E-Z-GO 625619 2012 Technician'S Repair And Service Manual Download

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Page R-1

Repair and Service Manual

GENERAL SPECIFICATIONS

Read all of Section B and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.

MODEL: TERRAIN 1500
TYPE: GASOLINE POWERED TRUCK
MODEL YEAR: 2012

Part No:. 618860

Engine:

16 hp (11.9 kW) rated, 4 cycle, 29.2 ci (480 cc) V-Twin, air-cooled Vanguard

Valve Train:

Overhead valve

Fuel System:

Fixed float bowl with remote pulse fuel pump

Lubrication:

Pressurized oil system, spin-on oil filter

Ignition:

Electronic spark/magneto

Balancer:

Internal counter rotating balance shaft

Air Cleaner:

Replaceable dry cartridge w/permanent pre-filter/remote air

Electrical:

Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (525 CCA, 60 minute reserve)

Drive Train:

Automatic, continuously variable transmission (CVT). Locking rear axle (Operator selectable from center console)

Brakes:

Dual rear wheel hydraulic self-adjusting drum brakes. Hand operated park brake located in center console

Transaxle:

Differential with helical gears, ground speed governor, forward/reverse

Seating:

Two bucket seats

Cargo Bed:

Roto-molded cross-linked polyethelene. Lifts for access to powertrain. Removable hinged multi-position tailgate requires no latch mechanism

Dimensions

Vehicle Power Cont.

Overall Length

110.5 in (281.0 cm)

Gear Selection

Forward-Reverse

Overall Width

50.0 in (127.0 cm)

Rear Axle Ratio

13.32:1

Overall Height (No Canopy) 49.0 in (125.0 cm) (Top of steering wheel)

Performance

Overall Height (With Canopy) 75.0 in (191.0 cm)

Seating Capacity

2 Persons

Wheel Base

78.5 in (199.0 cm)

Dry Weight

1110 lb (505 kg)

Front Wheel Track

38.0 in (96.0 cm)

Curb Weight

1150 lb (525 kg)

Rear Wheel Track

38.5 in (97.0 cm)

Bed Load Capacity

500 lb (225 kg)

Gnd Clearance @ Differential 6.0 in (15.0 cm)

Vehicle load capacity

800 lb (360 kg)

Cargo Box Width (inside)

44.0 in (112.0 cm)

Outside Clearance Circle

23.5 ft (7.2 m)

Cargo Box Length (inside)

36.0 in (91.0 cm)

Intersecting Aisle Clearance N/A

Cargo Box Depth (inside)

10.5 in (27.0 cm)

Speed (Level Ground)

16 mph ± 0.5 mph (25.7 kph ± 0.8 kph)

Cargo Box Capacity

9.6 cu ft (0.27 m3)

Towing Capacity

500 lb (225 kg)

Cargo Box Material

Roto-molded polyethylene

Steering & Suspension

Vehicle Power

Steering

Self-compensating rack and pinion

Power Source

4 cycle, 29.2 ci (480 cc)

Front Suspension

Leaf springs with hydraulic shock absorbers

Valve Train

V Twin Cylinder OHV

Rear Suspension

Leaf springs with hydraulic shock absorbers

Horsepower (kW)

16.0 hp (11.9 kW) rated

Service Brake

Rear wheel hydraulic self-adjusting drum

Electrical System

Starter/Generator, solid-state regulator

Parking Brake

Hand operated

Battery (Qty, Type)

One 12 Volt maintenance free

Front Tires

Stryker 22 x 9 - 10 Uni-Directional

Key or Pedal Start

Pedal Start

Rear Tires

Stryker 22 x 9 - 10 Uni-Directional

Air Cleaner

Dry cartridge w/permanent pre-filter/remote air

Body & Chassis

Lubrication

Pressurized oil system

Frame

Welded steel with DuraShield™ powder coat

Oil Filter

Spin-on oi filter

Front Body & Finish

Injection Molded TPO

Cooling System

Air cooled

Rear Body & Finish

Steel. Base coat/clear coat

Fuel Capacity

5.8 gallon (22.0 L) tank

Standard Color

Hunter Green

Drive Train

Continuously variable transmission (CVT)

Differential

Helical gears with manual lock-up

Some items shown may be optional equipment

PRODUCT SPECIFICATION

PRODUCT OVERVIEW

CONFIGURATION HIGHLIGHTS

Specifications are subject to change without notice

* Field installed accessories may require installation charges

Noise & Vibration

Sound pressure; continued A-weighted equal to or less

than 80 db(A)

Highest RMS value of weighted acceleration is 1.25 m/s

Highest RMS value of weighted acceleration is less

than 2.5 m/s

The uncertainty of measurement is 0.24 m/s

Noise

Vibration, WBV

Vibration, HAV

Summary of Contents for 625619 2012

Page 1: ...GASOLINE POWERED UTILITY VEHICLE TECHNICIAN S REPAIR AND SERVICE MANUAL 625610 625619 ISSUED JUNE 2012 REVISED AUGUST 2012 ...

Page 2: ...ery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm WAS H HANDS AFTER HANDLING WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm CONTAIN LEAD AND RELATED PARTS BATTERY WARNING BATTERIES 25 DO NOT DRIVE ACROSS SLOPES IN EXCESS OF 1...

Page 3: ...contained in this Manual may be revised periodically by E Z GO and therefore is subject to change without notice E Z GO DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and E Z GO SPECIFICALLY DISCLAIMS LIABILITY FOR INCIDENTAL AND CON SEQUENTIAL DAMAGES resulting from the use of the information and materials in this Manual TO CONTACT US NORTH AMERICA TECHNICAL ASSISTANCE WARRANTY PHONE 1 800 774 394...

Page 4: ...he 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 batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C B...

Page 5: ...CTION GENERAL INFORMATION ROUTINE MAINTENANCE A SAFETY B BODY C BRAKES D CONTINUOUSLY VARIABLE TRANSMISSION CVT E DIRECTION SELECTOR F ELECTRICAL G ENGINE H FRONT SUSPENSION AND STEERING J FUEL SYSTEM K REAR AXLE AND SUSPENSION L ELECTRONIC SPEED CONTROL M TROUBLESHOOTING N WEATHER PROTECTION P WHEELS AND TIRES Q GENERAL SPECIFICATIONS R ...

Page 6: ...Page iv Repair and Service Manual NOTES TABLE OF CONTENTS ...

Page 7: ...alf of E Z GO I am directing that E Z GO Branch personnel Distributors and Dealers advise all customers to adhere to this SAFETY RESTRICTION in connection with the use of all products new and used the Distributor or Dealer has rea son to believe may be operated in personal transportation applications Information on FMVSS 571 500 can be obtained at Title 49 of the Code of Federal Regulations sectio...

Page 8: ...or terrain or conditions Apply service brake to control speed on steep grades Maintain adequate distance between vehicles Reduce speed in wet areas Use extreme caution when approaching sharp or blind turns Use extreme caution when driving over loose terrain Use extreme caution in areas where pedestrians are present MAINTENANCE Always Maintain the vehicle in accordance with the manufacturer s perio...

Page 9: ...ons 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 VENTILATION Always store gasoline veh...

