Ezgo 605586 Repair And Service Manual Download

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Repair and Service Manual

Page viii

SAFETY INFORMATION

NOTES:

Summary of Contents for 605586

Page 1: ...GASOLINE POWERED GOLF CARS REVISED DATE JANUARY 2007 TECHNICIAN S REPAIR AND SERVICE MANUAL 605586 ...

Page 2: ...known to cause cancer and reproductive harm BATTERY WARNING WASH HANDS AFTER HANDLING WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm BATTERIES CONTAIN LEAD AND RELATED PARTS 14 25 DO NOT DRIVE ACROSS SLOPES IN EXCESS OF 14 Throughout this guide NOTE CAUTION and WARNING will be used A NOTE indicates a con...

Page 3: ...gation to make these changes on units previously sold and the information contained in this manual is subject to change without notice TEXTRON Golf Turf Specialty Products is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual CUSTOMER SERVICE DEPARTMENT IN USA PHONE 1 800 241 5855 FAX 1 800 448 8124 OUTSIDE USA PH...

Page 4: ...bove factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to maintain the 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 varie...

Page 5: ...ation 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 Selector K Electrical Wiring L Brakes M Rear Suspension N Rear Axle P Weather Protection Q Paint R Troubleshooting S Limited Warranty T General Specifications U ...

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

Page 7: ...es BE OPER ATED ONLY BY PERSONS WITH VALID DRIVERS LICENSES AND IN ACCORDANCE WITH APPLICABLE STATE REQUIREMENTS This restriction is important to the SAFE USE AND OPERATION 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 products new and used the Distr...

Page 8: ... the safety of the vehicle Vehicles that are capable of higher speeds must limit their speed to no more than the speed of other vehicles when used in a golf course 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 vehicle in safe operating condition Re...

Page 9: ...t 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 warning caution or information labels Keep complete records of the maintenance history of the vehicle The manufacturer cannot anticipate all situations therefore people attempting to maintain or repair ...

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

Page 11: ...AINTENANCE A 3 BRAKES A 3 TIRES A 3 CARE AND CLEANING OF THE VEHICLE A 4 VEHICLE CARE PRODUCTS A 4 TOP AND WINDSHIELD A 4 TRAILERING A 5 WINTER OR PROLONGED STORAGE A 5 HARDWARE A 5 TORQUE SPECIFICATIONS A 5 PERIODIC SERVICE SCHEDULE A 6 LIST OF ILLUSTRATIONS Fig 1 Serial Number Plate Location A 1 Fig 2 Initial Service Chart A 2 Fig 3 Neutral Lock Direction Selector A 3 Fig 4 Lubrication Points A ...

Page 12: ...A 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 Notes Cautions and Warnings ...

Page 13: ...ry charge level The generator is not designed to charge a discharged battery Since the engine stops when the accelerator is released jump starting should not be attempted If the vehicle is equipped with lights and or accessories that are used when the vehicle is not in motion the starter generator may not be adequate to maintain bat tery charge In this situation the battery may require charging wi...

Page 14: ...n vehi cle being towed Do not attempt to tow the vehicle with ropes chains or any device other than a factory approved tow bar Towing a dis abled vehicle can be dangerous and requires extra caution Attempting to tow with devices other than an approved tow bar may result in severe personal injury or death Place direction selector in neutral The neutral lock located on the rear axle or direction sel...

Page 15: ...on Points POWERTRAIN MAINTENANCE Access the powertrain by raising or removing seat Some service procedures may require the vehicle 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 suspension refer to the particular section See the TABLE OF...

Page 16: ... PRODUCTS To help maintain the vehicle the manufacturer has sev eral products available through a local Distributor an authorized Branch or the Service Parts Department among them are Touch up paint specially formulated to match vehicle colors for use on both metal and TPE plastic bodies P N 28140 G and 28432 G Multi purpose Battery Protectant formulated to form a long term flexible non tacky dry ...

Page 17: ...n Page A 3 Add fuel stabilizer to the tank in accordance with the manu facturer s recommendations Disconnect the fuel line from the engine at the fuel tank With proper area of ventilation start the engine and allow to run until the engine stops due to lack of fuel Drain carburetor bowl using drain screw and re tighten the drain screw Remove the air filter and spray a commercial fogging or cylinder...

Page 18: ...ion and adjust if required PARKING BRAKE 3 Check brake performance and adjust if required CHOKE CABLE 3 Check for smooth movement and adjustment DO NOT LUBRICATE CABLE CARBURETOR LINKAGE 3 Check attachment adjust as required DIRECTION SELECTOR 3 Check attachment adjust as required ENGINE 3 Check for unusual noise vibration acceleration oil leaks COOLING FAN 3 Check for build up of foreign matter i...

Page 19: ...r exceeds SF SG CC oil DO NOT OVERFILL ANNUAL 250 300 HOURS includes items listed in previous tables the following FRONT WHEEL BEARINGS Adjust see Technician s Repair and Service Manual Pack use wheel bearing grease REAR AXLE 3 Check lubricant add lubricant SAE 30 oil as required S Replace lubricant after 5 years SERVICE BRAKES Clean and adjust see Technician s Repair and Service Manual 3 Check br...

Page 20: ...A 8 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 Notes Cautions and Warnings ...

Page 21: ...L ASME NGCMA B 7 NOTES CAUTIONS AND WARNINGS B 11 IMPORTANT SAFETY WARNING B 11 MODIFICATIONS TO VEHICLE B 11 GENERAL MAINTENANCE B 11 BEFORE SERVICING THE VEHICLE B 11 Battery Removal and Installation B 12 LIFTING THE VEHICLE B 13 LIST OF ILLUSTRATIONS Fig 1 Battery Removal B 13 Fig 2 Lifting the vehicle B 13 ...

Page 22: ...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 Notes Cautions and Warnings ...

Page 23: ...ating instructions stated in this Standard b The user shall survey specific operating conditions and environment and establish and train carrier operators to comply with additional specific safety practices 4 3 Nameplates Markings Capacity and Modifications 4 3 1 The user shall maintain in a legible condition all nameplates warnings and instructions which are supplied by the manufacturer 4 3 2 The...

Page 24: ...e periodic inspections of the carrier to be certain that the sound producing and or visual device s are maintained in good operating condition 4 9 2 The user shall determine if operating conditions require the carrier to be equipped with additional sound pro ducing and or visual devices and be responsible for providing and maintaining such devices in accordance with the manufacturer s recommendati...

Page 25: ... the appropriate safety standards 5 4 7 Report all accidents involving personnel building structures and equipment 5 4 8 Operators shall not add to or modify the carrier 5 4 9 Carriers shall not be parked or left unattended such that they block or obstruct fire aisles access to stair ways or fire equipment 5 3 Traveling 5 5 1 Observe all traffic regulations including authorized speed limits Under ...

Page 26: ...ated until it has been restored to safe operating condi tion 5 7 2 If during operation the carrier becomes unsafe in any way the matter shall be reported immediately to the designated authority and the carrier shall not be operated until it has been restored to safe operating condition 5 7 3 Do not make repairs or adjustments unless specifically authorized to do so 5 7 4 The engine shall be stoppe...

Page 27: ...ly and maintained in a safe operating condition h Special carriers or devices designed and approved for hazardous area operation shall be inspected to ensure that maintenance preserves the original approved safe operating features i Fuel systems shall be checked for leaks and condition of parts If a leak is found action shall be taken to prevent the use of the carrier until the leak has been elimi...

Page 28: ...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 Notes Cautions and Warnings ...

Page 29: ...e for example 5 2 1 See also NGCMA Golf Course Safety Guidelines and NGCMA Golf Car Storage Facility Safety Guidelines 5 2 1 Grades All grades shall be descended at a reduced speed Excessive speed while descending grades adversely affects the stability of the golf car and its ability to stop In areas where steep grades exist golf car operations should be restricted to designated golf car paths and...

Page 30: ... if so equipped to the off position to prevent leakage or accumulation of flammable fuels d Avoid fire hazards and have fire protection equipment available e Before performing any maintenance on an electric golf car disconnect the electrical system in accordance with the manufacturer s instructions f Use only properly insulated tools when performing maintenance g Periodically inspect and maintain ...

