E-Z-GO RXV GASOLINE Service & Repair Manual Download

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RXV GASOLINE SERVICE & REPAIR

ISSUED FEBRUARY 2009 REVISED APRIL 2010

611104

Summary of Contents for RXV GASOLINE

Page 1: ...RXV GASOLINE SERVICE REPAIR ISSUED FEBRUARY 2009 REVISED APRIL 2010 611104...

Page 2: ...ry posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm BATTERY WARNING WASH HANDS AFTER HANDLING WARNING Battery posts termina...

Page 3: ...nual may be revised periodically by the E Z GO Division and therefore is subject to change without notice The E Z GO Division DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and the E Z GO Division SPEC...

Page 4: ...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...

Page 5: ...RAL INFORMATION ROUTINE MAINTENANCE A SAFETY B BODY C WHEELS AND TIRES D FRONT SUSPENSION AND STEERING E SPEED CONTROL F ENGINE G FUEL SYSTEM H CONTINUOUSLY VARIABLE TRANSMISSION CVT J DIRECTION SELEC...

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

Page 7: ...of the product On behalf 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 pro...

Page 8: ...e environment Additionally speed should be further moderated by the environmental conditions terrain and common sense GENERAL OPERATION Always Use the vehicle in a responsible manner and maintain the...

Page 9: ...not be operated Test drive the vehicle after any repairs or maintenance All tests must be conducted in a safe area that is free of both vehicular and pedestrian traffic Replace damaged or missing war...

Page 10: ...Repair and Service Manual Page viii SAFETY INFORMATION Notes...

Page 11: ...TRAIN MAINTENANCE A 3 BRAKES A 3 TIRES A 4 VEHICLE CLEANING AND CARE A 4 SUN TOP AND WINDSHIELD A 4 HAULING A 4 WINTER OR PROLONGED STORAGE A 5 HARDWARE A 5 PERIODIC SERVICE SCHEDULE A 6 LIST OF ILLUS...

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

Page 13: ...vehicle model serial number and manufac ture date code SERIAL NUMBER LOCATION Three serial number and manufacture date code plates are on the vehicle One is placed on the steering col umn the second...

Page 14: ...er form properly as the result of normal use age wear or abuse It is virtually impossible to anticipate all possible compo nent failures or the manner in which each component may fail A vehicle requir...

Page 15: ...ce direction selector in R and remove seat Pull out 1 and rotate 2 the neutral lock pin handle so that the pointed portion of the handle is over the side of the direction selector cam Move direction s...

Page 16: ...indshield with lots of water a mild soap and a clean cloth Removal of oil tar asphalt shoe polish etc requires the use of a commercially available vinyl rubber cleaner The painted surfaces of the vehi...

Page 17: ...n the engine Preparing the engine for winter or a prolonged storage calls for a few simple steps to prevent build up of var nish and gum in the carburetor and corrosion in the en gine Place the direct...

Page 18: ...n a hill C A C A C A C A Accelerator smooth operation Starter Generator Belt tension wear cracks Fig 7 PERIODIC SERVICE SCHEDULE Initial oil change after 8 hours of run time NOTE Some maintenance item...

Page 19: ...ing fins CL CL CL CL Steering Assembly excessive play loose or missing hardware Tie Rods excessive play bent rods loose or missing hardware Rear Axle fluid level oil leakage noise loose or missing ha...

Page 20: ...check replace as necessary Drive Belt cracks frayed excessive wear REMARKS before each use DAILY WEEKLY 20 rnds 20 hrs 100 miles 160 kms MONTHLY 60 rnds 60 hrs 300 miles 500 kms QUARTERLY 125 rnds 12...

Page 21: ...9 Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings GENERAL INFORMATION ROUTINE MAINT...

Page 22: ...10 Repair and Service Manual Notes GENERAL INFORMATION ROUTINE MAINTENANCE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and W...

Page 23: ...ervice Manual NOTES CAUTIONS AND WARNINGS 1 IMPORTANT SAFETY WARNING 1 MODIFICATIONS TO VEHICLE 1 GENERAL MAINTENANCE 1 BEFORE SERVICING THE VEHICLE 1 Battery Removal and Installation 2 LIFTING THE VE...