Page 10: ...Page viii Repair and Service Manual B SAFETY INFORMATION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 11: ...ERTRAIN MAINTENANCE A 3 BRAKES A 4 TIRES A 4 CARE AND CLEANING OF THE VEHICLE A 4 VEHICLE CARE PRODUCTS A 4 SUN TOP AND WINDSHIELD A 5 TRAILERING A 5 WINTER OR PROLONGED STORAGE A 5 HARDWARE A 5 TORQUE SPECIFICATIONS A 6 PERIODIC SERVICE SCHEDULE A 7 LIST OF ILLUSTRATIONS Fig 1 Serial Number Location A 1 Fig 2 Intial Service Chart A 2 Fig 3 Fuel Tank A 2 Fig 4 Neutral Lock A 3 Fig 5 Lubrication Po...

Page 12: ... Repair and Service Manual B GENERAL INFORMATION ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 13: ...ging with a 12V 10 amp max charger Observe all instructions provided by the manufacturer of the charger SERVICING THE VEHICLE To prevent severe injury or death resulting from improper servicing techniques observe the following Warnings Do not attempt any type of servicing operations before reading and understanding all notes cautions and warnings in this manual Any servicing requiring adjustments ...

Page 14: ...or the expansion of gasoline Leave at least 1 2 5 cm of space below the bottom of the filler neck Fig 3 Fuel Tank When refueling inspect the fuel tank cap for leaks or breaks in the housing that could result in fuel spillage To prevent a possible explosion do not smoke near the fuel tank or refuel near open fire or electrical items which could produce a spark Always wear safety glasses while refue...

Page 15: ...eas that could damage components Fig 5 Lubrication Points POWERTRAIN MAINTENANCE Access the powertrain by raising or removing the seat bottom Some service procedures may require the vehi cle be lifted Refer to LIFTING THE VEHICLE in section B for proper lifting procedure and safety information For maintenance procedures relating to the engine speed control fuel system transmission and rear axle or...

Page 16: ...t brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the use of a commercially available vinyl rubber cleaner The painted surfaces of the vehicle provide attractive appearance and durable protection Frequent washing with lukewarm or cold water is the best method of pre serving the painted surfaces Do not use hot water strong soap or harsh chemical detergents R...

Page 17: ...ter heater or other appliance that uses a pilot light or has a device that can create a spark When refueling inspect the fuel cap for leaks or breaks that could result in fuel spillage Always wear safety glasses while refuel ing to prevent possible eye injury from gasoline or gasoline vapour Keep hands clothing and jewelry away from moving parts Use care not to con tact hot objects Raise the rear ...

Page 18: ...ware are used in the vehi cle Grade 5 hardware can be identified by the three marks on the hexagonal head Unmarked hardware is Grade 2 Ref Fig 6 Fig 6 Bolt Grades Grade 2 Grade 5 TORQUE SPECIFICATIONS ALL TORQUE FIGURES ARE IN FT LBS Nm BOLT SIZE Grade 2 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 Unless otherwise noted in text tighten all hardware in accordance with this chart The table below specif...

Page 19: ...kes aggressive stop test C A C A C A C A Park Brake operation does it hold on a hill C A C A C A C A Accelerator smooth operation Starter Generator Belt tension wear cracks Wiring loose connections broken or missing insula tion Carburetor Linkage attachment C A C A C A C A Carburetor CL Direction Selector attachment and mechanism C A C A C A C A Cooling Fan build up of debris inside blower housing...

Page 20: ... kingpins worn bushings loose or missing hardware Front Wheel Alignment unusual tire wear C A C A C A Fuel System leaks at tank cap system lines for cracks deterioration filters pump Fuel Filter R Spark Plug R Throttle Governor Linkage operation governed speed Air Filter Element check replace as necessary Drive Belt cracks frayed excessive wear REMARKS before each use DAILY WEEKLY 20 rnds 20 hrs 1...

Page 21: ...epair and Service Manual B B GENERAL INFORMATION ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 22: ... Repair and Service Manual B GENERAL INFORMATION ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 23: ... NOTICES CAUTIONS WARNINGS AND DANGERS B 1 IMPORTANT SAFETY WARNING B 1 MODIFICATIONS TO VEHICLE B 1 GENERAL MAINTENANCE B 1 BEFORE SERVICING THE VEHICLE B 1 Battery Removal and Installation B 3 LIFTING THE VEHICLE B 3 LIST OF ILLUSTRATIONS Fig 1 Battery Removal B 3 Fig 2 Lifting the vehicle B 4 ...

Page 24: ...Page B ii Repair and Service Manual B SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 25: ...oxide battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools listed in the tool list and wear approved safety equipment MODIFICATIONS TO VEHICLE ...

Page 26: ...bserved at the spark plug be sure to install a spare spark plug into the open cylinder before operating the starter Never test the function of a fuel pump in the vicinity of a hot engine or other source of flame or combustion Never confuse the hoses to and from the fuel pump Verify that the carburetor and pulse lines are correctly installed before starting the engine see FUEL SYSTEM section Wrap w...

Page 27: ...ft lbs 19 24 Nm Be sure to remove all corrosion from terminals and hard ware After installing battery coat terminals with com mercially available terminal protectant LIFTING THE VEHICLE Tool List Qty Floor Jack 1 Jack Stands 4 Chocks 4 Some servicing operations may require the front rear or the entire vehicle to be raised To prevent possible injury or death resulting from a vehicle falling from a ...

Page 28: ...at the center of the front axle Raise the vehicle and position jack stands under the frame cross member as indicated Lower the jack and test the stability of the vehicle on all four jack stands If only the front or rear of the vehicle is to be raised place the chocks in front and behind each wheel not being raised in order to stabilize the vehicle Lower the vehicle by reversing the lifting sequenc...

Page 29: ...Page B 5 Repair and Service Manual B B SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 30: ...Page B 6 Repair and Service Manual B SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 31: ... C 7 Truck Bed Replacement C 7 PAINTING C 12 Minor Scratches C 12 Larger Scratches C 12 Complete Panel Repair C 12 LIST OF ILLUSTRATIONS Fig 1 Drill Out Metal Rivet C 1 Fig 2 Drive Rivet Removal C 1 Fig 3 Removing Ratchet Fasteners C 1 Fig 4 Body Components Front C 2 Fig 5 Front Bumper C 4 Fig 6 Seat Components C 4 FIg 7 Body Components Rear C 5 FIg 8 Electric Lift Toggle Switch and Winch Receptac...

Page 32: ...Page C ii Repair and Service Manual B BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 33: ...onal remov able hardware nuts bolts washers and screws Some components are mounted with pop rivets which require that the rivet head be removed in order to push out the shank of the rivet The rivet head is easily removed by drilling into the head with a sharp drill bit that is slightly larger than the shank of the rivet Ref Fig 1 Care must be exercised when drilling to prevent the drill from being...

Page 34: ... 9 6 4 16 8 15 14 10 12 11 Instrument Panel Replacement Tool List Qty Insulated wrench 1 2 1 Electric air drill 1 Drill bit 7 32 1 Pry bar 1 Punch small 1 Hammer 1 Rivet Gun 1 If the instrument panel is to be replaced the serial number plate must be removed and reinstalled on the new instrument panel Ref Fig 4 on page C 2 The instrument panel may be removed without removing the cowl or may be remo...

Page 35: ...for removal Assemble in reverse order of disassembly using new riv ets Cowl Replacement Tool List Qty Insulated wrench 1 2 1 Socket 1 2 1 Ratchet 1 Electric air drill 1 Drill bit 7 32 1 Phillips screwdriver 1 Rivet gun 1 Torque wrench ft Ibs 1 To prevent personal injury disconnect the negative battery cables before servicing vehicle Using an insulated wrench disconnect negative cables from battery...