Page 31: ...e fire and safety codes for the specific ventilation levels required See NGCMA Golf Car Safety Storage Guidelines and SAE J1718 7 2 The controlling party shall require battery changing and charging facilities and procedures to be in accordance with applicable ordinances or regulations 7 3 The controlling party shall supervise the storage and handling of liquid fuels in accordance with ANSI NFPA 30...

Page 32: ...Page B 10 Repair and Service Manual NOTES SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 33: ...eet 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 Do not modify the vehicle in any manner that will change the weight distribution of the vehicle Changes to the weight distribution or the cen ter of gravity may make the vehicle unstable ...

Page 34: ...revent the possibility of a dropped wrench from shorting out a battery which could result in an explosion and severe personal injury or death Aerosol containers of battery terminal pro tectant must be used with extreme care Insulate metal container to prevent can from contacting battery terminals which could result in an explosion To prevent illness or death observe the follow ing Never work aroun...

Page 35: ...ehind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process When lifting the vehicle position jacks and jack stands only on the areas indicated To raise the entire vehicle install chocks in front and behind each front wheel Ref Fig 2 on Page B 13 Center the jack under the rear frame crossmember Raise the vehicle and locate a jack stand unde...

Page 36: ...Page B 14 Repair and Service Manual NOTES SAFETY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 37: ...Instrument Panel Replacement C 1 Cowl Replacement C 5 Front Shield Replacement C 5 Rocker Panel Replacement C 5 Body Replacement C 6 Shuttle 2 2 Component Replacement C 6 Rear Bumper Replacement C 7 LIST OF ILLUSTRATIONS Fig 1 Drill Out Metal Rivet C 1 Fig 2 Body Components Front C 2 Fig 3 Body Components Rear C 3 Fig 4 Shuttle 2 2 Components C 4 ...

Page 38: ...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 Notes Cautions and Warnings ...

Page 39: ...nted 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 on Page C 1 Care must be exercised when drill ing to prevent the drill from being forced through the plastic body components where it could damage...

Page 40: ...anual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B Fig 2 Body Components Front 1 4 5 6 7 8 9 10 11 14 15 16 12 17 18 19 20 6 Frame 22 23 24 25 26 11 ...

Page 41: ...nual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B B Fig 3 Body Components Rear 27 32 30 31 33 34 29 Shuttle 2 2 Model Only 28 48 49 53 52 53 52 51 50 ...

Page 42: ...ir and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B Fig 4 Shuttle 2 2 Components 36 37 38 40 41 42 43 44 45 46 47 39 ...

Page 43: ...pacers 16 under each sill plate for reuse when sill plates are rein stalled Drill out the rivets 17 securing the sides of the cowl to the frame From underneath the cowl remove the ratchet fastener 18 attaching the center of the splash panel 19 to the frame cross member Remove the four screws 8 located within the instru ment panel pockets Remove the bolts and washers 20 from the sides of the cowl a...

Page 44: ...ea Drill out the heads of the large head rivets 31 that secure the bottom of the body panel to the side of the vehicle Remove the rivets 32 that secure the floor of the bag well area to the frame underneath Remove the body If the trunk lid 33 is to be reused remove the hardware 34 securing the trunk lid to the body panel Remove the trunk lid Installation of rear body is in the reverse order of dis...

Page 45: ... the rear bumper To replace the bumper place the rear bumper against the rear body panel and tighten the shoulder bolts 52 to 9 12 ft lbs torque Ref Fig 3 on Page C 3 Replace the plugs Using the existing holes in the frame as a guide drill holes in the bumper from underneath the vehicle and install new rivets For Shuttle 2 2 remove bolt 50 and J nut 51 located at each end of the rear bumper 49 Ref...

Page 46: ...Page C 8 Repair and Service Manual NOTES BODY Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 47: ...Repair and Service Manual WHEELS AND TIRES TABLE OF CONTENTS FOR SECTION D SECTION TITLE PAGE NO WHEEL AND TIRE SERVICE D 1 Tire Repair D 1 Wheel Installation D 1 LIST OF ILLUSTRATIONS Fig 1 Wheels and Tires D 2 ...

Page 48: ...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 Notes Cautions and Warnings ...

Page 49: ...IONS section for recommended tire inflation pressure For outdoor applications with major use on grassy areas the follow ing should be considered On hard turf it is desirable to have a slightly higher inflation pressure On very soft turf a lower pressure prevents tires from cutting into the turf For vehicles being used on paved or hard surfaces tire inflation pressure should be in the higher allowa...

Page 50: ...is will 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 Finger tighten lug nuts in a cross sequence pattern Ref Fig 1 on Page D 2 Then tighten lug nuts to 50 85 ft lbs 70 115 Nm torque in 20 ft lbs 30 Nm increments following the same cross sequence pattern Fig 1 Wheels and Tires Tire style may vary 1 2 3 4 CROSS SEQUENC...

Page 51: ...nd Pinion Unit Clearance E 14 Steering Wheel Replacement E 15 Steering Shaft and Column Replacement E 16 LIST OF ILLUSTRATIONS Fig 1 Steering and Front Suspension E 1 Fig 2 Lubrication Points E 2 Fig 3 Bearing Adjustment E 3 Fig 4 Wheel Alignment E 4 Fig 5 Disconnect Intermediate Shaft to Center Steering Wheel E 4 Fig 6 Front Suspension Components E 5 Fig 7 Front Axle Alignment E 7 Fig 8 Hub Repla...

Page 52: ...Page 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 Notes Cautions and Warnings ...

Page 53: ...dure Pay particular attention to all Notes Cautions and Warnings Fig 1 Steering and Front Suspension Part of Frame Part of Frame Wave Washer Bearing Outer Snap Ring Inner Snap Ring Intermediate Shaft with U Joints Rack Pinion Unit King Pin Tube Thrust Washer Spindle King Pin Bushing Formed Axle Spacer Rack Ball Joint Rack Extension ...

Page 54: ...ction B of this manual Be sure the vehicle is on a firm and level surface Never get under a vehicle while it is supported by a jack Use jack stands and test the stability of the vehicle on the stands before starting any repair procedure Always place chocks in front and behind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process Lift the fr...

Page 55: ...ight resistance is felt Rotate the wheel 2 3 more turns to displace excess grease If required tighten castellated nut 3 again until slight resistance is felt If the cotter pin hole in the spin dle 5 aligns with a slot in the castellated nut insert a new cotter pin 2 If the hole does not align the castel lated nut must be loosened to align with the closest available slot in the nut Check for smooth...

Page 56: ... groove has conventional right hand threads To adjust wheel alignment loosen tie rod jam nuts 1 and turn tie rod 2 until correct alignment is achieved Tighten jam nuts to 36 40 ft lbs 49 54 Nm torque Test drive vehicle and confirm steering wheel is cor rectly centered If it is not centered disconnect interme diate shaft from steering shaft and center steering wheel Ref Fig 5 on Page E 4 Reconnect ...

Page 57: ...the front axle 3 Ref Fig 6 on Page E 5 Compress shock absorber to clear the mounting bracket Loosen the nut securing the top of the shock absorber to the vehicle frame and then rotate the shock absorber while holding the nut in place with a wrench Remove the shock absorber Installation of shock absorber is reverse of disassembly Mounting nuts should be tightened until rubber bushings 4 expand to d...

Page 58: ...g apart intermediate shaft Remove the three 1 3 4 long bolts 18 two 1 1 2 long bolts 28 spring plate 24 and five lock nuts 19 secur ing axle to springs and discard lock nuts At the 3 1 2 long bolt 20 securing front of left spring note location of washer 22 and remove it from end of bolt Remove nut 21 3 1 2 long bolt 20 spring plate 24 and spacer 23 and retain them for assembly at their original lo...