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

Page 25: ...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 shoul...

Page 26: ...to 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...

Page 27: ...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 vehi...

Page 28: ...e two jack stands Place the jack 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 vehic...

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

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

Page 31: ...pair C 12 LIST OF ILLUSTRATIONS Fig 1 Body C 1 Fig 2 Christmas Tree Rivet Removal C 1 Fig 3 Front Bumper C 2 Fig 4 Rocker Panel Removal C 2 Fig 5 Floor Mat Fastener Removal C 3 Fig 6 Floor Mat C 3 Fig...

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

Page 33: ...s be removed before any servicing that could gen erate sparks or repairs that require welding or cutting In general body component replacement can be accom plished with a minimum of specialized tools...

Page 34: ...re as required It is recommended that all locking nuts be replaced after 5 removals Fig 3 Front Bumper and Cowl Support Rocker Panels Ref Fig 4 Tool List Qty Torx Bit T 45IP 1 Ratchet 1 Torque Wrench...

Page 35: ...panels and the floor mat as described in the previous sections 1 Remove four torx screws 11 securing the trim panel 12 to the instrument panel 13 and cowl 14 2 Locate the tab in the fender well area...

Page 36: ...ent panel 1 Remove two christmas tree rivets 22 securing front splash guard 21 to vehicle Ref Fig 2 Reassemble in reverse order Replace any worn or damaged hardware as required Fig 9 Front Splash Guar...

Page 37: ...worn or damaged hardware with new as required It is recommended that all locking nuts be replaced after 5 removals Fender Liner Ref Fig 2 Ref Fig 10 Tool LIst Qty Notched Pry Bar 1 NOTE The fender li...

Page 38: ...inge plates 7 Remove two inner torx screws 34 from the back edge of seat opening in the rear body 8 Remove four torx screws 31 from the lower edge of the rear body two on the driver side and two on th...

Page 39: ...1 Ratchet 1 Torque Wrench ft lbs 1 Wrench 15 mm 1 1 Remove four hex head bolts 10 that secure the seat bottom to the hip restraints 2 Lift the seat bottom 11 up and remove it from the vehicle Fig 12 R...

Page 40: ...head bolts 23 that secure the driver side hip restraint to the seat back support 8 Hold or support the hip restraint before removing the torx head bolts 23 once these bolts are removed the hip restrai...

Page 41: ...sulated Wrench 9 16 1 Torque Wrench ft lbs 1 Before the floorboard can be removed the lower and upper rocker panels the floor mat the pedal cover accel erator and brake pedal assemblies the instrument...

Page 42: ...m Cut Rubbing Compound 1 qt 3 M 39003 Finishing Material 1 qt 3 M 39009 Polishing Pad Glaze for dark colors 1 qt 3 M 05995 Polishing Pad Glaze for light colors 1qt Coarse Cut Foam Compound Pad for Buf...

Page 43: ...Cut Foam Compound Pad for Buffer 1 Fine Cut Polish Pad for Buffer 1 Sandpaper 1200 Grit wet or dry 1 Sandpaper 1500 Grit wet or dry 1 Wet Sanding Block 1 Soft Clean Cotton Cloths Masking Tape For larg...

Page 44: ...Page C 12 Repair and Service Manual Notes BODY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 45: ...S FOR SECTION D SECTION TITLE PAGE NO WHEELS AND TIRES Page D i Repair and Service Manual WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 2 LIST OF ILLUSTRATIONS Fig 1 Wheel and Tire I...

Page 46: ...Page D ii Repair and Service Manual Notes WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 47: ...personal injury Tire inflation should be determined by the condition the terrain See GENERAL SPECIFICATIONS section for recommended tire inflation pressure For outdoor appli cations with major use on...

Page 48: ...pattern when installing lug nuts This will assure even seating of the wheel against the hub With the valve stem to the outside mount the wheel onto the hub Install lug nuts 1 finger tight make sure t...

Page 49: ...l E 6 Steering Column Assembly and Yoke E 7 Rod End Ball Joint E 7 Steering Box E 8 LIST OF ILLUSTRATIONS Fig 1 Front Suspension and Steering E 1 Fig 2 Tire Wear E 2 Fig 3 Wheel Alignment E 2 Fig 4 Ti...