Page 36: ...or reuse and note the location of each spacer 25 26 to ensure proper placement Remove rocker panel Replacement is the reverse order of disassembly mak ing sure hardware and spacers are replaced in the appropriate locations Seat Bottom Replacement Tool List Qty Straight blade screwdriver small 1 Phillips screwdriver large 1 To remove driver seat bottom 27 loosen setscrew 28 in choke knob 29 and rem...

Page 37: ...d all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 7 Body Components Rear 55 60 61 5 23 25 43 22 26 44 24 22 58 59 48 46 47 45 37 50 36 49 51 62 63 56 64 52 54 53 ...

Page 38: ...Qty Electric air drill 1 Drill bit 7 32 1 Rivet gun 1 Drill out rivets 49 securing filler panel 50 51 to side panel 44 45 Ref Fig 7 on page C 5 Remove seat filler panel Install using new rivets Side Panel Replacement Tool List Qty Electric pneumatic drill 1 Drill bit 7 32 1 Socket 7 16 1 Ratchet 1 Wrench 7 16 1 Rivet gun 1 To replace either driver or passenger side panel first remove rocker panel ...

Page 39: ...removal Tail light should be replaced in rear fender with wiring at top of tail light Rear Panel Replacement Tool List Qty Electric air drill 1 Drill bit 7 32 1 Rivet gun 1 Drill out two rivets 60 on each side of rear panel 61 securing it to rear fenders 55 56 Ref Fig 7 on page C 5 Remove rear panel Install in reverse order of disassembly using new rivets Truck Bed Replacement Tool List Qty Back B...

Page 40: ...ad all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 10 Plastic Truck Bed Components manual Lift C B A A B C Plastic Bed Latch Plate Rubber Bumper Latch Handle ...

Page 41: ...procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 11 Plastic Truck Bed Components Power Actuator Electric Actuator Actuator may be rotated 90 on some models Plastic Bed UP DOWN ELECTRIC DUMP RED from Battery RED from Actuator WHT from Actuator Front of Vehicle BLK from Battery ...

Page 42: ... B BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 12 Metal Truck Bed Components Manual Lift A B C B C A Metal Bed Latch Plate Latch Handle ...

Page 43: ... Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 13 Metal Truck Bed Components Power Actuator Metal Bed ELECTRIC DUMP Electric Actuator Actuator may be rotated 90 on some models ...

Page 44: ...y clean the surface to be repaired with alco hol and dry II Mask area to be painted common masking tape is adequate prior to repair and use aerosol type touch up paint III Apply spray touch up paint in light even overlapping strokes Multiple coats may be applied to provide ade quate coverage and finish Always remember to shake the can for a minimum of one minute to mix the paint and achieve the be...

Page 45: ...Page C 13 Repair and Service Manual B B BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 46: ...Page C 14 Repair and Service Manual B BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 47: ...7 Resassembly D 8 Replacing an Adjuster D 8 Adjustment D 8 WHEEL BRAKE ASSEMBLY REPLACEMENT D 9 BLEEDING AND FLUSHING D 9 Bleeding D 9 Bleeding Sequence D 9 Flushing D 10 BRAKE PEDAL REMOVAL AND INSTALLATION D 10 PARKING BRAKE D 11 Lubrication D 11 Adjustment D 11 Cable Replacement D 11 LIST OF ILLUSTRATIONS Fig 1 Hydraulic Brake System Components D 1 Fig 2 Replacing Master Cylinder D 4 Fig 3 Brak...

Page 48: ...Page D ii Repair and Service Manual B BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 49: ...gs and Dangers Fig 1 Hydraulic Brake System Components Shaft Bellcrank Brake Pedal Part of Frame Master Cylinder Brake Light Switch Plug Banjo Bolt Copper Gasket Secondary Brake Line Primary Brake Line Bushing Bushing Clip Flexible Brake Hose Linkage Rod Part of Part of Frame Frame Torsion Spring Self Adjusting Wheel Brake Mechanical Parking Brake Lever Part of Frame ...

Page 50: ...g clearance The rear brake includes a parking feature consisting of a lever and strut The lever is applied by a cable attached to the parking brake lever hand operated The parking brake is used to retain the vehicle when stationary It may also be used as an emergency brake in the event of hydraulic system failure MAINTENANCE Daily Brake Performance Test To assure correct braking performance all pe...

Page 51: ...ed with fresh DOT 3 standard automotive brake fluid It is important to maintain proper fluid levels in the mas ter cylinder The fill cap for the cylinder is located under the driver seat To prevent contamination when checking fluid wipe off any dirt from fill cap before removing it Reservoir fluid level should be checked per PERIODIC SERVICE SCHEDULE in Section A When required clean brake fluid sh...

Page 52: ...bs 8 9 Nm torque Mount master cylinder to frame bracket using new lock nuts Do not reuse original lock nuts Tighten lock nuts to 28 32 in lbs 3 4 Nm torque Insert push rod through rubber boot and washer into master cylinder make sure rod is through washer inside boot Snap rubber boot back onto master cylinder Install both clevis yokes back onto bellcrank using clevis pins and new cotter pins To pr...

Page 53: ... Do not use pres surized air to blow dust from brake assemblies Remove cap to gain access to the castellated nut and the cotter pin Ref Fig 5 on page D 6 Remove the cotter pin and castellated nut as shown Do not apply the brake when removing the nut as the shoes may not fully retract preventing removal of the brake drum Remove washer Slide the brake drum from the axle shaft If required tap the dru...

Page 54: ...ot back off nut to install cotter pin Install the remaining hardware and tighten the nut to 70 ft lbs 95 Nm torque Continue to tighten until a new cotter pin can be installed through the castellated nut and the hole in the axle Maximum torque is 140 ft lbs 190 Nm Fig 5 Wheel Brake Components Lock Nut Brake Shoe Cotter Pin Inner Brake Drum Washer Cup and Spring Lower Shoe to Shoe Spring Upper Shoe ...

Page 55: ... and remove shoes If the wheel cylinder must be removed begin by loosen ing and removing the brake line from the back of the wheel cylinder Next remove the wheel cylinder bolts and remove the wheel cylinder from the backing plate Cleaning and Inspection The drum must not be turned to true a worn friction surface Turning will make the drum too thin causing drum and brake failure which could cause s...

Page 56: ...osition If the wheel cylinder was removed install it now into the backing plate Insert and tighten the wheel cylinder mounting bolts to 120 in lbs 14 Nm torque Reconnect and tighten the brake fluid line to 124 177 in lbs 14 20 Nm torque Position shoes on backing plate and install hold down springs Install parking brake strut with tab on strut engaged in brake shoe web Place upper end of shoe webs ...

Page 57: ...n Loosely install wheel brake assembly to axle tube flange using new hardware Attach brake line to wheel cylinder using new copper gaskets and tighten banjo bolt to 124 177 in lbs 14 20 Nm torque Tighten allen head bolts and lock nuts to 23 27 ft lbs 31 37 Nm torque BLEEDING AND FLUSHING Tool List Qty Shop towels A R Hose A R Clean container 1 Brake fluid DOT 3 A R Wrench 1 4 box end 1 Crowfoot wr...

Page 58: ...damage internal components 3 If the brake pedal goes to the floorboard without removing all of the air bubbles close the bleeder screw and release the brake pedal slowly Then repeat Steps 2 and 3 The bleeder valve at the wheel cylinder must be closed at the end of each stroke and before the brake pedal is released to insure that air cannot enter the system It is also important that the brake pedal...