Page 59: ...9 27 to secure the rack and pinion unit 16 two short bolts 18 and rear bolts 25 To detach passenger side spring Remove the hardware 18 19 24 28 securing the front of the passenger side leaf spring 17 to the axle 3 and discard lock nuts 19 Ref Fig 6 on Page E 5 Pull upper passenger side of floor mat out of plastic trim retainer and away from floor Locate and remove hard ware 25 27 securing rear of ...

Page 60: ... Wheel Bearing and Race Replacement Tool List Qty Required Non ferrous punch 1 Ball peen hammer 1 Bearing driver 1 Remove hub 1 from spindle Ref Fig 10 on Page E 8 Hub Replacement on Page E 7 Remove the grease seal 3 inner wheel bearing 4 and bearing races 5 by tapping through the other side of hub the bearing race using a hammer and a soft non ferrous punch Tap race in a circular pattern while mo...

Page 61: ...1 2 drive 1 To remove rack ball joint 1 loosen passenger side front wheel and lift and support front of vehicle per SAFETY section Ref Fig 11 on Page E 9 Remove passenger side front wheel and turn steering wheel fully to the left Remove the cotter pin 2 and loosen the castellated nut 3 until rack ball joint 1 threads are protected Using a ball joint separator as a lever apply pressure to ball join...

Page 62: ... per WHEELS AND TIRES section and lower vehicle per SAFETY section Check front wheel alignment and adjust if necessary Wheel Alignment on Page E 3 Tie Rod Inspection Replacement Tool List Qty Required Tape measure 1 Wrench 3 4 1 Wrench 9 16 1 Needle nose pliers 1 Wrench 11 16 1 Ball joint separator 1 Plastic faced hammer 1 Socket 11 16 1 2 drive 1 Torque wrench 1 2 drive ft lbs 1 Crowfoot socket 3...

Page 63: ...e measure 1 Wrench 3 4 1 Wire cutters 1 Wire tie 8 long 1 Torque wrench 1 2 drive ft lbs 1 Socket 11 16 1 2 drive 1 To replace bellows 1 Ref Fig 14 on Page E 11 first loosen passenger side front wheel and lift and support front of vehicle per SAFETY section Fig 14 Bellows Replacement Remove passenger side front wheel and turn steering wheel fully to the left Remove rack ball joint 2 and jam nut 3 ...

Page 64: ...l fully into bore until it stops and wipe clean of any excess grease Attach rack and pinion unit to front axle Rack and Pin ion Unit Replacement on Page E 14 Spindle Replacement Tool List Qty Required Needle nose pliers 1 Wrench 11 16 1 Ball joint separator 1 Plastic faced hammer 1 Wrench 3 4 1 Socket 3 4 1 2 drive 1 Socket 11 16 1 2 drive 1 Torque wrench 1 2 drive ft lbs 1 The spindle bearings ar...

Page 65: ...assemble rack and pinion unit 1 by first removing screw 13 and tensioner 2 to relieve pressure on rack 3 and pinion 4 Ref Fig 17 on Page E 13 Loosen jam nut 5 and remove rack ball joint 6 from rack extension 7 Cut wire ties 8 14 securing bellows 9 and slide bellows off rack extension Pull rack 3 from unit 1 Remove pinion seal 10 Pinion Seal Replace ment on Page E 11 Remove internal retaining ring ...

Page 66: ... pin ion unit can now be removed from vehicle Retain washers 19 spacers 20 and the two bolts 16 for assembly Replace rack and pinion unit in reverse order of removal Use new lock nuts 18 and tighten them to 35 50 ft lbs 50 70 Nm torque Tighten castellated nut 3 to 36 ft lbs 50 Nm torque and continue to tighten as needed to insert new cotter pin Maximum torque is 50 ft lbs 70 Nm Tighten bolt 13 sec...

Page 67: ...ment Tool List Qty Required Socket 15 16 1 2 drive 1 Ratchet 1 2 drive 1 Plastic faced hammer 1 Ball peen hammer 1 Anti seize compound 1 Torque wrench 1 2 drive ft lbs 1 To maintain correct orientation when replacing steering wheel first turn wheels straight ahead To prevent damage to the clipboard perform the follow ing removal procedure Do not use a screwdriver to push or pry the retaining tabs ...

Page 68: ...Fig 20 on Page E 15 If stress lines are present replace clipboard Install by carefully pressing first the top two then the bottom two retaining tabs into the matching slots in steering wheel Steering Shaft and Column Replacement Tool List Qty Required Ratchet 1 2 drive 1 Socket 3 4 1 2 drive 1 Socket 13 mm 3 8 drive 1 Ratchet 3 8 drive 1 Socket 9 16 1 2 drive 1 Snap ring pliers 1 Bearing separator...

Page 69: ...g 12 at top of column and press steering shaft and bearing assem bly into column base Secure with large retaining ring making sure it is fully seated in groove of column Place steering column on vehicle and tighten column bolts 5 to 29 ft lbs 39 Nm torque Tighten bolt 1 securing intermediate shaft to steering shaft to 156 216 in lbs 180 250 kg cm torque Install front wheel s per WHEELS AND TIRES s...

Page 70: ...Page E 18 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 Notes Cautions and Warnings ...

Page 71: ...S F 2 Throttle Cable Removal F 2 Throttle Cable Installation F 3 Throttle Cable Adjustment F 3 Accelerator Cable Removal F 3 Accelerator Cable Installation F 3 Accelerator Cable Adjustment F 3 PEDAL BOX ADJUSTMENTS F 3 Accelerator Pedal Arm Adjustment F 3 Micro Switch Adjustment F 4 LIST OF ILLUSTRATIONS Fig 1 Accelerator and Governor System F 1 Fig 2 Throttle Cable Removal F 2 Fig 3 Accelerator C...

Page 72: ...Page F ii Repair and Service Manual NOTES SPEED CONTROL ALL CABLES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 73: ...spring Ref Fig 1 on Page F 1 As the accelerator pedal moves the parking brake is released the micro switch closes and activates the igni tion circuit The rear end of the accelerator rod is joined to the micro switch cam which connects to the accelerator cable As the micro switch cam moves to the rear it pulls the accelerator cable which pulls against the governor spring When the accelerator cable ...

Page 74: ...stem improper adjustment of linkage system Other factors may effect the performance characteristics of the vehicle but they should be investigated only after confirm ing the linkage adjustment SPEED CONTROL CABLES Tool List Qty Required Phillips screwdriver 1 Needle nose pliers 1 Slip joint pliers 1 Straight blade screwdriver 1 Open end wrench 9 16 1 Open end wrench 1 2 1 Open end wrench 3 8 1 Dri...

Page 75: ...overnor arm by using a pair of pliers to squeeze prongs on accelerator cable bush ing Accelerator Cable Installation To install the accelerator cable proceed in reverse order Accelerator Cable Adjustment To adjust the accelerator cable position the cable in the accelerator cable bracket at the rear axle so that the throttle is fully closed while allowing 1 travel at the top of the accelerator peda...

Page 76: ...GOVERNOR COMPRESSION SPRING ADJUSTMENT If the governor requires service the service must be per formed by an authorized service Branch or Distributor Tampering with or adjusting the governor to permit the vehicle to operate at above the factory governed speed as specified in GENERAL SPECIFICATIONS will void the warranty Hold the accelerator cable when removing adjusting the compression spring lock...

Page 77: ...on before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B B Fig 5 Accelerator Linkage 2 1 2 63 5 mm To Governor Accelerator Cable Accelerator Cable Throttle Cable Governor Arm To Pedal Box Throttle Cable To Carburetor 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 ...

Page 78: ...Page F 6 Repair and Service Manual NOTES SPEED CONTROL ALL CABLES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 79: ...Controls and Wiring G 12 Removing the Engine from the Vehicle G 12 Engine Installation G 12 DRIVE CLUTCH REMOVAL G 13 STARTER GENERATOR REPLACEMENT G 13 ENGINE ISOLATION MOUNT REMOVAL G 14 Engine Isolation Mount Installation G 14 MUFFLER REMOVAL G 14 Muffler Installation G 14 LIST OF ILLUSTRATIONS Fig 1 Clean Entire Dipstick G 1 Fig 2 Check Oil Level on Dipstick G 1 Fig 3 Oil Viscosity Chart G 1 F...

