other reproductive harm. The exhaust emissions of this vehicles’ engine complies with regulations set forth by the Environ- mental Protection Agency (EPA) of the United States of America (USA) at time of manufacture. Significant fines could result from modifications or tampering with the engine, fuel, ignition or air intake systems. Battery posts, terminals and related accessories contain lead and lead com- pounds. Wash hands after handling. This spark ignition system meets all requirements of the Canadian Interference-Causing Equipment Regulations. ! ! ! ! ! ! Ce système d'allumage par étincelle de véhicule respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.

i OWNER’S MANUAL & SERVICE GUIDE ST 480 Textron Golf, Turf & Specialty Products reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice. Textron Golf, Turf & Specialty Products is not liable for errors in this manual or for incidental or consequential damage that result from the use of material in this manual. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124 OUTSIDE USA PHONE: 010-1-706-798-4311 FAX: 010-1-706-771-4609 TEXTRON GOLF, TURF & SPECIALTY PRODUCTS, P.O. BOX 388 AUGUSTA, GEORGIA 30903-0388 USA

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

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

EZ GO 480 GOLF CART Service Parts Manual

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