Page 59: ...r The hand operated parking brake lever requires periodic lubrication with a dry graphite or molybdenum disulfide lubricant Raise the lever and spray into the underside to access the pivot arm and ratchet mechanism of the parking brake See Section A Periodic Service Sched ule for recommended lubrication schedule Adjustment The parking brake adjustment is made at the clevis yoke on the end of the p...

Page 60: ...particular attention to Notices Cautions Warnings and Dangers Fig 9 Parking Brake System Components Boot If equipped Parking Brake Cable Part of Frame Equalizer Park Brake Lever Jam Nut Clevis Yoke Pulley Support Bracket Park Brake Lever Cable Retaining Ring Center Console Subframe Parking Brake Cable Parking Brake Lever ...

Page 61: ...Page D 13 Repair and Service Manual B B BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 62: ...Page D 14 Repair and Service Manual B BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 63: ...oad E 2 Equilibrium E 2 Drive Clutch Removal E 2 Drive Clutch Installation E 3 Driven Clutch Removal E 3 Driven Clutch Repair E 3 Driven Clutch Assembly E 3 Driven Clutch Installation E 3 CLUTCHES E 4 Removing the Drive Belt E 4 Drive Belt Service E 4 STORAGE E 4 LIST OF ILLUSTRATIONS Fig 1 Continuously Variable Transmission System CVT E 1 Fig 2 CVT Components E 2 Fig 3 Removing the Drive Belt E 3...

Page 64: ... Repair and Service Manual B CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 65: ...t The ratio is greatly decreased and provides maximum speed When the accelerator is released the engine speed is decreased and the cams exert less pressure on the moveable sheave which is forced outwards against the cams by a compression spring The drive belt disen gages from the clutch sheave when engine speed is reduced to the point where the cams exert less force than the spring Driven Clutch T...

Page 66: ...ifugal force exerted by the cams in the drive clutch This forces the belt lower into the drive clutch which increases the drive ratio This downshifting applies more torque to the rear axle without an appreciable change to the engine speed since the governor opens the carburetor in direct response to the reduction in ground speed Equilibrium The CVT functions because the drive and driven clutches m...

Page 67: ...ng the moveable sheave in and out several times to seat the clutch with the tapered crankshaft Ref Fig 2 on page E 2 Install the lock washer 3 and the large pilot washer 4 onto the clutch bolt 2 Apply thread locking adhesive to the threads of the clutch bolt and install and tighten to 40 ft lbs 55 Nm torque Driven Clutch Removal Tool List Qty External snap ring pliers 1 Socket 5 8 1 Ratchet 1 Phil...

Page 68: ... and loosen the belt tension Ref Fig 3 on page E 4 The belt may then be rolled off the driven clutch Fig 3 Removing the Drive Belt Drive Belt Service The drive belt will require no service unless the vehicle has been operated in an extremely dusty or muddy loca tion in which case it should be washed with plain water If the belt becomes frayed or badly worn it must be replaced STORAGE If the vehicl...

Page 69: ...Repair and Service Manual B B CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 70: ... Repair and Service Manual B CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 71: ...nd Service Manual DIRECTION SELECTOR DIRECTION SELECTOR F 1 Removing Direction Selector F 1 Replacing the Reverse Warning Buzzer F 2 Replacing a Micro Switch F 2 Shift Cable Adjustment F 2 LIST OF ILLUSTRATIONS Fig 1 Direction Selector F 1 Fig 2 Shift Cable Adjustment F 2 ...

Page 72: ...Page F ii Repair and Service Manual B DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 73: ...ever disconnect a circuit under load at a bat tery terminal The battery negative cable must be removed before starting work on vehicle Wrap wrenches with vinyl tape to prevent the possi bility of a dropped wrench from shorting out a bat tery which could result in an explosion and severe personal injury or death Before replacing a suspect direction selector or replac ing the buzzer or micro switch ...

Page 74: ...ll sound If no sound is heard the buzzer must be replaced Remove the wires from the failed buzzer and attach the wires to the replacement buzzer Test as above to insure replacement buzzer is in good condition After restoring power test the wiring to insure it is operational by con necting wires to replacement buzzer and moving the direction selector to REVERSE position before continu ing Once it i...

Page 75: ...Page F 3 Repair and Service Manual B B DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 76: ...Page F 4 Repair and Service Manual B DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 77: ...ent G 7 BATTERY VOLTAGE TEST G 7 STORAGE OF BATTERY G 8 TROUBLESHOOTING G 8 POWER SUPPL Y G 8 ACCESSORY WIRING G 10 FAULTY WIRE REPLACEMENT G 10 LIGHT BULB REPLACEMENT G 10 LIST OF ILLUSTRATIONS Fig 1 Electrical System Components G 1 Fig 2 Electrical Plate Assembly G 2 Fig 3 DVOM G 3 Fig 4 Starting and Charging System Wiring Diagram G 5 Fig 5 Starter Generator G 6 Fig 6 Removing Starter Generator ...

Page 78: ...Page G ii Repair and Service Manual B ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 79: ...ure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Electrical System Components Chassis Harness Starter Generator Cover F 2 A2 A1 F1 Electrical Plate Assembly DF Ground Cable To Engine Block To Electronic Ignition Control Module To Ground Terminal on Engine Battery Positive Post Negative Post ...

Page 80: ...ent movement of vehicle all tests performed requiring starter generator or engine to rotate must be performed with the rear wheels raised see Section B or the neutral lock engaged see Section A Follow the lifting procedure in Section B of this manual Place wheel chocks in front of and behind the front wheels Check the stability of the vehicle on the jack stands before starting any repair procedure...

Page 81: ...AL VOLT OHM METER Before performing any test of wiring compo nents disconnect the battery cables from the battery posts to prevent electrical shock or explosion see procedure in Section B Electrical tests of the wiring for continuity may be made with a DVOM Digital Volt Ohm Meter available through the Service Parts Department P N 27481G01 The actual model may vary depending on availability The DVO...

Page 82: ...pedal is pressed replace the solenoid TESTING CHARGING CIRCUIT Tool List Qty DVOM 1 To prevent the possibility of injury resulting from vehicle inadvertently starting the drive belt must be removed or both rear wheels raised see procedure in Section B The charging circuit consists of a starter generator voltage regulator and battery Ref Fig 4 on page G 5 The solenoid must be functional in order to...

Page 83: ...nd Charging System Wiring Diagram Fuse 7 5 AMP RED BLK BLK RED Reverse Warning Buzzer Battery BLK Solenoid B A BLK BLK BLK BLK Engine Starter Generator A2 F1 F2 DF A1 GRN Letters Are For Reference Only And Do Not Appear On Solenoid RED Voltage Regulator MS3 D C BLU Key Switch MS4 RED WHT GRN GRN Key Switch BLK RED GRN A B D A A BLK Magneto Accelerator Pedal Box BLK Ignition Shutoff Module WHT BLK ...

Page 84: ...o overhaul the unit Some checks and repairs however can be accomplished by a skilled mechanic Make your own evaluation of the equipment and skills available before starting disassembly Hold the pulley 1 and remove the pulley nut 2 Remove the pulley screws 4 and front cover 3 Ref Fig 5 on page G 6 Remove the brush covers 6 by prying out with a screwdriver Pull up on the brush springs and move to th...

Page 85: ...f an open circuit exists replace the field coils Check for continuity between all four terminals and the frame outer shell If continuity is indicated the field coils are grounded against the frame and the field coils must be replaced 5 Clean all parts to be reinstalled and reassemble in the reverse order of disassembly Tighten bolts and nuts to the following values 5 mm torque to 15 21 in Ibs 1 66...