Page 50: ...ge E ii Repair and Service Manual Notes FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnin...

Page 51: ...ng any repair procedure NEVER work on a vehicle that is supported by a jack alone MAINTENANCE Routine maintenance of the front suspension and steer ing consists of Periodic inspections for loose worn...

Page 52: ...t lbs 1 Socket 18 mm 1 Ratchet 1 1 Lift the front of the vehicle and support on jack stands as instructed in the SAFETY section 2 Rotate each wheel and scribe a paint line around the circumference of...

Page 53: ...quired It is recom mended that locking nuts be replaced after a maxi mum of 5 removals Spindle Assembly Ref Fig 5 Tool List Qty Wrench 16 mm 1 Socket 16 mm 1 Socket 18 mm Deep well 1 Ratchet 1 Torque...

Page 54: ...the spindle arm until it is flush with the end of the tie rod end 2 Using a ball joint separator as a lever apply pressure to the ball joint and tap the spindle arm sharply with the hammer to release...

Page 55: ...escribed in the Wheels and Tires section of this manual 1 Remove the hex head bolt 11 securing the a arm 13 to the strut 2 Remove bushings 14 16 from a arm being careful to retain sleeve 15 3 Inspect...

Page 56: ...ard retaining tabs Fig 6 Clipboard Removal 3 Loosen the steering wheel retaining nut two or three turns Do not remove nut at this time 4 Apply upward pressure to the steering wheel by plac ing a plast...

Page 57: ...scribed in the Electrical Wiring section of this manual 2 Remove the lower cross bolt 8 from the yoke Fig 9 Lower Cross Bolt 3 Remove four torx head screws 9 securing steering column assembly to vehic...

Page 58: ...ator 1 Ball Peen Hammer 1 Inspect rod end or ball joint by grasping the end and checking for vertical motion If the rod moves up or down this is an indication that the ball joint is worn and requires...

Page 59: ...e yoke to the steering box pinion 6 Loosen the upper cross bolt securing the yoke to the intermediate shaft 7 Remove the yoke from the steering box pinion by slid ing it up the intermediate shaft 8 Re...

Page 60: ...ge E 10 Repair and Service Manual Notes FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnin...

Page 61: ...at Governor F 3 Accelerator Cable Removal and Installation at Pedal F 3 Accelerator Pedal Arm Adjustment F 3 Road Test F 3 Accelerator Pedal Assembly F 4 LIST OF ILLUSTRATIONS Fig 1 Accelerator and Sp...

Page 62: ...Page F ii Repair and Service Manual Notes SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 63: ...orted by a jack alone SYSTEM OPERATION As the accelerator pedal is depressed the parking brake if applied is released and the accelerator cable pulls against the governor spring When the accelerator c...

Page 64: ...e investigated only after confirming the linkage adjustment SPEED CONTROL Tool List Qty Phillips Screwdriver 1 Flat Blade Screwdriver 1 Needle Nose Pliers 1 Slip Joint Pliers 1 Open End Wrench 10 mm 2...

Page 65: ...e For fleet vehicles drive the vehicle at the max imum governed road speed the engine should run at a maximum of 2500 RPM Accelerator Cable Removal and Installation at Pedal To access the accelerator...

Page 66: ...rator pedal assembly is a modular unit the only serviceable items contained in the assembly are the pedal pad and the throttle switch The complete pedal assembly may be replaced as a unit To access th...

Page 67: ...fore attempting any procedure Pay particular attention to all Notices Cautions and Warnings B B Install the pedal cover floor mat and rocker panels Replace worn or damaged hardware as required ITEM TO...

Page 68: ...Page F 6 Repair and Service Manual SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings Notes...

Page 69: ...he Engine from the Vehicle G 11 Engine Installation G 11 DRIVE CLUTCH REMOVAL G 11 LIST OF ILLUSTRATIONS Fig 1 Clean Entire Dipstick G 1 Fig 2 Check Oil Level on Dipstick G 1 Fig 3 Oil Viscosity Chart...