Page 80: ...17 Overhead Valve Cam System G 7 Fig 18 Four Cycle Operation G 8 Fig 19 Overhead Valve Adjustment G 9 Fig 20 Valve Cover Tightening Sequence G 9 Fig 21 Timing Belt Adjustment G 10 Fig 22 Compression Gauge G 11 Fig 23 Engine Assembly G 12 Fig 24 Engine Mounting G 13 Fig 25 Starter Generator Wiring G 14 ...

Page 81: ...member that oil expands as it gets hot Do not overfill Ref Fig 2 on Page G 1 Check that the oil cap is firmly in place When adding oil between oil changes do not mix brands and viscosity grades of oil Both the oil dipstick and fill cap must be in place before oper ating the engine Failure to install the dipstick and fill cap will result in oil becoming contaminated and or oil being dis charged int...

Page 82: ...clean with a soft brush Ref Fig 6 on Page G 2 Fig 6 Clean Oil Filter Blow out the filter with low pressure air at 30 psi 210 kPa or less from no closer than 3 8 cm and allow to dry Ref Fig 7 on Page G 2 Fig 7 Blowing Out Oil Filter Wipe the area around the filter mount with a lint free cloth and inspect both filter O rings for damage replace if necessary Install the filter into the engine The filt...

Page 83: ...seat Ref Fig 9 on Page G 3 Inspect and replace air fillter in accordance with the Periodic Service Schedule Ref Section A Clean inside of cover canister and dust collector Install the element and cover the same way they were removed Be sure the positioning arrow on the cover is pointing upward and all clips are fastened securely Cleaning the Air Filter Element Do not use compressed air to clean th...

Page 84: ...place and tighten the upper jam nut against it Ref Fig 12 on Page G 4 Fig 12 Adjusting the Belt Tension Using a 3 4 socket and open end wrench tighten the starter generator pivot bolt COOLING SYSTEM CLEANING At least once a year or more often under adverse condi tions the cooling system should be cleaned Cleaning will assure an adequate supply of air to the cooling fins Compressed air may be used ...

Page 85: ...r cycle air cooled in line twin cylin der overhead cam unit It incorporates pressure lubri cation a washable permanent oil filter and a counter rotating balance shaft Ref Fig 17 on Page G 7 An electronic ignition system fires both spark plugs simultaneously which eliminates the need for a distribu tor The pistons are aligned together which means that they both are at TDC Top Dead Center and BDC Bo...

Page 86: ...nt Adjustment Procedure The valve clearances are adjustable from the top of the engine and should be done with the engine cold Ref Fig 19 on Page G 9 As an annual 250 hour inspec tion the valve clearance check consists of removing the valve cover and sliding a 004 10 mm flat feeler gauge between the valve rocker and the heel lowest portion of the cam If the gauge slides in and out with some light ...

Page 87: ...Cautions and Warnings Fig 17 Overhead Valve Cam System VALVE OPERATION Valve Cover Camshaft Cam Lobe Cylinder Head Cylinder Piston Timing Belt Screw Type Adjuster Cam Lobe Up Cam Lobe Down Valve Return Spring VALVE OPEN VALVE CLOSED Timing Belt Pulley NOTE This is a simplified diagram for explanatory use only Rockers guides seals etc have been omitted ...

Page 88: ...pting any procedure Pay particular attention to all Notes Cautions and Warnings B Fig 18 Four Cycle Operation First Revolution Second Revolution COMPRESSION INTAKE Intake Exhaust EXHAUST POWER NOTE This is a simplified diagram for explanatory use only Rockers guides seals etc have been omitted ...

Page 89: ... 4 1 2 turn Rotate the engine one full turn which will allow the spring to apply tension to the belt Tighten the idler adjusting nut to 10 13 ft lbs 14 18 Nm torque Spray the rubber plug with a vinyl protective spray in order to ease the installation of the plug For information relating to the replacement of the timing belt refer to 4 Cycle Engine Shop Rebuild and Service Parts Manual P N 27615 G0...

Page 90: ...ng may be inaccurate and indi cate low 6 The engine must be at normal operating temperature in order for the components to expand To prevent possibility of personal injury never operate without spark plug installed in the cyl inder not being tested Fuel drawn into the cyl inders will be expelled through the spark plug opening and could be ignited by the ignition system or another source resulting ...

Page 91: ...ase in compression If so a top end overhaul should be considered Refer to Engine Rebuild manual part number 27615 G01 ENGINE REMOVAL Tool List Qty Required Socket 10 mm 3 8 drive 1 Socket 12 mm 3 8 drive 1 Socket 1 2 3 8 drive 1 Socket 5 8 3 8 drive 1 Open end wrench 9 16 2 Open end wrench 5 16 1 Extension 3 3 8 drive 1 Extension 6 3 8 drive 1 Ratchet 3 8 drive 1 Straight blade screwdriver 1 Phill...

Page 92: ... Fig 23 on Page G 12 It is not necessary to remove the muffler as part of the engine removal Remove the four bolts 15 that secure the engine to the engine support castings 13 17 Lift the engine and drive clutch vertically through the engine compartment using a hoist or with the assistance of another person Engine Installation When installing the fuel and pulse lines pay particular attention to ass...

Page 93: ...wrench will remove the most stubborn clutch To prevent damage to the clutch be sure to remove all grease from the body of the clutch since grease penetrating the seal may cause premature clutch failure It is not necessary to remove the engine to remove the clutch Refer to the CONTINUOUSLY VARIABLE TRANSMISSION CVT section for removal and installa tion with the engine installed in the vehicle START...

Page 94: ...stration are installed facing the isolation mount Loosely attach the isolation mount 9 and hardware to the isolation mount bracket 12 and engine frame 13 Ref Fig 24 on Page G 13 Attach the isolation bracket to the vehicle frame and tighten the flanged nuts 11 to 21 25 ft lbs 28 34 Nm torque Tighten the isolation mount bolt 10 to 21 25 ft lbs 28 34 Nm torque In cases where the rear springs or the r...

Page 95: ...moval H 3 Carburetor Disassembly H 3 Float Level Adjustment H 4 Throttle Shaft Adjustment H 4 Carburetor Installation H 4 FUEL PUMP H 6 Fuel Pump Replacement H 6 FUEL LINES AND FILTER H 7 FUEL LINES FILTER CALIFORNIA EMISSION REQUIREMENT H 8 Carb Installation H 8 FUEL AND STORAGE H 9 Prolonged Storage H 9 CARBURETOR TROUBLESHOOTING H 9 LIST OF ILLUSTRATIONS Fig 1 Fuel Tank H 1 Fig 2 Fuel System H ...

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

Page 97: ...titude or heavy use load applications may benefit from higher octane gaso line CARBURETOR OPERATION The carburetor consists of four different systems float pilot jet main jet choke Fig 1 Fuel Tank Float System The float chamber is located on the underside of the car buretor and the correct fuel level is maintained by means of the float and needle valve As the fuel flows from the fuel pump it must ...

Page 98: ...ich will cause premature deterioration of the cable FUEL SYSTEM COMPONENT SER VICE AND REPLACEMENT Choke Cable and Housing Removal Tool List Qty Required Open end wrench 1 2 2 Open end wrench 7 8 1 Phillips screwdriver 1 Loosen the screw 9 attaching the carburetor choke shaft to the inner choke cable 1 Ref Fig 3 on Page H 2 Remove the nuts 2 securing the outer choke cable 3 to its bracket Fig 3 Ch...

Page 99: ...ive 1 Ratchet 1 4 drive 1 Extension 3 1 4 drive 1 Parallel jaw pliers 1 Straight blade screwdriver 1 Phillips screwdriver 1 Torque wrench 1 4 drive in lbs 1 Loosen the hose clamps 1 from each end of the air intake hose 2 Remove hose Ref Fig 4 on Page H 4 Remove the two nuts 3 and two studs 4 that secure the baffle 5 to the carburetor adapter 8 Remove the two nuts 6 and two washers 7 that secure th...