Page 86: ...tion starting at the battery and working out to the device that is not working Be sure to check both sides of all switches and fuses When no battery voltage is found the problem lies between the point where no voltage is detected and the last place that voltage was detected In circuits where no voltage is expected the same procedure may be used except that the DVOM is set to continuity Place the n...

Page 87: ...icity flow must be corrected whether by repairing or replacing the wire the switch or accessory FAULTY WIRE REPLACEMENT A faulty wire should be replaced with one of the same gauge and color wired between the correct components and secured to the harness bundle with a wire tie The faulty wire should be cut back close to the harness and the ends protected with vinyl electrical tape LIGHT BULB REPLAC...

Page 88: ... 15 AMP 15 AMP 15 AMP 15 AMP BLU WHT BLU WHT Light Switch Part Of Key Switch RED RED RED RED RED BRN BLK YEL Turn Signal Switch GRN GRN GRA WHT YEL YEL WHT BLK Flasher YEL Low Oil Pressure Light Oil Pressure Switch Fuel Sender Fuel Gauge BLU WHT BLK BLK BLK WHT WHT WHT RED RED Turn Signal Turn Signal Taillight Taillight YEL WHT WHT Key Switch Driver Side Passenger Side Indicates Butt Connection Wi...

Page 89: ...s section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 9 Horn and Fuse Block HORN Floorboard 65 63 64 67 64 Seatwrap Support BLK YEL WHT BLU WHT RED YEL RED RED WHT ORN WHT NOTE Truck Bed and Driver Seat Not Shown For Clarity ...

Page 90: ...his section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 10 Ignition Switch and 12 Volt Power Outlet ON OFF FUEL F E Ignition Switch Fuel Gauge Ignition Key Light Indicator Wire Harness Chassis Console Plate Power Outlet ...

Page 91: ...ection B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 11 Headlight Turn Signal and Taillight Rear Fender Head Light Turn Signal Flasher Turn Signal Switch Turn Signal Steering Wheel Tail Light ...

Page 92: ... Manual B ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 12 Hour Meter HOURMETER Solenoid BLACK Hour Meter Hour Meter YELLOW ...

Page 93: ...Page G 15 Repair and Service Manual B B ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 94: ...Page G 16 Repair and Service Manual B ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 95: ... Starter Generator Removal H 10 Starter Generator Installation H 10 LIST OF ILLUSTRATIONS Fig 1 Engine H 1 Fig 2 Cleaning Air Intake H 2 Fig 3 Oil Viscosity Chart H 2 Fig 4 Cleaning Top of the Engine H 3 Fig 5 Cleaning Entire Dipstick H 3 Fig 6 Checking Oil Level on Dipstick H 3 Fig 7 Removing Oil Filter H 3 Fig 8 Air Cleaner H 4 Fig 9 Checking Belt Tension with Gauge H 5 Fig 10 Checking Belt Tens...

Page 96: ...Page H ii Repair and Service Manual B ENGINE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 97: ...s section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Engine Oil Fill Cap Oil Dipstick Starter Generator Air Cleaner Starter Generator Belt Oil Drain Valve Oil Pressure Switch Oil Filter Spark Arrestor Remote Air Hose ...

Page 98: ...J or higher Do not use special additives and do not mix oil with gasoline The selection of oil viscosity is dependent upon the climate in which the vehicle will be used Most vehicles require SAE 30 oil however vehicles used in cold climates will require a mUlti viscosity oil Ref Fig 3 on page H 2 Synthetic oil meeting ILSAC GF 2 API certification mark and API service symbol with SJ CF ENERGY CONSE...

Page 99: ...ced after the first five 5 to eight 8 hours of operation After the initial oil change it should be changed per the Periodic Service Schedule in Sec tion A Be aware that engine fluids may be hot and contact to the skin may cause severe burns Wear rubber gloves to protect skin from expo sure to the old oil and degreaser The oil should be changed with the engine warm Park the vehicle on a level surfa...

Page 100: ...re with the spring clips Access the filters by unsnapping the spring clip on each side of the air cleaner and removing the air cleaner cover Ref Fig 8 on page H 4 If necessary vacuum or wipe out any loose dirt or trash from the air cleaner base Pre Cleaner Service Carefully remove pre cleaner from cartridge and wash it in liquid detergent and water Rinse Dry by squeezing pre cleaner in a clean clo...

Page 101: ...orce starter gen erator towards front of vehicle until proper belt tension is achieved Hold starter generator in place and tighten adjusting bolt Tighten pivot bolts to 25 ft lbs 35 Nm torque SPARK PLUGS Tool List Qty Spark plug socket 5 8 1 Ratchet 1 Plug gauge wire type 1 Anti seize compound AR Torque wrench ft lbs 1 Fig 11 Adjusting the Belt Tension Remove and inspect the spark plugs per the Pe...

Page 102: ...nter the spark plug fires which causes a rapid burn ing of the air fuel mixture The temperature rises rapidly which causes the air fuel mixture to expand The piston has been carried through TDC by centrifugal force and is now forced downwards into the third or power stroke by the expanding gases As the piston reaches BDC it enters the fourth cycle The exhaust valve opens and the piston rises forci...

Page 103: ...uel line 1 Cap for fuel pump 1 Wrench 10mm 1 Wrench 3 4 1 Socket 1 4 hex bit 1 Impact wrench 1 Impact socket 5 8 1 Impact socket 13 16 1 Socket 6mm hex bit 1 Socket 5 8 1 In the following text there are references to removing install ing bolts etc Additional hardware nuts washers etc that is removed must always be installed in its original position unless otherwise specified Non specified torque f...

Page 104: ... hose from air cleaner Remove air cleaner cover and filter Remove five bolts that mount air cleaner base to engine disconnect crankcase breather hose and remove base Secure a clean towel over car buretor with a rubber band to prevent any debris falling into engine At rear axle remove cotter and clevis pin connecting dif ferential lock cable to differential lock arm To maintain cable adjustment loo...

Page 105: ... the driven clutch was and care fully maneuver engine out of vehicle If replacing engine Remove starter generator and its mounting brack ets from old engine Remove choke governor cable bracket from old engine Detach governor cable and choke link from carburetor Remove oil drain valve and clamp from fan cover of old engine Retain for use on new engine ENGINE INSTALLATION Tool List Qty Socket 5 8 1 ...

Page 106: ...en driven clutch bolt to torque specified in CONTIN UOUSLY VARIABLE TRANSMISSION section Center end of exhaust pipe between driven clutch and subframe and tighten clamp till no loose play is present Check oil level in engine and adjust as needed See POWERTRAIN MAINTENANCE on page H 2 Reconnect negative battery cables and tighten hard ware to 60 in lbs 7 Nm STARTER GENERATOR REPLACEMENT Starter Gen...

Page 107: ...o Notices Cautions Warnings and Dangers Fig 17 Starter Generator Mounting Fig 18 Starter Generator Wiring DF Drive Clutch Not Shown For Clarity Front Pivot Bolt Adjusting Bolt Belt Spacer REAR VIEW F1 A2 A1 F2 Rear Pivot Bolt A1 A2 Ground FROM TO F1 On Starter Generator F1 A2 On Starter Generator F2 A on Solenoid DF Green from Voltage Regulator ...