Page 70: ...Page G ii Repair and Service Manual Notes ENGINE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 71: ...ating range as indicated on the dip stick Do not operate vehicle if oil level is below the safe area indicated on the dipstick Oil should be added to bring the level into the safe oper ating range Rem...

Page 72: ...burn you severely Place the oil drain pan under the oil drain plug 1 found at the rear of the engine base Remove the drain plug 1 allow the oil to drain into the drain pan Fig 5 Oil Drain Plug Before...

Page 73: ...overfill engine Too much oil may cause smok ing or allow oil to enter the air filter enclosure Fig 8 Add Engine Oil Both the oil dipstick and fill cap must be in place before operat ing the engine Fa...

Page 74: ...over clip is fastened securely STARTER GENERATOR BELT TEN SION Tool List Qty Belt Tension Gauge 1 Wrench 13 mm 1 Wrench 14 mm 2 Wrench 15 mm 1 Ratchet 1 Socket 13 mm 1 Socket 15 mm 1 The starter gener...

Page 75: ...torque value STARTER GENERATOR REPLACE MENT Ref Fig 13 Tool List Qty Wrench 8 mm 1 Wrench 10 mm 1 Wrench 13 mm 1 Wrench 14 mm 2 Wrench 15 mm 1 Ratchet 1 Socket 13 mm 1 Socket 15 mm 1 Torque wrench ft...

Page 76: ...xtension 1 Torque Wrench ft lbs 1 This engine uses Spark Plug NGK BPR2ES with a gap of 028 031 70 80 mm Using a 13 16 spark plug socket or wrench remove the spark plug at 125 hours or semi annually an...

Page 77: ...hoke valve fully open Attach the compression gauge 1 to the adapter 2 and insert firmly into the plug hole Fig 19 Compression Gauge Place the spark plug cap 3 on the removed spark plug 4 and ground th...

Page 78: ...Place the piston at TDC of the compression stroke turning the crankshaft in its rotational direction Then check the valve clearance with a feeler gauge 7 measure the valve clearance between the rocker...

Page 79: ...t by rotating clutch toward rear of vehicle when the belt is slipped off the top of the clutch Remove belt from vehicle 5 Disconnect the DF wire from starter using 8mm wrench lay harness out of the wa...

Page 80: ...gine from the Vehicle Place suitable blocks under the engine frame for support Although the blocks are not required for engine removal they will help maintain the alignment of the frames and simplify...

Page 81: ...filled with grease Install the clutch puller and use the impact wrench to drive off the clutch The combination of hydraulic pressure grease and the impact wrench will remove the most stubborn clutch...

Page 82: ...Page G 12 Repair and Service Manual Notes ENGINE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 83: ...sing Removal H 3 Choke Cable and Housing Installation H 3 Carburetor Service H 3 Carburetor Removal H 3 Carburetor Disassembly H 4 Float Level Alignment H 5 Carburetor Installation H 5 FUEL PUMP H 6 F...

Page 84: ...Page H ii Repair and Service Manual Notes FUEL AIR SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 85: ...el near open flame or elec trical items which could produce a spark Always wear safety glasses while refueling to prevent pos sible eye injury from gasoline or gasoline vapor When refueling inspect th...

Page 86: ...on is to deliver fuel to the engine during acceleration and heavy load conditions Fuel flow is determined by the main jet size Air is mixed with fuel that passes through the bleed opening in the main...

Page 87: ...ons unless otherwise specified Non specified torque specifications are as shown in the table contained in Section A Feed the choke cable assembly 8 through the hole in the bezel 8 Ref Fig 3 Insert the...

Page 88: ...he outside of the carburetor thoroughly with solvent All work should be done on a clean surface Care should be taken when disassembling the carburetor or removing the jets Most carburetor malfunctions...

Page 89: ...r free movement of the choke shaft before installing the carburetor Lubricate the bushings with WD 40 oil or equivalent Fig 7 Float Adjustment Carburetor Installation To prevent possible injury from e...

Page 90: ...ting the oil and possible engine damage The length of the pulse hose from the fuel pump is important for efficient pump operation If the hose is to be replaced be sure to replace with a hose of the sa...

