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Ezgo WorkHorse ST 480 User Manual

Ezgo WorkHorse ST 480
164 pages
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R
ST
ST 480
GASOLINE POWERED UTILITY VEHICLE
ISSUED: 2001 REVISED: APRIL 2011
TECHNICIAN’S
REPAIR AND SERVICE MANUAL
28580-G01

Table of Contents

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Ezgo WorkHorse ST 480 Specifications

General IconGeneral
BrandEzgo
ModelWorkHorse ST 480
CategoryUtility Vehicle
LanguageEnglish

Summary

Safety Information

General Safety Practices

General safety practices and important warnings for vehicle operation.

General Operation Guidelines

Guidelines for safe and responsible vehicle operation.

Maintenance Safety

Safety precautions during vehicle maintenance and servicing.

Ventilation Safety

Safety considerations for ventilation, especially with gasoline fumes.

General Information and Routine Maintenance

Servicing the Vehicle

General guidelines and warnings for servicing the vehicle.

Routine Maintenance Schedule

Overview of routine maintenance tasks and schedules.

Torque Specifications

Table of torque specifications for various fasteners.

Periodic Service Schedule

Schedule for regular maintenance tasks based on operating hours or time.

Body and Truckbed Components

General Bodywork Information

General notes and references for body and truckbed work.

Component Replacement Procedures

Procedures for replacing various body and truckbed components.

Truck Bed Replacement

Steps for replacing the truck bed assembly.

Brake System Maintenance and Repair

Hydraulic System Operation

Explanation of the hydraulic brake system's operational principles.

Brake System Maintenance

Maintenance procedures and inspections for the brake system.

Master Cylinder Service

Information on the master cylinder, its function, and replacement.

Brake Drum Removal and Installation

Detailed steps for removing and installing brake drums.

Bleeding and Flushing the Brake System

Instructions for bleeding and flushing the hydraulic brake system.

Parking Brake System

Information and procedures related to the parking brake system.

Continuously Variable Transmission (CVT)

General CVT Information

General overview of the Continuously Variable Transmission (CVT).

Drive Clutch Service

Details regarding the drive clutch, its operation and service.

Drive Belt Service

Information and procedures related to the drive belt.

Direction Selector System

Direction Selector Removal

Steps for removing the direction selector assembly.

Micro Switch Replacement

Procedure for replacing the micro switch within the system.

Shift Cable Adjustment

How to adjust the shift cable for proper operation.

Electrical System Diagnostics

Circuits and Controls Overview

Description of electrical circuits and control components.

Starter/Generator Service

Information on the starter/generator unit and its modes.

Testing Starting and Charging Circuits

Procedures for testing the vehicle's starting and charging circuits.

Electrical Troubleshooting

Troubleshooting common electrical issues.

Engine Maintenance and Service

Powertrain Maintenance

Maintenance procedures for the engine's powertrain.

Engine Oil Service

Checking and changing the engine oil.

Air Cleaner Maintenance

Maintenance procedures for the air cleaner system.

Spark Plug Service

Information and procedures related to spark plugs.

Engine Removal and Installation

Procedures for removing and installing the engine.

Front Suspension and Steering

Front Suspension Components

General information about the front suspension system.

Front Axle and Spring Replacement

Procedures for replacing front axles and springs.

Tie Rod and Wheel Bearing Service

Inspection and replacement procedures for tie rods and wheel bearings.

Steering System Service

Procedures for servicing steering wheel, shaft, and components.

Wheel Alignment Procedures

Steps for performing wheel alignment.

Fuel System Service

Fuel System Components

Overview of fuel system components.

Fuel System Service and Replacement

Service and replacement of fuel system components.

Fuel Lines and Filters

Procedures for servicing fuel lines and filters.

Choke System and Cable Service

Information and procedures for the choke system and cable.

Carburetor Service

Information and procedures related to the carburetor.

Paint Repair and Refinishing

Painting Procedures

General guidelines for painting the vehicle.

Minor Scratch Repair

Procedures for repairing minor scratches on the paint.

Larger Scratch Repair

Procedures for repairing larger scratches on the paint.

Complete Panel Paint Repair

Procedures for repairing paint on entire panels.

Rear Axle and Suspension Service

Rear Axle Maintenance

General information and maintenance of the rear axle.

Differential Lock Cable Adjustment

Procedures for adjusting the differential lock cable.

Rear Axle Removal and Installation

Steps for removing and installing the rear axle assembly.

Rear Suspension Service

Information and procedures for rear shock absorbers and springs.

Speed Control System

Accelerator, Governor, and Carburetor Linkage

Information on the linkage system for accelerator, governor, and carburetor.

Governor Operation and Adjustment

Description of the governor's function and adjustment.

Cable Adjustment Procedures

General procedures for adjusting control cables.

Governor Compression Spring Adjustment

Adjusting the governor compression spring.

Road Test for Speed Control

Procedures for conducting a road test to verify speed control.

Troubleshooting Guide

Engine Troubleshooting

Troubleshooting common engine issues and performance problems.

Starter/Generator Troubleshooting

Troubleshooting starter/generator problems.

Suspension and Steering Troubleshooting

Troubleshooting suspension and steering system issues.

Weather Protection Systems

Top and Windshield Service

Information about the top and windshield components.

Sun Top Installation

Installation procedures for the sun top.

Fold Down Windshield Installation

Steps for installing and folding the windshield.

One-Piece Windshield Installation

Steps for installing a one-piece windshield.

Wheels and Tires Service

Wheel and Tire Service Overview

Procedures for servicing wheels and tires.

Tire Repair Procedures

Information and procedures for repairing tires.

Wheel Installation

Steps for installing wheels onto the vehicle.

General Vehicle Specifications

Standard Equipment List

Comprehensive list of standard features and components included with the vehicle.

Engine Specifications

Detailed specifications related to the vehicle's engine.

Vehicle Dimensions

Detailed measurements and diagrams of the vehicle's physical size.

Performance Specifications

Key performance metrics including incline, turning, and aisle clearance.

Limited Warranty Information

Emission Control System Warranty

Statement regarding the emission control system warranty.

Engine Owner Warranty Policy

Policy details for the engine owner's warranty.

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