Page 108: ...Page H 12 Repair and Service Manual B ENGINE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 109: ...ent J 6 Rack Replacement J 6 Rack Ball Joint Removal J 6 Rack Ball Joint Installation J 6 Steering Pinion and Bearing Replacement J 7 MAINTENANCE J 7 Lubrication J 7 Wheel Bearing Inspection Packing J 7 Seal Installation J 8 Bearing Adjustment J 8 King Pin Bushing Replacement Torque J 8 Wheel Alignment J 9 LIST OF ILLUSTRATIONS Fig 1 Suspension Components J 2 Fig 2 Front Axle Alignment J 2 Fig 3 R...

Page 110: ... J ii Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 111: ...absorber to clear the mounting bracket Remove clamps securing the boot to the shock absorber and slide boot down and off the shock absorber Replace shock boot and reattach shock absorber as instructed above Front Axle Replacement Tool List Qty Wheel chocks 4 Floor jack 1 Jack stands 2 Impact wrench 1 Impact socket 3 4 1 Pliers 1 Wrench 3 4 1 Plastic faced hammer 1 Socket 9 16 1 Wrench 9 16 1 Torqu...

Page 112: ...pension Components Part of Frame Part of Frame 18 17 20 18 19 11 10 21 8 9 23 2 13 12 1 6 5 4 12 13 22 19 14 16 15 Fig 2 Front Axle Alignment Replace front wheels per WHEELS AND TIRES section and lower vehicle Front Spring Replacement Tool List Qty Wheel chocks 4 Floor jack 1 Jack stands 4 Impact wrench 1 Impact socket 3 4 1 Torque wrench ft Ibs 1 Pliers 1 Wrench 3 4 1 Socket 9 16 1 Wrench 9 16 1 ...

Page 113: ...e front wheels per WHEELS AND TIRES section and lower vehicle Tie Rod Wheel Bearing and King Pin Inspection Grasp the tie rod and check for any vertical motion which would indicate a worn condition and require replacement Grasp the top and bottom of the wheel and use a rocking motion to check for excessive king pin or wheel bearing movement which indicates a worn or loose condition Tie Rod Replace...

Page 114: ...f steering wheel Squeeze tabs to allow insertion of hub Do not force Squeeze hub on top and bottom to fully seat Replace steering wheel by first lightly coating the splines of the steering shaft with a commercially available anti seize compound With the vehicle wheels in the straight ahead position align the steering wheel on the steering shaft and slide wheel on shaft Tighten the steering wheel n...

Page 115: ...e bearing 14 and bushing 15 Ref Fig 6 on page J S The bearing and bushing must be pressed out To remove the steering housing assembly remove the driver side front wheel remove the steering wheel 3 and remove the steering shaft 12 as instructed above Remove the cotter pins and loosen the two nuts 16 until ball joint 17 end threads are protected Using a ball joint separator as a lever apply pressure...

Page 116: ...t Tool List Qty Wrench 9 16 1 Needle nose pliers 1 Wrench 11 16 1 Ball joint separator 1 Plastic faced hammer 1 Straight blade screwdriver 1 The rack can be removed by loosening the tensioner bolts 31 removing cotter pin and backing off nut 20 on rack ball joint 21 until end threads of ball joint are pro tected Ref Fig 6 on page J 5 Using a ball joint separa tor as a lever apply pressure to ball j...

Page 117: ...service schedule or if a bearing replacement is required Routine examination of the tires will provide indications that an alignment is required Lubrication Tool List Qty Grease gun 1 Grease the rack tensioner 26 at fitting 29 the idler bushing 15 at 42 rack ball joint 21 at 43 tie rod ends 17 and spindle 11 Ref Fig 8 on page J 8 per Periodic Service Schedule Do not use more than three 3 pumps of ...

Page 118: ...flange side of the seal facing into the bore Tap gently into place with a seal installation tool until it is flush with the outside of the hub assembly Lubricate the seal surface with a light oil Ref Fig 10 on page J 8 Bearing Adjustment Assemble hub with bearings on spindle Reinstall wheel on hub Rotate the wheel while tightening the castellated nut 1 Ref Fig 11 on page J 8 Tighten the castellate...

Page 119: ...sure the distance between the chalk lines at both the front and rear of the tires Ref Fig 12 on page J 9 The measurement taken at the front of the tire should be 1 4 1 8 6 mm 3 mm less than the rear Manufacturing tolerances may cause some variance however typical dimensions would be 33 1 2 85 cm front and 33 3 4 86 cm rear Fig 12 Front End Alignment To adjust the wheel alignment first turn the ste...

Page 120: ... J 10 Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 121: ...YSTEM COMPONENT SERVICE AND REPLACEMENT K 2 Fuel Lines and Filters K 3 Fuel Pump K 3 Fuel Tank K 3 Choke System K 3 Choke Operation K 3 Choke Cable Removal K 3 Choke Cable Installation and Adjustment K 4 Carburator K 4 WINTER OR PROLONGED STORAGE K 4 LIST OF ILLUSTRATIONS Fig 1 Fuel System Components K 1 Fig 2 Fuel Tank K 2 Fig 3 Choke Cable K 4 ...

Page 122: ...Page K ii Repair and Service Manual B FUEL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 123: ...ilter In the following text there are references to removing installing bolts etc Additional hardware nuts washers etc that are removed must always be installed in their original positions unless otherwise specified Non specified torque specifications are as shown in the table contained in Section A The fuel system consists of a fuel tank fuel lines fuel fil ter fuel pump and carburetor on CARB ve...

Page 124: ...ated gasoline are gasoline blended with alcohols or ethers Excessive amounts of these blends can damage the fuel system or cause performance problems If any undesirable operat ing symptoms occur use gasoline with a lower percent age of alcohol or ether Do not over fill the fuel tank Allow adequate space for the expansion of gasoline Leave at least 1 2 5 cm space below bottom of filler neck The fue...

Page 125: ...r 1 Pliers 1 Wrench 3 8 2 Wrench 1 2 2 Raise passenger seat Remove seat filler panel See BODY AND TRUCKBED section Disconnect fuel hose and gauge wires from tank Remove tank mounting hardware and tank from vehicle Install new fuel tank in reverse order of removal Carburetor Service Be sure that the ignition system is functioning correctly before determining that servicing the carburetor is require...

Page 126: ...ure that there are no sharp bends or kinks in the cable before firmly tightening the jam nuts Carburetor Tool List Qty Pliers 1 Insulated wrench 1 2 1 Wire lead with alligator clips 1 To properly prepare for carburetor service a Disconnect fuel hose at fuel filter and plug ends to prevent contamination Empty carburetor by run ning engine until it stops from lack of fuel b Disconnect negative cable...

Page 127: ...Page K 5 Repair and Service Manual B B FUEL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 128: ...Page K 6 Repair and Service Manual B FUEL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 129: ...Installation L 5 Rear Spring Removal L 5 Rear Spring Installation L 5 LIST OF ILLUSTRATIONS Fig 1 Rear Axle and Suspension components L 1 Fig 2 Checking Adding or Draining Rear Axle Lubricant L 2 Fig 3 Differential Lock Cable Adjustment L 2 Fig 4 Disconnecting Parking Brakes Cables L 3 Fig 5 Disconnecting Brake Lines L 3 Fig 6 Disconnecting Accelerator Cable and Governor L 4 Fig 7 Disconnecting Di...

Page 130: ...ge L ii Repair and Service Manual B REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 131: ...ponents Subframe Rear Axle O I L Shock Absorber Rear Axle Link Spring Frame Shock Stop Mount REAR AXLE Maintenance The rear axle is provided with a lubricant level check plug located on the driver side at rear of housing Unless leakage is evident an annual lubricant check is suffi cient Checking the Lubrication Level Tool List Qty Wrench 13 mm 1 Funnel 1 For vehicles with LSD axle add 2 ounce of f...