Page 91: ...er is marked with a flow direction arrow Be sure that the arrow points towards the fuel pump To prevent possibility of injury from explosion or fire never attempt to repair a damaged or leaking fuel t...

Page 92: ...Page H 8 Repair and Service Manual Notes FUEL AIR SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 93: ...2 Equilibrium J 2 Removing the Drive Belt J 2 Drive Belt Service J 2 Drive Clutch Removal J 2 Drive Clutch Installation J 4 Driven Clutch Removal J 4 Driven Clutch Repair J 4 Torque Ramp Buttons J 4 D...

Page 94: ...ii Repair and Service Manual Notes CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Wa...

Page 95: ...depressed the engine speed is increased which causes the cams weights within the centrifugal drive clutch to move outwards and force the moveable sheave inwards The drive belt is engaged by the clutc...

Page 96: ...e centrifugal 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 with...

Page 97: ...19 mm bolt 2 from the center of the drive clutch 5 Raise the frame with the floor jack so that the power train drops and the clutch puller bolt clears the spring hanger Remove the front eyebolt from t...

Page 98: ...clutch from the rear axle input shaft Driven Clutch Repair Parts must be reassembled in same position as their original position Mark all components to facilitate accurate reassem bly Some minor field...

Page 99: ...5 Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings CONTINUOUSLY VARIABLE TRANSMISSI...

Page 100: ...6 Repair and Service Manual Notes CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Wa...

Page 101: ...anual DIRECTION SELECTOR K 2 Direction Selector K 1 Micro Switch K 1 Shift Cable Adjustment K 2 Neutral Lock Operation K 2 LIST OF ILLUSTRATIONS Fig 1 Direction Selector K 1 Fig 2 Direction Selector H...

Page 102: ...Page K ii Repair and Service Manual Notes DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 103: ...an electrical explosion be sure that the key switch is off and all electrical accessories are turned off before starting work on vehicle Never disconnect a circuit under load at a bat tery terminal Th...

Page 104: ...at the forward cable mount while selec tor is in the REVERSE position until direction selector cam will contact both stops or contacts the reverse stop and maintains no more than an 1 8 gap at the FOR...

Page 105: ...Page K 3 Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings B B Fig 5 Neutral Lock Return to...

Page 106: ...Page K 4 Repair and Service Manual Notes DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 107: ...air and Replacement L 7 BATTERY VOLTAGE TEST L 7 STORAGE OF BATTERY L 8 DVOM DIGITAL VOLT OHM METER L 8 Fig 9 DVOM L 9 TROUBLESHOOTING L 9 POWER SUPPLY L 9 ACCESSORY WIRING L 10 LIST OF ILLUSTRATIONS...

Page 108: ...Page L ii Repair and Service Manual Notes ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 109: ...enerator func tions as a generator This is used for charging the bat tery and for the ignition system Generated output is controlled by the voltage regulator at 14 25 14 75 V without regard to engine...

Page 110: ...BLUE 1 8 5 4 BLK BLK GRN REVERSE MICRO REF ONLY GND TO ELE PLATE STARTER GENERATOR REF ONLY TO ENGINE REF A A B B B C D D E F 6 GA BLACK WIRE REF ONLY DF A1 A2 F2 F1 REV BUZZER RED WHT PEDAL BOX BRN F...

Page 111: ...s not grounded properly If the engine will not run but the starter will turn the engine proceed as follows 1 Check for loose terminals wires and connections 2 Check for an electrical discharge through...

Page 112: ...wn in the following illustrations Fig 3 Resistance Between A B and A C A normal reading with the negative lead on A and the positive lead on B would be 2 18 K A normal reading with the negative lead o...

Page 113: ...be on terminal A of the solenoid Place the positive probe on terminal B The DVOM should indicate approximately 12 V b Press the accelerator pedal The DVOM will indi cate 0 voltage if the solenoid cont...

Page 114: ...sh holder insulators Check the brushes for length approximately 11 16 17 mm or to the line marked on the brush and signs of carbonization 3 Inspect the armature for distortion or broken wires 4 Inspec...

Page 115: ...ing a DVOM check the field coils for continuity between F1 and F2 and DF and F1 If an open circuit exists replace the field coils Check for continuity between all four terminals and the frame outer sh...

