Club Car Carryall 1500 2016, Maintenance And Service Manual

Page: 277 / 436

SECTION 15 — GASOLINE ENGINE, MUFFLER, FUEL SYSTEM,
AND CLUTCHES
15
Gasoline Engine, Muffler, Fuel System, and Clutches
DANGER
• See General Warnings, Section 1, Page 1-2.
WARNING
• See General Warnings, Section 1, Page 1-2.
GASOLINE ENGINE
See General Warnings, Section 1, Page 1-2.
This section contains information on removing and installing the Kawasaki gasoline engine. For complete instructions
on engine disassembly, repair, rebuilding, and reassembly, refer to the engine manual.
See the Kawasaki FH680D
engine manual (CC P/N 103351201).
ENGINE REMOVAL
See General Warnings, Section 1, Page 1-2.
CAUTION
• Before removal and disassembly, clean the engine.
1. Disconnect battery and spark plug wire(s). See Side-Post Battery: Disconnecting the Battery –
Gasoline/Diesel Vehicles on page 1-3.
See Top-Post Battery: Disconnecting the Battery- Gasoline/Diesel Vehicles on page 1-4.
2. Remove the cargo bed. See Cargo Bed Removal, Section 4, Page 4-12.
3. Remove seat(s) and remove the center seat plate (bucket seat vehicles only).
4. Remove the ROPS (Roll Over Protection Structure) and the lower rear ROPS bars. See ROPS Removal,
Section 4, Page 4-7.
5. Remove the seat frame. See Seat Support Removal, Section 4, Page 4-10.
6. Remove the engine top cover (1) (Figure 15-1, Page 15-2) .
7. Remove the engine front cover (2).
8. Close the shut-off valve on the fuel tank.
9. Remove the fuel line from the fuel pump (3) on the engine. See following DANGER.
DANGER
• Gasoline! Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle
and service area.
10. Remove the choke cable. See Choke Cable Removal on page 15-22.
11. Remove the engine air inlet hose (4).
2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual Page 15-1