Page 132: ...ng Capacity of axle is 48 oz 1 4 liters Differential Lock Cable Adjustment Tool List Qty Wrench 1 2 1 With lever in the unlocked position loosen jam nuts at bracket Ref Fig 3 on page L 2 Tighten front jam nut until arm on differential lock unit begins to pivot Back off front jam nut one turn and hold while tightening rear jam nut Rear Axle Removal Tool List Qty Lug wrench 3 4 1 Wheel chocks 1 Jack...

Page 133: ...ic brakes is required after any hydraulic part is removed or replaced Loosen clamp and remove exhaust pipe from muffler Remove drive belt and driven clutch See CONTINU OUSLY VARIABLE TRANSMISSION section Remove push nut securing end of accelerator cable to governor To maintain cable adjustment loosen only the rear jam nut anchoring accelerator cable to accelerator cable bracket and remove cable Re...

Page 134: ...cting Direction Selector Cables Fig 9 Detaching Differential Link Place floor jack under center section of rear axle and raise it just enough to take weight off springs With both rear axle and frame properly supported remove U bolts mounting axle to subframe Ref Fig 10 on page L 6 Lower rear axle and pull it out from under side of vehi cle Rear Axle installation Rear axle installation is in the re...

Page 135: ...f the rear bumper Remove the bottom shock absorber nut Ref Fig 10 on page L 6 Compress the shock absorber and remove the top shock absorber nut Remove the shock absorber Shock Absorber Installation Shock absorber installation is in the reverse order of dis assembly except that the shock absorber nuts must be tightened until the shock absorber bushings expand to the diameter of the shock absorber w...

Page 136: ...on before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 10 Rear Suspension Shock Stop Mount Front of Vehicle Shock Absorber Front Spring Hardware U Bolt Spring Shock Absorber Nut Washer Bushing Shock Absorber Nut Rear Axle Rear Spring Shackle Assembly ...

Page 137: ...ge L 7 Repair and Service Manual B B REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 138: ...age L 8 Repair and Service Manual B REAR AXLE AND SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 139: ...ESHOOTING M 2 GENERAL CABLE ADJUSTMENT PROCEDURE M 2 ACCELERATOR GOVERNOR CABLE ADJUSTMENT M 2 PEDAL BOX ADJUSTMENTS M 3 Accelerator Pedal Arm Adjustment M 3 Micro Switch Adjustment M 3 Control Arm Link M 4 GOVERNOR COMPRESSION SPRING ADJUSTMENT M 5 Road Test M 5 LIST OF ILLUSTRATIONS Fig 1 Accelerator and Governor System M 1 Fig 2 Cable Adjustment M 2 Fig 3 Accessing Pedal Box M 3 Fig 4 Accelerat...

Page 140: ...ge M ii Repair and Service Manual B ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 141: ...ivates the ignition circuit The rear end of the accelerator rod is joined to the control arm link which in turn is attached to the control arm with a pin which slides within a slot in the control arm link As the accelerator rod moves to the rear of the vehicle the control arm rotates and pulls the accelerator cable When the accelerator cable pulls against the accelerator cable governor spring the ...

Page 142: ... indicate A possible governor failure within the rear axle Worn components in the governor system Improper adjustment of linkage system Other factors may effect the performance characteristics of the vehicle but they should be investigated only after confirming the linkage adjustment GENERAL CABLE ADJUSTMENT PROCEDURE Properly adjusted the cable should be short enough to be slightly loose but not ...

Page 143: ...X ADJUSTMENTS Tool List Qty Wrench 1 2 1 Phillips screwdriver 1 Wrench 7 16 1 Wrench 3 8 1 Socket 1 8 hex bit 1 Ratchet 1 Torque wrench in I bs 1 Crowfoot wrench 1 2 1 White lithium grease 1 Socket 3 8 1 Socket 9 16 1 if any adjustments are made in the Pedal box or accelerator area it is necessary to go back and perform the accelerator governor cable adjustment again This must be done because any ...

Page 144: ...25 43 in Ibs 3 5 Nm torque and be sure that arm rotates smoothly on its shaft If shaft 16 has been removed from pedal box tighten nut 17 to 120 144 in Ibs 14 16 Nm torque Be sure accelerator pedal moves smoothly and acceler ator cable 7 pulls smoothly on governor arm 18 Ref Fig 4 on page M 4 Replace the cover on the pedal box Tap lightly to set the cover before installing screws Replace the access...

Page 145: ...holding governor rod and rotating governor adjuster until a dimension of 1 3 4 44 mm is achieved between the inside of the cup washers 22 This dimension is a start ing point and may be further adjusted after a road test Tighten the jam nut 19 and perform road test See Road Test on page M 5 Road Test Install the negative battery cable Test drive the vehicle and confirm that the compression spring a...

Page 146: ...age M 6 Repair and Service Manual B ELECTRONIC SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 147: ...w Leak N 6 Poor Low Speed Performance N 6 Poor Fuel Economy N 6 Poor Acceleration N 6 Hard Starting N 6 Poor High Speed Operation N 7 Abnormal Combustion Fuel Mixture N 7 Loss of Power Insufficient Fuel N 7 Loss of Power Insufficient Air N 7 Surging N 7 STARTER GENERATOR N 7 Starter is Noisy N 7 Rectification is Imperfect N 8 Generator Does Not Charge N 8 SUSPENSION AND STEERING N 8 Uneven Tire We...

Page 148: ...Page N ii Repair and Service Manual B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 149: ... replace wire and or connections Blown fuse Investigate cause and replace fuse Solenoid faulty If no audible click is heard check power and ground Replace solenoid if power and ground is good Accelerator switch Check continuity Starter generator terminals are loose or corroded Tighten or clean Leads are broken or faulty ground Check for breaks at bend or joint Replace cable Field coils are open Re...

Page 150: ...cted coil wires Check or replace Faulty magneto Check or replace Incorrect spark plug gap type Set gap correctly Fuel pump faulty Repair or replace Fuel line clogged or clamp loose Clean or replace if required Cracked or broken fuel line Replace with new hose Main jet blocked Clean jet Throttle lever motion restricted Check all linkages Dirt or water in fuel line or carburetor Clean lines and carb...

Page 151: ... adjustment Check and adjust Faulty governor adjustment Check and adjust POOR MIDRANGE OR HIGH SPEED PERFORMANCE Spark plug fouled Clean or replace Weak spark Check magneto Carburetor float not level Adjust Incorrect or plugged main jet Check size for appropriate altitude Clean Dirty air filter Clean or replace Brake dragging Perform brake maintenance Low compression Check engine Governor not adju...

Page 152: ...ion Clean fuel system carburetor Incorrect float level Adjust Clogged air filter element Clean or replace EXCESSIVE SMOKING Wrong oil weight Replace with recommended oil Dirty oil Change Crankcase overfilled with oil Drain and fill to recommended level Clogged PCV valve Replace Piston rings worn or broken Replace Valves worn Replace Valve seals or valve guides worn Replace BACKFIRING Accelerator l...

Page 153: ...n with solvent Carburetor float sticking Disassemble and correct per the service manual Faulty fuel pump Check for correct output Verify fuel is not returning through the pulse line Clean vent screen Faulty accelerator adjustment function Correct per the service manual Dirty or restricted air filter Replace and clean air box High pressure in the fuel system Check fuel cap for venting Make sure car...