Page 116: ...e problem Example 1 If the vehicle will not start and none of the lights function or burn dimly the battery should be tested before trying to troubleshoot the lighting circuit Example 2 If a problem o...

Page 117: ...th the test Due to the resistance of the wires involved within the harness voltage readings may be somewhat lower than battery voltage A reading of 1 volt below battery voltage is acceptable 3 Check p...

Page 118: ...B A A B B A BLK PS HEADLIGHT HORN SWITCH BLK YEL BLK BRN WHT BRN GRY BRAKE RELAY GRY TURN SIGNAL BRAKE TIMER RELAY GRN WHT BRAKE SWITCH GRY GRY GRY BRAKE LIGHT JUMPER RECEPTACLE YEL WHT DS HEADLIGHT...

Page 119: ...Page L 11 Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings ELECTRICAL...

Page 120: ...Page L 12 Repair and Service Manual Notes ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 121: ...Backing Plate Entire Wheel Brake Assembly Removal and Installation M 12 Brake Shoe and Adjuster Replacement M 12 Brake Cable Snap Ring Removal M 13 Brake Cable and Equalizer Assembly Removal and Inst...

Page 122: ...Page M ii Repair and Service Manual Notes MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 123: ...brake will not be adequate The self adjusting mechanism in the wheel brakes requires enough cable travel at the wheel brake to work reliably When the brake is released there must be slack in the syst...

Page 124: ...released position Fig 2 Wheel Brake Adjustment How the Parking Brake Works The parking brake is operated by a smaller pedal which extends across the top of the service brake pedal It is attached to th...

Page 125: ...rts per the Troubleshooting Table Then perform the Periodic Brake Performance Test to evaluate system performance Based on the results of the inspection and tests refer to the Troubleshooting Table in...

Page 126: ...ve freely and be free of corro sion The kick off cam should rotate when the acceler ator pedal is depressed Periodic Brake Performance Test PBPT To prevent severe injury or death resulting from operat...

Page 127: ...oose If they are loose return vehicle to ser vice If they are tight adjust free travel Adjusting Brake Pedal Free Travel on Page M 8 Then repeat the Periodic Brake Performance Tests If vehicle fails r...

Page 128: ...ere injury or death 2 Inspect the brake drum Look for a blue coloration or blistered paint that would indicate that it has overheated Check for evidence of scoring Check for excessive wear indicated b...

Page 129: ...chor assembly Replace both backing plates if any gouges or galling is found 9 Measure the brake shoe thickness Measure at the most worn area Brake shoe thickness must never be less than 060 1 5 mm at...

Page 130: ...of worn components is critical to the operation of the brake system In some cases component replacement may be more cost effective than the removal cleaning inspec tion and reassembly of the component...

Page 131: ...a safe location free from people and vehicles drive the vehicle at reduced speed and apply the brakes aggressively As the brakes adjust and stop the vehicle effectively start driving at maximum speed...

Page 132: ...the adjuster and require that both wheel brake assemblies be replaced If the drum does not slide from the brake assembly the brake shoes must be retracted Rotate the hub so that the hole in the drum...

Page 133: ...not use com pressed air to remove brake dust from brake assembly Do NOT use a commercial brake cleaner unless the entire brake has been disassembled Remove any accumulated brake dust with a brush Remo...

Page 134: ...n to 23 28 ft lbs 31 38 Nm torque Brake Shoe and Adjuster Replacement It is recommended that when brake shoes are replaced the adjusters and springs also be replaced It is good practice to do one side...

Page 135: ...oks installed down through the brake shoes Check to see that the brake is functioning properly Install the brake drum Brake Drum Removal and Installa tion on Page M 10 Repeat on other side of vehicle...

Page 136: ...attention to all Notices Cautions and Warnings B Fig 17 Brake Cable Equalizer and Compensator BRAKE TROUBLESHOOTING Refer to the following troubleshooting table in Section S only after the thorough vi...

Page 137: ...Page M 15 Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings MECHANICAL BRAKES...