Page 100: ...st by inserting needle nose pliers into the slot on the top of tang 1 and hold firmly while adjusting the floats by gently lifting or pushing with the other hand Reinstall the bowl copper gasket and the screw Check for fuel leaks After adjusting float level reassemble the carburetor in reverse order of assembly The pilot screw is factory set Check for free movement of the choke shaft before instal...

Page 101: ...FUEL SYSTEM Page H 5 Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B B Fig 5 Carburetor ...

Page 102: ...e moves the diaphragm within the fuel pump Ref Fig 7 on Page H 6 This movement draws fuel from the fuel tank into the fuel pump chamber This action also closes the out let valve which prevents fuel back flowing from the car buretor As the pistons move down in the cylinders a positive pressure is formed in the crankcase which causes the diaphragm to move in the opposite direction away from the engi...

Page 103: ...tor through flexible fuel hoses An in line filter is installed in the hose between the fuel tank and the fuel pump Ref Fig 8 on Page H 7 Fig 8 Fuel Lines and Filter To prevent possibility of personal injury tests that involve fuel flow should be avoided if at all possible If a test to determine fuel vapor pres ence or flow is required the ignition system must be disabled Remove the input wires to ...

Page 104: ...on Page H 8 Read and understand the following text and warnings before attempting installation Carb Installation 1 Disconnect the negative ground from the battery before starting the installation 2 Remove the existing hoses and clamps from the fuel tank to the fuel pump and from fuel pump to the carburetor and discard Care should be taken while removing hoses due to the presents of fuel remaining ...

Page 105: ...Section B and support on jack stands Add fuel stabilizer to the tank in accor dance with the manufacturer s recommendations Dis connect the fuel line from the engine at the fuel tank With proper ventilation start the engine and allow to run until the engine stops due to lack of fuel Drain carbure tor bowl using drain screw and re tighten the drain screw Remove the air filter and spray a commercial...

Page 106: ...e with fresh fuel POOR HIGH SPEED OPERATION Fuel pump faulty Replace fuel pump Loose main jet Tighten main jet Incorrect fuel level in float bowl Adjust float Dirt in fuel tank or hoses Clean Clogged fuel filter Replace fuel filter Clogged main jet or main jet air passage Clean jet Dirty air filter Clean replace filter element ABNORMAL COMBUSTION FUEL MIXTURE Dirty carburetor Clean carburetor Dirt...

Page 107: ...ibrium J 2 Drive Clutch Removal J 2 Drive Clutch Installation J 3 Driven Clutch Removal J 3 Driven Clutch Repair J 3 Torque Ramp Buttons J 3 Driven Clutch Assembly J 3 Driven Clutch Installation J 3 DRIVE BELT J 4 Removing the Drive Belt J 4 Drive Belt Service J 4 STORAGE J 4 LIST OF ILLUSTRATIONS Fig 1 Continuously Variable Transmission System CVT J 1 Fig 2 CVT Components J 2 Fig 3 Removing the D...

Page 108: ...J 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 Notes Cautions and Warnings ...

Page 109: ...hen 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 The driven clutch sheaves are closed at rest which results in ...

Page 110: ...reases the drive ratio This downshifting applies more torque to the rear axle with out 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 maintain equilibrium Clutch sets are tuned to the vehicle that they are designed to operate Changes in vehicle ...

Page 111: ...y thread sealant to the threads of the clutch bolt and install and tighten to 40 44 ft lbs 54 60 Nm torque Driven Clutch Removal Tool List Qty Required External snap ring pliers 1 Socket 5 8 1 2 drive 1 Ratchet 1 2 drive 1 Thread locking sealant AR Phillips screwdriver 1 Torque wrench 1 2 drive ft lbs 1 Remove the drive belt 1 Refer to Removing The Drive Belt procedure elsewhere in this section Re...

Page 112: ...elt 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 vehicle is to be out of service for an extended period of time...

Page 113: ...F CONTENTS FOR SECTION K SECTION TITLE PAGE NO DIRECTION SELECTOR K 1 Removing Direction Selector K 1 Replacing the Reverse Warning Buzzer K 1 Replacing a Micro Switch K 1 Shift Cable Adjustment Single Cable K 1 LIST OF ILLUSTRATIONS Fig 1 Direction Selector K 2 ...

Page 114: ...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 Notes Cautions and Warnings ...

Page 115: ...ction selector from body Replacing the Reverse Warning Buzzer To replace the reverse warning buzzer remove the attaching hardware Ref Fig 1 on Page K 2 Carefully remove the two electrical wires from the buzzer Reat tach the wires to the new buzzer After restoring power test the buzzer to ensure it is operational before con tinuing by moving the direction selector to REVERSE position Once it is det...

Page 116: ...ll of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B Fig 1 Direction Selector Reverse Warning Buzzer Micro Switch Shift Cable Adjustment Shift Cable Adjustment Direction Selector Cam Front ...

Page 117: ...ter Generator Disassembly L 6 Starter Generator Inspection L 8 Starter Generator Repair and Replacement L 8 BATTERY VOLTAGE TEST L 8 STORAGE OF BATTERY L 8 DVOM DIGITAL VOLT OHM METER L 8 TROUBLESHOOTING L 9 POWER SUPPLY L 9 ACCESSORY WIRING L 10 LIST OF ILLUSTRATIONS Fig 1 Electrical System Wiring Diagram L 2 Fig 2 Electrical System Physical Location L 3 Fig 3 Ignition Coil Check Method L 5 Fig 4...

Page 118: ...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 Notes Cautions and Warnings ...

Page 119: ... is running the starter generator 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 speed However the charging current will vary depending on the condition of the bat tery If it is fully charged current is controlled at 3 to 5 amps WIRING Before performing an...

Page 120: ...ings B Fig 1 Electrical System Wiring Diagram Fuse 7 AMP RED BLK Reverse Warning Battery BLK Solenoid A B RED BLK BLK Ignitor BLK RED WHT WHT Ignition Coil Pulser Coil 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 BLUE RED Key Switch MS4 RED WHT GRN GRN BLK RED GRN BLK A B C D A A ...

Page 121: ...l of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B B Fig 2 Electrical System Physical Location Starter Generator Battery Ignition Coil GRN F 2 A2 A1 F1 DF 25 26 24 Front of Vehicle ...

Page 122: ...ut of this range or if a reading of no continuity is displayed replace the pulser coil Make certain that the air gap is correct Set with a 032 feeler gauge There is no timing adjustment TESTING STARTING CIRCUIT To prevent the possibility of injury resulting from vehicle inadvertently starting disconnect battery for steps 1 through 8 see Section B Tool List Qty Required DVOM 1 If the engine will no...

Page 123: ...r pedal The DVOM will indi cate 0 voltage if the solenoid contacts are closed c If 0 voltage is not indicated while the accelerator pedal is pressed replace the solenoid Fig 3 Ignition Coil Check Method Fig 4 Normal Circuit Primary Secondary K To K To Black Probe Black Probe Red Probe Red Probe B A Ignition Coil 12 VDC Frame Ground Pulser Coil Spark Plugs Solenoid Fuse Key Switch Ignition Coil Ign...

Page 124: ...there is a malfunction in the charg ing circuit 7 If the reading is above 15 volts check to assure the wiring harness and generator field winding green lead is not grounded If it is not replace the regulator 8 If the reading is below 14 volts disconnect the regulator s green field wire from the sys tem harness Temporarily connect the green field wire to ground If the voltage rises above its prior ...

Page 125: ...ocedure Pay particular attention to all Notes Cautions and Warnings B B Fig 5 Starter Generator Fig 6 Starter Generator Brush Removal Fig 7 Bearing Removal 7 6 8 2 4 9 1 3 Brush Brush Spring Spring Position for Installed Brushes Spring Position for Removing Replacing Brushes Brush Puller Bearing Adapter Puller ...

Page 126: ...to 30 43 in lbs 35 50 kg cm 6 mm torque to 52 74 in lbs 60 85 kg cm 14 mm torque to 33 40 ft lbs 45 55 Nm Tighten terminal nuts to the following torques F1 F2 torque to 43 52 in lbs 50 60 kg cm DF torque to 26 35 in lbs 30 40 kg cm BATTERY VOLTAGE TEST Battery voltage can be checked using a voltmeter Attach the negative lead of the DVOM to the ground terminal of the battery The positive lead is th...

