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EZ-GO ST 4X4 - User Manual

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ST 4X4
GASOLINE POWERED 4 WHEEL DRIVE
UTILITY VEHICLE
STARTING MODEL YEAR: 2004
TECHNICIAN’S
REPAIR AND SERVICE MANUAL
600392
Ref Fcv 19

Table of Contents

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Summary

Safety

General Operational Safety

Safe vehicle use, off-road operation, speed limits, and general driving practices.

Maintenance and Servicing Safety

Precautions for maintenance, battery handling, lifting, and pre-service procedures.

Operator Responsibilities and Qualifications

Operator qualifications, training, responsibilities, and driving rules.

General Information and Routine Maintenance

General Servicing and Maintenance

Label locations, general servicing, towing, and jump starting procedures.

Maintenance Procedures and Schedules

Routine maintenance, powertrain, brakes, tires, care, storage, torque, capacities, and schedule.

Body and Truckbed

Component Replacements

Procedures for replacing seats, guards, panels, cowl, and instrument panel.

Panel Repairs

Procedures for repairing rocker panels, floorpans, fenders, and seat supports.

Brakes

Hydraulic System Operation and Inspection

Explains system function, components, and inspection procedures.

Brake System Service and Repair

Covers master cylinder, drums, pads, rotors, bleeding, and pedal replacement.

Parking Brake System

Operation, adjustment, and cable replacement for the parking brake.

Continuously Variable Transmission (CVT)

CVT System Overview and Operation

Explains CVT function, clutches, and handling of increased load.

Clutch and Drive Belt Service

Procedures for clutch replacement and drive belt service.

Direction and Drive Selector

Selector System Operation and Safety

Covers system operation, safety warnings, and cable adjustment.

Selector Component Replacement

Procedures for replacing direction and drive selectors and proximity sensors.

Electrical

System Overview and Testing

Covers circuits, controls, starting, charging, and DVOM usage.

Electrical System Testing Procedures

Detailed tests for ignition, starting, battery, and charging circuits.

Component Troubleshooting

Addresses battery storage, power supply, instrument cluster, solenoids, and switches.

Engine and Transmission

Powertrain Maintenance

Covers debris removal, oil checks, oil filter, air cleaner, and belt tension.

Engine Description, Operation, and Spark Plugs

Details engine specs, operation cycle, and spark plug service.

Engine and Transmission Service

Procedures for removing/installing engine, transmission, starter, muffler, and exhaust.

Front Suspension and Steering

Front Suspension Service

Covers disassembly, wheel/brake removal, tie rod, control arm, knuckle, strut, bearing, ball joint.

Steering System Service

Covers drive shaft, differential guard, steering assembly, wheel, and column replacement.

Wheel Alignment

Procedure for adjusting wheel alignment.

Fuel System

Fuel System Components and Safety

Covers overview, safety, lines, filter, pump, and tank.

Choke System and Carburetor Service

Covers choke operation, cable replacement, and carburetor cleaning.

Paint

Painting Procedures

Covers general painting, scratch repair, panel repair, and cowl painting.

Rear Axle and Suspension

Rear Axle Maintenance and Components

Covers lubrication, solenoid, drive shaft, differential guard, and axle components.

Rear Suspension Service

Covers shock absorber and spring removal procedures.

Speed Control

Accelerator, Governor, and Linkage Operation

Explains system operation, governor function, and cable adjustment.

Speed Control Adjustments, Replacement, and Testing

Covers governor spring adjustment, cable adjustment, pedal replacement, and road tests.

Troubleshooting

Engine Troubleshooting

Covers starter, starting, performance, overheating, spark plugs, carburetor, smoking, backfiring, speed.

Starter;Generator and Suspension;Steering Troubleshooting

Covers starter noise, battery, charging, tire wear, steering, and vibration.

Wheels and Tires

Wheel and Tire Service

Covers general service, tire replacement/repair, and inflation.

Wheel Installation

Procedure for installing wheels and lug nuts.

General Specifications

Vehicle Specifications

Detailed list of standard equipment and vehicle specifications.

Vehicle Dimensions and Incline Specifications

Diagrams and data for dimensions, ramp grade, and tilt.

Limited Warranty

Warranty Statements

Emission control system and engine warranty information.

General Warnings

Operating Warnings

Warnings before operating the vehicle.

Servicing Warnings

Warnings before servicing the vehicle.

EZ-GO ST 4X4 Specifications

General IconGeneral
BrandEZ-GO
ModelST 4X4
CategoryGolf Cars
LanguageEnglish