Page 138: ...Page M 16 Repair and Service Manual Notes MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 139: ...N N SECTION TITLE PAGE NO REAR SUSPENSION Page N i Repair and Service Manual GENERAL N 1 SHOCK ABSORBER N 1 REAR LEAF SPRING N 3 LIST OF ILLUSTRATIONS Fig 1 Rear Suspension N 1 Fig 2 Shock Absorber N...

Page 140: ...Page N ii Repair and Service Manual Notes REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 141: ...rame The removal of the rear axle is covered in the section in this book titled REAR AXLE SHOCK ABSORBER Ref Fig 2 Tool List Qty Wheel Chocks 4 Jack Stands 4 Floor Jack 1 Insulated Wrench 9 16 1 Torx...

Page 142: ...laced and the rear axle is not being removed it is important to remove and replace one leaf spring at a time It is recommended that leaf springs be replaced in pairs Removal 1 Raise the rear of the ve...

Page 143: ...osition the shackle plates 12 over the bushings and install the hex head bolt 15 and nut 11 13 Install the remaining pair of flanged urethane bushings 13 and spacer 14 in the leaf spring 16 Position t...

Page 144: ...Page N 4 Repair and Service Manual Notes REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 145: ...sassembly P 2 Axle Shaft Seal Removal and Replacement P 3 Axle Shaft Replacement P 3 LIST OF ILLUSTRATIONS Fig 1 Neutral Lock Direction Selector P 1 Fig 2 Add Check and Drain Rear Axle Lubricant P 1 F...

Page 146: ...Page P ii Repair and Service Manual Notes REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 147: ...s locked in the neutral position To activate the direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole 3 in the direction select...

Page 148: ...gardless of mileage Always wipe the seals and O rings with a light oil before installing To reduce the possibility of personal injury fol low the lifting procedure in SAFETY section of this manual Pla...

Page 149: ...nner surface of axle tube at the sealing area Replace the seal by lightly tapping around the circum ference with a plastic faced hammer Tighten bolts 4 to 26 31 ft lbs 35 42 Nm torque Axle Shaft Repla...

Page 150: ...Page P 4 Repair and Service Manual Notes REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 151: ...E PAGE NO WEATHER PROTECTION Page Q i Repair and Service Manual TOP AND WINDSHIELD Q 1 WINDSHIELD Q 2 GOLF CAR TOP Q 2 2 2 TOP Q 4 LIST OF ILLUSTRATIONS Fig 1 Top and Windshield Q 1 Fig 2 Windshield Q...

Page 152: ...Page Q ii Repair and Service Manual Notes WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 153: ...ter and a clean cloth Minor scratches in the windshield may be removed using a commercial plastic polish or Plexus plastic cleaner Trailering Personal injury to occupants of other highway vehicles may...

Page 154: ...is equipped with a windshield remove it before working with the top Removal 1 Remove six flanged hex nuts 1 and the hex bolts 2 securing the top to the struts 2 Lift the top off of the struts and set...

Page 155: ...head bolts 5 and nuts 4 finger tight only 4 Place the top onto the struts and install six hex head bolts 2 down through the top and struts place the nuts 1 on finger tight 5 Make sure that the grommet...

Page 156: ...1 Ratchet Extension 1 Wrench 15 mm 1 Torque Wrench Inch Pound 1 Flat Screwdriver 1 If vehicle is equipped with a windshield remove it before working with the top Removal 1 Remove four hex nuts 10 and...

Page 157: ...sition the front strut 4 with the bend angled to the rear of the vehicle slide the strut through the grom mets and into position Looking through the access holes align the holes in the strut with the...

Page 158: ...Page Q 6 Repair and Service Manual Notes WEATHER PROTECTION Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings...

Page 159: ...r Low Speed Performance S 6 Poor Fuel Economy S 6 Poor Acceleration S 6 Hard Starting S 6 Poor High Speed Operation S 7 Abnormal Combustion Fuel Mixture S 7 Loss of Power Insufficient Fuel S 7 Loss of...

Page 160: ...Page S ii Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 161: ...eld coils are open Replace fields Armature coil is open Replace armature STARTER TURNS SLOWLY Terminals are loose or corroded Retighten or clean Weak battery Charge battery Leads are nearly broken or...