Page 127: ...ndicated between the two head lights In some cases where battery voltage is expected the easiest way to test the circuit is to set the DVOM to DC volts and place the negative probe of the DVOM to the negative battery terminal Move the positive probe to each wire termination starting at the battery and working out to the device that is not working Be sure to check both sides of all switches and fus...

Page 128: ...power to the entire fuse block 4 Check fuse Place the red probe to each wire terminal on the fuse block A reading of battery voltage indicates that the fuse is in good condition No reading indicates a faulty fuse replace with a good 15 amp fuse ACCESSORY WIRING After determining that there is power to the fuse panel and the fuse is good continue checking the circuit using the procedures previously...

Page 129: ...HT BLK Flasher Solenoid YEL Low Oil Pressure Light Oil Pressure Sender Fuel Sender Fuel Gauge RED BLU WHT BLK BLK BLK BRN WHT BRN WHT WHT RED RED Turn Signal Turn Signal Taillight Taillight YEL BRN For Vehicles Without Turn Signals Remove WHT Wire From Driver Side Taillight RED Wire And YEL Wire From Passenger Side Taillight RED Wire Connect Each RED Wire To BRN Wire Indicates Wires Included In Li...

Page 130: ...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 Notes Cautions and Warnings ...

Page 131: ...zer Assembly Removal and Installation M 19 Compensator Assembly Removal and Installation M 19 Brake Pedal Removal and Installation M 19 Parking Brake Catch Bracket Removal and Installation M 20 Parking Brake Pedal Removal and Installation M 20 Pedal Bumper Adjustment M 20 Parking Brake Release Linkage Removal and Replacement M 21 Parking Brake Kick Off Cam Removal Replacement and Installation M 21...

Page 132: ...ke Lubrication Points M 17 Fig 23 Backing Plate Removal and Installation M 17 Fig 24 Brake Shoes and Springs M 18 Fig 25 Setting Adjuster Screw M 18 Fig 26 Brake Cable Equalizer and Compensator M 19 Fig 27 Brake Pedal Removal and Installation M 19 Fig 28 Catch Bracket and Latch Arm M 20 Fig 29 Pedal Bumper Adjustment M 20 Fig 30 Parking Brake Release Linkage and Kick OffCam Removal and Installatio...

Page 133: ...ove the brake shoes against the brake drums The travel of the brake cables is governed by the brake pedal If the cables can not travel far enough to absorb the slack free travel in the system and still apply the shoes to the drums the braking effort at the wheel brake will not be adequate The self adjusting mechanism in the wheel brakes requires enough cable travel at the wheel brake to work relia...

Page 134: ... and eliminate the need for manual brake shoe adjustment Do not manually adjust the brakes by prying back the adjuster arm and turning the star wheel Permanent damage to adjuster will result Adjustment takes place only when the brake is fully applied and released while the vehicle is moving Ref Fig 2 on Page M 2 It is very important that the brake cables permit the brake levers to release fully wh...

Page 135: ... bracket This is the preferred method which minimizes wear on components 2 Pressing the accelerator pedal rotates the kick off cam which forces the pedal latch arm to move away from the catch bracket The spring loaded Parking Brake pedal returns to its original position releasing the brake Compensator Assembly The compensator assembly contains a spring which is compressed until the stop tube withi...

Page 136: ...t Providing free travel is correctly adjusted the clevis pins will not be under tension by the brake cables Test Result Fails 2 out of 3 Fails 2 out of 3 Perform the Periodic Brake Performance Test PBPT 3 Times 3 Aggressive Stop Test 10 times 4 2 Bad Seal and Thrust Washer Condition Good Remove Excess Brake Dust from Brake Components 8 Yes Return To Service Go to 2 Go to 6 Remove Both Drums Don t ...

Page 137: ...ing Do this by first verifying that some braking function exists Then drive vehicle at slow speed and apply the brakes aggressively As the brakes adjust and stop the vehicle more effectively start driving at maximum speed and brake aggressively 10 times At the spherical nut readjust the free travel Drive and brake aggressively 10 more times Repeat until the pedal free travel stabilizes within the ...

Page 138: ...vided 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 Starting 2001 Model Year In excess of 1 1 8 2 9 cm free pedal travel Soft Pedal Prior to 2001 Model Year In excess of 2 1 4 5 7 cm free pedal travel Soft Pedal Low pedal force at parking brake latch Adjust pe...

Page 139: ...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 Check for binding of brake pedal Check brake pedal free travel Grabbing brakes oversensitive Moisture has caused surface rust on drums Apply moderate force to pedal while at maximum level ground speed to rem...

Page 140: ...liminate the need for routine brake testing and inspection as shown on the Periodic Service Schedule in Section A Contin ued proper brake operation depends on periodic main tenance Brake Pedal and Linkage Inspection 1 Inspect brake pedal return bumper Be sure that the brake pedal is contacting the pedal return bumper when released that the bumper is in good condition and that a 1 4 3 8 6 9 5 mm ga...

Page 141: ...the inner cable or lack of free motion when the pedal is applied and released Inspect the brake cable sup ports to be sure the cables are properly secured If any of these conditions are found replace both cables and equalizer as a set 5 Check the clevis pins Check clevis pins attaching the brake cables to the brake lever They must be loose when the brake pedal has been released Ref Fig 19 on Page ...

Page 142: ...vere injury or death resulting from operating a vehicle with improperly oper ating brake system the braking system must be properly maintained All driving brake tests must be done in a safe location with regard for the safety of all personnel The Periodic Brake Performance Test PBPT should be performed regularly see Periodic Service Schedule in the GENERAL INFORMATION AND ROUTINE MAIN TENANCE sect...

Page 143: ...avel Adjusting Brake Pedal Free Travel on Page M 14 Then repeat the Periodic Brake Performance Tests If vehicle fails remove from service and refer to Wheel Brake Inspection to evalu ate the reason for failure Aggressive Stop Test To prevent serious injury or death all brake tests must be done in a safe location with regard for the safety of all personnel Always conduct a visual inspection and eva...

Page 144: ...ck for evidence of scoring Check for excessive wear indicated by the friction surface being significantly worn and leaving a ledge of unworn drum Inspect the splines for galling wear and corrosion If any of these problems are found the drum must be replaced 3 Remove any accumulated brake dust from the wheel brake assembly with a brush 4 Visually inspect the axle seal for oil leakage and the condit...

Page 145: ...cking 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 06 1 5 mm at any point on the shoe It is normal for the shoes to show more wear at the leading and trailing edges Ref Fig 16 on Page M 13 If the brake shoe thickness is approaching 06 1 5 mm it is recommended that the shoes be replaced It is r...

Page 146: ...er able labor to do correctly Assessment of the condition 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 s Adjusting Brake Pedal Free Travel Brake pedal free travel MUST be checked and adjusted any time that the brake system is serviced or when p...

Page 147: ...pins attaching the brake cables to the brake levers are loose Ref Fig 19 on Page M 15 If they are not loose inspect system again and correct as required If the clevis pins are loose tighten jam nut to 10 11 ft lbs 14 15 Nm at the spherical nut Fig 19 Check Clevis Pins The parking brake latching force can be checked as ver ification after setting brake pedal free travel To check parking brake latch...

Page 148: ...einstalled when the brake is reassembled To install the brake drum clean the axle shaft and the splines on the brake drum to remove dirt grease and foreign matter Apply a small amount of anti seize com pound to the axle spline Install the inner brake drum washer 6 and slide the brake drum 5 into place Check to ensure the nose of drum hub is beyond the end of the axle splines If not remove drum and...

Page 149: ... sure that the adjusting screw is screwed into the star wheel nut until only 1 2 threads are exposed Ref Fig 25 on Page M 18 If the brake shoes are replaced replace the three brake springs and the adjuster com ponents Replace the springs one side at a time using the other side as a guide Install brake drum as described in Brake Drum Removal and Installation Repeat on other side of vehicle Adjust t...