Page 154: ...VERFLOW LEAK Worn inlet valve or dirty valve seat Replace valve or clean valve seat Worn float mounting tang Replace float Worn float pin Replace pin Damaged float bowl gasket Replace gasket Damaged float Replace float POOR LOW SPEED PERFORMANCE Clogged pilot port Clean pilot port Clogged low speed jet Clean low speed jet Loose low speed jet Tighten jet POOR FUEL ECONOMY Loose jets Tighten jets Ch...

Page 155: ... or replace Clogged air or fuel filter Replace Poor fuel quality Replace with fresh fuel LOSS OF POWER INSUFFICIENT FUEL Faulty fuel pump Replace fuel pump Dirty carburetor Clean carburetor Dirt in fuel tank or hoses Clean Clogged fuel filter Replace fuel filter Air leak in system Check mounting hardware and gaskets Repair or replace LOSS OF POWER INSUFFICIENT AIR Dirty air cleaner Clean replace f...

Page 156: ...e regulator ground connection Repair Open or short circuit Repair or replace Faulty starter generator Repair starter generator Condition Possible Cause Correction Condition Possible Cause Correction UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure Improper alignment Incorrect toe in Align front tires Damaged or worn components Replace STIFF STEERING Rusted or contaminated k...

Page 157: ...Check brake cable and replace if sticky or damaged Brake shoes severely worn Replace Brake shoes glazed Sand shoes with emery cloth provided that shoes have 06 1 5 mm min material System not adjusted properly Check and adjust per manual End of brake cable loose from anchor brackets Check and repair Cracked brake drum Replace IN EXCESS OF 1 2 5 CM FREE PEDAL TRAVEL SOFT PEDAL Low pedal force at par...

Page 158: ...on of wheel that is not locking Sticky dragging cable Check for brake lever return Check that brake levers return at equal rate Indication of dragging cable Cracked brake drum Replace Brake shoes wet or glazed Check again when shoes are dry Rusted or sticky brake pivot hardware Replace NEITHER WHEEL LOCKS Brake system requires complete adjustment Adjust entire system Brake pedal not returning Chec...

Page 159: ...Page N 11 Repair and Service Manual B B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 160: ...Page N 12 Repair and Service Manual B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 161: ...rvice Manual WEATHER PROTECTION SUN TOP AND WINDSHIELD P 1 Trailering P 1 SUN TOP P 1 Rear Support Installation P 1 Front Struts P 1 Sun Top P 1 SPLIT WINDSHIELD P 3 FULL WINDSHIELD P 3 LIST OF ILLUSTRATIONS Fig 1 Sun Top P 2 Fig 2 Split Windshield P 3 Fig 3 Full Windshield P 4 ...

Page 162: ...Page P ii Repair and Service Manual B WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 163: ...e the vehicle to the trailer using ratchet tie downs SUN TOP Tool List Qty Plastic faced mallet 1 Wrench 1 2 2 Wrench 9 16 2 Hex wrench 7 32 1 Straight blade screwdriver 1 Rear Support Installation At driver side of vehicle align the holes in the rear strut 5 with the holes in the seat back support bracket being sure that the open end of the strut faces the front of the vehicle as shown See Detail...

Page 164: ...ure Pay particular attention to Notices Cautions Warnings and Dangers Fig 1 Sun Top B A C D Front of Vehicle D Bumper Front of Vehicle A seat back support seat Front of Vehicle C Front of Vehicle B 3 21 13 20 7 18 3 5 3 9 1 5 11 10 6 4 7 6 16 15 17 5 2 CANOPY STRUT KIT includes item 3 8 8 HARDWARE KIT includes item 9 16 18 ...

Page 165: ...it snaps into place See Details B and C Repeat for opposite side of windshield Position top grips 8 as shown See Detail D at top hole on each side of front strut Secure with top grip fasteners 9 Fig 2 Split Windshield Strut Rubber Latch Front of Vehicle Windshield Retainer Strut Front of Vehicle DETAIL D DETAIL B 9 8 2 3 7 5 6 5 4 Windshield DETAIL A 3 Windshield DETAIL C 3 It may be necessary on ...

Page 166: ...ts properly See Detail A Insert screw 4 through washer 5 rubber grommet 6 and existing hole in front strut Secure with washer 5 and lock nut 7 See Detail B Do not over tighten or squeeze grommet Place bottom section of windshield on rubber grommets and press the sash starting at the bottom onto the front strut so that it snaps into place See Details B and C Repeat for opposite side of windshield F...

Page 167: ...Page P 5 Repair and Service Manual B B WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 168: ...Page P 6 Repair and Service Manual B WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 169: ...CONTENTS FOR SECTION Q SECTION TITLE PAGE NO Page Q i Repair and Service Manual WHEELS AND TIRES WHEEL AND TIRE SERVICE Q 1 Tire Repair Q 1 Wheel Installation Q 2 LIST OF ILLUSTRATIONS Fig 1 Wheel and Tires Q 2 ...

Page 170: ...Page Q ii Repair and Service Manual B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 171: ... caution when inflating tires Due to the low volume of these small tires over inflation can occur in a matter of seconds Over inflation could cause the tire to sepa rate from the rim or cause the tire to explode either of which could cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure F...

Page 172: ...ll assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub with lug nuts Be sure to position the wheel on hub correctly with arrow indicating direction of rotation when moving forward Finger tighten lug nuts in a cross sequence pattern Ref Fig 1 on page Q 2 Then tighten lug nuts to 50 85 ft Ibs 70 115 Nm torque in 20 ft Ibs 30 Nm increments ...

Page 173: ...Page Q 3 Repair and Service Manual B B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 174: ...Page Q 4 Repair and Service Manual B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 175: ... SECTION R SECTION TITLE PAGE NO Page R i Repair and Service Manual GENERAL SPECIFICATIONS TERRAIN 1500 R 1 LIST OF ILLUSTRATIONS Fig 1 Vehicle Dimensions R 2 Fig 2 Incline Specifications and Turning Clearance Diameter R 3 ...

Page 176: ...age R ii Repair and Service Manual B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 177: ...m Vehicle load capacity 800 lb 360 kg Cargo Box Width inside 44 0 in 112 0 cm Outside Clearance Circle 23 5 ft 7 2 m Cargo Box Length inside 36 0 in 91 0 cm Intersecting Aisle Clearance N A Cargo Box Depth inside 10 5 in 27 0 cm Speed Level Ground 16 mph 0 5 mph 25 7 kph 0 8 kph Cargo Box Capacity 9 6 cu ft 0 27 m3 Towing Capacity 500 lb 225 kg Cargo Box Material Roto molded polyethylene Steering ...

Page 178: ...ns Warnings and Dangers 34 in 86 0 cm 10 5 in 27 0 cm 18 in 46 0 cm 6 in 15 cm Ground Clear ance 110 5 in 281 0 cm 49 0 in 125 0 cm 78 5 in 199 0 cm 15 in 38 cm 44 0 in 122 0 cc 36 0 in 91 0 cm Rear 38 0 in 96 cm Front 38 5 in 97 cm TERRAIN 1500 75 0 in 191 0 cm Maximum Recommended Side Tilt 25 or 14 Max Maximum Recommended Ramp Grade 25 or 14 Max Fig 1 Vehicle Dimensions ...

Page 179: ...FICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TURNING CLEARANCE DIAMETER Approx 23 5 ft 7 2 m Fig 2 Incline Specifications and Turning Clearance Diameter ...

Page 180: ...Page R 4 Repair and Service Manual B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 181: ......

Page 182: ... of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Genuine E Z GO Parts Accessories Department or at www shopezgo com ...

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