Page 162: ...er or pipe Repair or replace Low compression in engine Check and repair ENGINE RUNS ROUGH OR LOSS OF POWER Dirty or clogged air filter element Replace as required Incorrect choke adjustment Adjust cho...

Page 163: ...justment 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 Adj...

Page 164: ...lve seat dirty Clean or replace Fuel contamination Clean fuel system carburetor Incorrect float level Adjust Clogged air filter element Clean or replace EXCESSIVE SMOKING Wrong oil weight Replace with...

Page 165: ...ct 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...

Page 166: ...FLOW 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 floa...

Page 167: ...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...

Page 168: ...egulator ground connection Repair Open or short circuit Repair or replace Faulty starter generator Repair starter generator Condition Possible Cause Correction Condition Possible Cause Correction UNEV...

Page 169: ...ck 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 pro...

Page 170: ...et 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 C...

Page 171: ...Page S 11 Repair and Service Manual Notes Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings TROUBLESHOOTING...

Page 172: ...Page S 12 Repair and Service Manual Notes TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 173: ...Repair and Service Manual LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION T SECTION TITLE PAGE NO FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY T 1 CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATE...

Page 174: ...Page T ii Repair and Service Manual Notes LIMITED WARRANTY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notices Cautions and Warnings...

Page 175: ...ic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connect...

Page 176: ...s MAINTENANCE REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL HOWEVER WARRANTY REPAIRS MUST BE PERFORMED BY A DISTRIBUTOR DEALE...

Page 177: ...urchased LENGTH OF COVERAGE This warranty shall be for a period of two 2 years from the initial date of purchase WHAT IS COVERED REPAIR OR REPLACEMENT OF PARTS Repair or replacement of warranted part...

Page 178: ...Page T 4 Repair and Service Manual VEHICLE WARRANTIES Notes...

Page 179: ...ervice Manual RXV GAS FLEET VEHICLE SPECIFICATIONS U 1 RXV GAS FREEDON VEHICLE SPECIFICATIONS U 2 RXV GAS SHUTTLE 2 2 VEHICLE SPECIFICATIONS U 3 Fig 1 Fleet Freedom Vehicle Dimensions U 4 Fig 2 Shuttl...

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

Page 181: ...PENSION Coil springs over hydraulic shock absorbers REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Single reduction rack pinion STEERING WHEEL Dual handgrips scorecard holder pen...

Page 182: ...over hydraulic shock absorbers REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Single reduction rack pinion STEERING WHEEL Dual handgrips scorecard holder pencil holder SEATING Fo...

Page 183: ...USPENSION Coil springs over hydraulic shock absorbers REAR SUSPENSION Leaf springs with hydraulic shock absorbers STEERING Single reduction rack pinion STEERING WHEEL Dual handgrips scorecard holder p...

Page 184: ...Page U 4 Repair and Service Manual GENERAL SPECIFICATIONS Fig 1 Fleet Freedom Vehicle Dimensions 65 7 167 cm 94 5 240 cm 35 5 90 cm 38 97 cm 45 7 116 cm 68 50 174 cm 47 119 cm...

Page 185: ...Page U 5 Owner s Guide GENERAL SPECIFICATIONS Fig 2 Shuttle 2 2 Vehicle Dimensions 65 7 167 cm 105 5 268 cm 35 5 90 cm 38 97 cm 45 7 116 cm 74 188 cm 47 119 cm...

Page 186: ...nd Service Manual GENERAL SPECIFICATIONS Fig 3 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter RECOMMENDED MAX RAMP 25 GRADE OR 14 MAX RECOMMENDED MAX SIDE TILT 25 GRADE OR 14...

Page 187: ...Page U 7 Owner s Guide Notes Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions and Warnings GENERAL SPECIFICATIONS...

Page 188: ...Page U 8 Owner s Guide Notes GENERAL SPECIFICATIONS Read all of this manual to become thoroughly familiar with this vehicle Pay particular attention to all Notices Cautions and Warnings...

Page 189: ...nsidered potentially hazardous Use extreme care when working on any vehicle When diagnosing removing or replac ing any components that are not operating correctly take time to consider the safety of y...

Page 190: ...l may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road...

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