Page 150: ... The adjusting screw must be screwed into the star wheel nut until only 1 2 threads are exposed Ref Fig 25 on Page M 18 Fig 25 Setting Adjuster Screw Install the actuator piston Be sure the hardened shim washer is installed as shown Ref Fig 22 on Page M 17 Always replace both brake shoes on both wheels as a set Install the shoes as indicated and install the shoe clamp 5 over the shoe clamp pin 4 a...

Page 151: ...ing new clevis pins and new cotter pins Adjust the brake pedal free travel Adjusting Brake Pedal Free Travel on Page M 14 Compensator Assembly Removal and Installation Disconnect the compensator assembly from the brake pedal by removing the cotter pin and clevis pin Ref Fig 26 on Page M 19 Loosen and remove the jam nut and the spherical nut connecting the compensator rod to the equalizer link Remo...

Page 152: ...ck off cam 3 Parking Brake Kick Off Cam Removal Replacement and Installation on Page M 21 Install wheel See WHEELS AND TIRES section Fig 28 Catch Bracket and Latch Arm Parking Brake Pedal Removal and Installa tion Note the location and orientation of the two torsion springs 8 Remove the push nut 9 and pin 10 Ref Fig 27 on Page M 19 and remove the parking brake pedal Some models may use two push nu...

Page 153: ...nd Kick Off Cam Removal and Installation Parking Brake Kick Off Cam Removal Replacement and Installation Disconnect the parking brake release linkage as described above Loosen the two setscrews 5 from the cam 6 and remove the cam pivot 7 cam and spacer 8 Ref Fig 30 on Page M 21 Inspect the bushings 9 10 and spacer If they are worn replace them with new ones Installation is in the reverse order of ...

Page 154: ...Page M 22 Repair and Service Manual NOTES MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 155: ... SECTION N SECTION TITLE PAGE NO REAR SUSPENSION N 1 GENERAL N 1 Shock Absorber Removal N 1 Shock Absorber Installation N 1 Rear Spring Removal N 1 Rear Spring Installation N 1 REAR AXLE REMOVAL N 3 Rear Axle Installation N 3 LIST OF ILLUSTRATIONS Fig 1 Rear Suspension N 2 ...

Page 156: ...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 Notes Cautions and Warnings ...

Page 157: ...g 1 on Page N 2 Compress the shock absorber 2 and remove the top shock absorber nut 3 Remove the shock absorber Shock Absorber Installation Shock absorber installation is in the reverse order of disassembly except that the shock absorber nuts 1 3 must be tightened until the shock absorber bushings 4 expand to diameter of the shock absorber washer 5 Rear Spring Removal To reduce the possibility of ...

Page 158: ... Repair and Service Manual Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B Fig 1 Rear Suspension 2 10 4 5 7 11 9 6 9 9 3 5 4 10 8 8 1 4 4 5 5 ...

Page 159: ...he triangular bracket supporting the differential to the engine frame Remove the U bolts holding axle to engine frame Remove the drive belt and driven clutch see CLUTCHES section Remove the F R shifter bracket nut and loosen the cable nuts then remove the cable and bracket from the differ ential Remove the accelerator cable from the accelerator bracket and take off the push nut holding the cable o...

Page 160: ...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 Notes Cautions and Warnings ...

Page 161: ...isassembly P 2 Axle Shaft Seal Removal and Replacement P 2 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 Fig 3 Removing Installing Outer Snap Ring P 2 Fig 4 Removing Installing Axle Shaft P 2 Fig 5 Pressing Bearing from Axle Shaft P 2 Fig 6 Removing Installing Seal P 3 Fig 7 Cut Away of Outer Bearing and...

Page 162: ...Page P iii Repair and Service Manual NOTES REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 163: ...e direction selector pull the neutral lock pin handle out and rotate until the pointed portion of the handle fits into the hole in the direction selector cam Fig 1 Neutral Lock Direction Selector REAR AXLE The rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing Ref Fig 2 on Page P 1 Unless leakage of rear axle lubricant is evident an annual...

Page 164: ...y Required Arbor press 1 Bearing separator 1 Needle nose pliers 1 Internal snap ring pliers 1 Slide hammer P N 18753 G1 1 For brake drum removal see BRAKES section Remove the outer snap ring from the axle tube Ref Fig 3 on Page P 2 Fig 3 Removing Installing Outer Snap Ring Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube Ref Fig 4 on Page P 2 Fig 4 ...

Page 165: ...aft until the spline engages with the differential side gears Install the outer snap ring Coat the outboard spline of the axle with an anti seize compound Install the brake hub and drum thrust washer nut and new cotter pin Ref Fig 7 on Page P 3 Tighten the castellated axle nut to 70 ft lbs 95 Nm torque minimum 140 ft lbs 190 Nm torque maximum Continue to tighten until the slot in the nut aligns wi...

Page 166: ...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 Notes Cautions and Warnings ...

Page 167: ...stallation Q 1 Front Strut Q 1 Sun Top Q 1 SHUTTLE 2 2 SUN TOP Q 3 Rear Support Installation Q 3 Front Support Installation Q 3 Sun Top Installation Q 3 SPLIT WINDSHIELD Q 5 ONE PIECE FRONT WINDSHIELD Q 6 REAR WINDSHIELD Q 7 LIST OF ILLUSTRATIONS Fig 1 Golf Car Sun Top Q 2 Fig 2 Shuttle 2 2 Sun Top Q 4 Fig 3 Split Windshield Q 5 Fig 4 Front Windshield Q 6 Fig 5 Rear Windshield Q 7 ...

Page 168: ...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 Notes Cautions and Warnings ...

Page 169: ...t This teflon washer is needed to prevent squeaking 3 Insert rear strut item 2 through the square hole in the top of the seat back support and push the bolt through the top hole in the rear strut Place washer item 3 and lock nut item 6 on the end of the bolt just enough to prevent the bolt from falling out 4 At the lower hole slide a teflon washer item 5 between rear strut and seat back support an...

Page 170: ... section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings B Fig 1 Golf Car Sun Top D A C B 6 2 3 5 3 4 DETAIL A DETAIL B 7 9 8 11 10 DETAIL C 16 1 18 13 7 14 15 FRONT 14 FRONT OF VEHICLE DETAIL D REAR 12 1 18 13 2 14 15 17 14 FRONT OF VEHICLE ...

Page 171: ...e Front Support Installation 1 Remove and discard four bolts from the front cowl See Detail B 2 At the upper hole both sides of vehicle install the front strut item 9 with bolt item 10 and black lock washer item 11 on the outside of strut and a spacer item 12 between the front cowl and strut Finger tighten hardware 3 At the lower hole secure the strut with bolt item 10 and black lock washer item 1...

Page 172: ...rocedure Pay particular attention to all Notes Cautions and Warnings B Fig 2 Shuttle 2 2 Sun Top D C B A DETAIL A 1 2 DRIVER S SIDE SHOWN 3 4 5 4 6 DETAIL B 9 11 10 13 12 DETAIL C FRONT FRONT OF VEHICLE 9 15 OUTSIDE TUBING ON SUN TOP 16 4 17 18 6 DETAIL D REAR 19 20 4 21 4 7 6 1 2 PASSENGER SIDE SHOWN REAR OF VEHICLE ...

Page 173: ...arting at the bottom onto the front strut so that it snaps into place See Details B and C Repeat for opposite side of windshield Position top grips item 8 as shown See Detail D at top hole on each side of front strut Secure with top grip fasteners item 9 It may be necessary on early production sun tops to drill a 9 32 hole in front face of both sides of front strut approximately 7 down from top of...

Page 174: ... sash to ensure wind shield seats properly See Detail A Insert screw item 4 through washer item 5 rubber grommet item 6 and existing hole in front strut Secure with washer item 5 and lock nut item 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 ...

Page 175: ...ensure rear windshield seats properly See Detail A Insert screw item 4 through washer item 5 rubber grommet item 6 and existing hole in rear strut Secure with washer item 5 and lock nut item 7 See Detail B Do not over tighten or squeeze grommet Place bottom section of rear windshield on rubber grom mets and press the sash starting at the bottom onto the rear strut so that it snaps into place See D...

Page 176: ...Page Q 8 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 177: ...Page R i Repair and Service Manual PAINT TABLE OF CONTENTS FOR SECTION R SECTION TITLE PAGE NO PAINTING R 1 Minor Scratches R 1 Larger Scratches R 1 Complete Panel Repair R 1 ...

Page 178: ...Page R ii Repair and Service Manual NOTES PAINT Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 179: ...lean the surface to be repaired with alco hol and dry 2 Mask area to be painted common masking tape is adequate prior to repair and use aerosol type touch up paint 3 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 best col...

Page 180: ...Page R 2 Repair and Service Manual NOTES PAINT Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 181: ...Page S i Repair and Service Manual TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION S SECTION TITLE PAGE NO GASOLINE VEHICLE PERFORMANCE S 1 STARTER GENERATOR S 6 SUSPENSION AND STEERING S 7 ...

Page 182: ...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 Notes Cautions and Warnings ...

Page 183: ...wer and ground Replace solenoid if power and ground is good Accelerator micro switch Check and adjust if no click is heard Replace if adjustment does not work Starter generator terminals are loose or corroded Tighten or clean Leads are broken or faulty ground Check for breaks at bend or joint Replace or repair leads Field coils are open Repair or replace Armature coil is open Repair or replace STA...

Page 184: ... replace Faulty ignitor Check or replace Faulty pulser unit 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 li...

Page 185: ...d intake exhaust valves Replace Incorrect carburetor float setting Adjust float setting Dirt or water in fuel line carburetor Clean lines carburetor and replace filter Plugged fuel tank vent Clean or replace vent cap Muffler damaged or plugged Repair or replace Fuel pump vent dirty Clean and replace if required Fuel pump has a ruptured diaphragm Replace Low compression Check engine Poor quality of...

Page 186: ...r plugged muffler Repair or replace Inadequate oil supply Check oil system inspect oil pump change oil fill to correct level REPEATED SPARK PLUG FOULING Wrong spark plug type Replace with correct spark plug Wrong spark plug gap Check and adjust if required Faulty coil Check and replace if required Faulty ignitor Check and replace if required Poor quality gasoline Use correct fuel check bulk storag...

Page 187: ...ver motion restricted Repair Carburetor throttle lever not closing fully Adjust Throttle stop preventing throttle from clos ing fully Adjust Carburetor throttle valve spring weak or broken Replace Incorrect adjustment of accelerator governor and carburetor linkages Adjust Carburetor throttle lever shaft bent Replace or rebuild carburetor Governor torsion spring weak or broken Replace Faulty plug w...

Page 188: ...RFECT Load exceeds specification Adjust load to specification Armature bent Repair or replace if necessary Brushes are worn beyond limits Replace Commutator is excessively rough Smooth with emery cloth Incorrect voltage output Check and replace any components if required Commutator is dirty with oil or dust Clean with a cleaner and dry cloth Field coil is shorted or broken Repair or replace GENERA...

Page 189: ...bellows and remove excess grease Insufficient lubricant in king pins tie rod ends idler bushing rack tensioner or steering box Add one shot of lubricant to each grease fitting and operate steering from lock to lock Do not overgrease If steering does not return to acceptable condition proceed to next step Bent rack Remove rack and place on flat surface with rack teeth up If a 015 381 mm feeler gaug...

Page 190: ...Page S 8 Repair and Service Manual NOTES TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to all Notes Cautions and Warnings ...

Page 191: ...i 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 STATEMENT T 3 ...

Page 192: ...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 Notes Cautions and Warnings ...

Page 193: ...ator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic 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 connectors and assemblies iii Filter lock assy ...

Page 194: ...as not been properly maintained Warranty claims will not be denied however solely because of the lack of required maintenance or failure to keep maintenance records 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 DEALER OR SERVICE PROVIDER AUTHO RIZED BY ...

Page 195: ...30 days If you have a question regarding your warranty rights and responsibilities you should contact your nearest authorized service center or call the E Z GO Warranty Department at 1 800 448 7476 WARRANTY COMMENCEMENT DATE The warranty period begins on the date the vehicle is purchased LENGTH OF COVERAGE This warranty shall be for a period of two 2 years from the initial date of purchase WHAT IS...

Page 196: ... the performance of any warranted maintenance or repair on evaporative emission related parts will be provided without charge to the owner if the part is under warranty EVAPORATIVE EMISSION CONTROL WARRANTY PARTS LIST Fuel Line fuel line fittings and fuel line clamps MAINTENANCE STATEMENT The owner is responsible for the performance of all required maintenance as defined in the owner s manual ...

Page 197: ...GE NO TXT GASOLINE FLEET CAR CE CARB U 1 TXT GASOLINE FREEDOM AND FREEDOM HP CE SE LE HP TXT GASOLINE FREEDOM CE SE LE HP FLEET CARB U 2 TXT GASOLINE SHUTTLE 2 2 CE CARB U 3 LIST OF ILLUSTRATIONS Fig 1 Vehicle Dimensions U 4 Fig 2 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter U 5 ...

Page 198: ...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 Notes Cautions and Warnings ...

Page 199: ...on foam Seating for operator and one passenger ENGINE 9 hp 6 7 kw rated 4 cycle 295cc twin cylinder air cooled VALVE TRAIN Overhead valve overhead cam belt drive LUBRICATION Pressurized oil system washable permanent filter BALANCER Internal counter rotating balance shaft IGNITION Solid State electronic timing advance and RPM limiter CARBURETOR Fixed jet AIR CLEANER Engine mounted with replaceable ...

Page 200: ...er ENGINE 9 hp 6 7 kw rated 4 cycle 295cc twin cylinder air cooled VALVE TRAIN Overhead valve overhead cam belt drive LUBRICATION Pressurized oil system washable permanent filter BALANCER Internal counter rotating balance shaft IGNITION Solid State electronic timing advance and RPM limiter CARBURETOR Fixed jet AIR CLEANER Engine mounted with replaceable dry cartridge element DRIVE TRAIN Automatic ...

Page 201: ... fuel gauge SEATING Formed fabric backed vinyl covers over cushion foam Seating for operator and three passengers ENGINE 9 hp 6 7 kw rated 4 cycle 295cc twin cylinder air cooled VALVE TRAIN Overhead valve overhead cam belt drive LUBRICATION Pressurized oil system washable permanent filter BALANCER Internal counter rotating balance shaft IGNITION Solid State electronic timing advance and RPM limite...

Page 202: ...ervice Manual GENERAL SPECIFICATIONS Fig 1 Vehicle Dimensions NOTE Shaded Area Indicates SHUTTLE 2 2 65 5 in 166 cm 92 5 in 235 cm 105 in 267 cm 46 5 in 118 cm Front 33 5 in 85 cm Rear 38 in 97 cm 49 in 124 cm 67 in 170 cm ...

Page 203: ...nual GENERAL SPECIFICATIONS Fig 2 Vehicle Dimensions Incline Specifications and Turning Clearance Diameter TURNING CLEARANCE DIAMETER 19 ft 5 8 m RECOMMENDED MAX RAMP 25 GRADE or 14o MAX RECOMMENDED MAX SIDE TILT 25 GRADE or 14o MAX ...

Page 204: ...Page U 6 Repair and Service Manual GENERAL SPECIFICATIONS NOTES ...

Page 205: ...here fore should be considered potentially hazardous Use extreme care when working on any vehicle When diag nosing removing or replacing any components that are not operating correctly take time to consider the safety of yourself and others around you should the component move unexpectedly Some components are heavy spring loaded highly cor rosive explosive or may produce high amperage or reach hig...

Page 206: ...ut the express permission of E Z GO Division of Textron Inc Technical Communications Department TEXTRON Golf Turf Specialty Products P O Box 388 Augusta Georgia 30906 3852 USA Inside USA Phone 1 800 241 5855 FAX 1 800 448 8124 Outside USA Phone 001 706 798 4311 FAX 001 706 771 4609 ...

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