Ezgo EXPRESS L4 Technician'S Repair And Service Manual Download

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Page T-1

Repair and Service Manual

GENERAL SPECIFICATIONS

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

MODEL: EXPRESS L4
TYPE: GAS POWERED PERSONNEL CARRIER

MODEL YEAR: 2012

Part No: 618864

Engine:

13 hp (9.7 kW) Exceeds SAE J1940 Standard, 4 cycle, 24.5 ci (401 cc) single cylinder, air-cooled by Kawasaki

Overhead valve

Drive Train:

Automatic, continuously variable transmission (CVT)

Electrical:

Starter/Generator, solid-state regulator, 12 Volt maintenance free battery (425 CCA, 60 minute reserve)

Transaxle:

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

Brakes:

Dual rear wheel mechanical self-adjusting drum brakes. Automatic single point park brake release
with self-compensating system

Capacity:

Seating for 4 persons. Rear Seat converts to Cargo Bed

Dimensions

PRODUCT SPECIFICATION

CONFIGURATION HIGHLIGHTS

PRODUCT OVERVIEW

Overall Height (No Canopy)

Overall Height (With Canopy)
Wheel Base
Front Wheel Track

Rear Wheel Track

Gnd Clearance @ Differential
Load Bed Width

Power Source

Performance

Steering & Suspension

Vehicle Power

Fuel Capacity

Body & Chassis

5.8 Gallon (22.0 L) tank

Drive Train

Continuously variable transmission (CVT)

Transaxle

Differential with helical gears

Forward - Reverse
11.42:1 (Forward) 15.78:1 (Reverse)

Some items shown may be optional equipment

Specifications are subject to change without notice

* Field installed accessories may require installation charges

107.0 in (272.0 cm)

46.5 in (118.0 cm)

Overall Length
Overall Width

65.5 in (166.0 cm)

38.5 in (98.0 cm)

40.0 in (102.0 cm)

5.5 in (15.0 cm)

Load Bed Length

32.0 in (81.0 cm)

4 Cycle 24.5 cu in (401.0 cc)

Valve Train

Horsepower (kW)
Electrical System
Batteries (Qty, Type)

Air Cleaner

Cooling System

Gear Selection
Rear Axle Ratio

Single Cylinder OHV
13 hp (9.7 kW) Exceeds SAE J1940 Std.
Starter/Generator. Solid State Regulator
One, 12 Volt Maintenance Free

Replaceable Dry Cartridge

Key or Pedal Start

Pedal

Lubrication

Pressurized Oil System

Oil Filter

Spin-On
Air Cooled

38.0 in (97.0 cm)

80.0 in (203.0 cm)

Vehicle load capacity

4 Persons
870.0 lb (395.0 kg) (Without Batteries)

Seating Capacity
Dry Weight

800.0 lb (360.0 kg)

Bed load capacity

250.0 lb (110.0 kg)

Curb Weight

910.0 lb (415.0 kg

Towing Capacity

20.3 ft (7.1 m)
N/A

Outside Clearance Circle

Intersecting Aisle Clrnce

N/A

Speed (Level Ground)

Fwd - 17.0 mph ± 0.5 mph (27.4 kph ± 0.8 kph)
Rev - 13.0 mph ± 0.5 mph (20.9 kph ± 0.8 kph)

Service Brake

Self-compensating rack and pinion
Leaf springs with hydraulic shock absorbers

Steering

Front Suspension

Rear wheel mechanical self-adjusting drum

Rear Suspension

Leaf springs with hydraulic shock absorbers

Self-compensating, single point engagement
Terra Trac 22 x 11 - 10 / Polished Spoke Whls

Parking Brake

Front Tires
Rear Tires

Terra Trac 22 x 11 - 10 / Polished Spoke Whls

Welded steel with DuraShield™ powder coat
Injection molded TPO

Frame
Front Body & Finish

Injection molded TPO

Rear Body & Finish

Electric Blue

Standard Color

49.0 in (124.0 cm) (Top of steering wheel)

Valve Train:

Pressurized oil system, spin-on oil filter

Lubrication:

Internal counter rotating balance shaft

Balancer:

Fixed float bowl with remote pulse fuel pump

Fuel System:

Electronic spark/magneto

Ignition:

Replaceable dry cartridge

Air Cleaner:

Noise & Vibration

Sound pressure; continued A-weighted equal to or less
than 78 db(A)
Highest RMS value of weighted acceleration is 0.98 m/s

Highest RMS value of weighted acceleration is less than
2.5 m/s

The uncertainty of measurement is 0.54 m/s

Noise

Vibration, WBV
Vibration, HAV

Summary of Contents for EXPRESS L4

Page 1: ...625610 625617 ISSUED MAY 2012 REVISED AUGUST 2012 GASOLINE POWERED UTILITY VEHICLE TECHNICIAN S REPAIR AND SERVICE MANUAL ...

Page 2: ...tery 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 terminals and related accessories contain lead and lead compounds chemicals known to cause cancer and reproductive harm BATTERIES CONTAIN LEAD AND RELATED PARTS 25 DO NOT DRIVE ACROSS SLOPES IN EXCESS OF 1...

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

Page 4: ...he United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the batteries A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C B...

Page 5: ...LE SECTION GENERAL 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 SELECTOR K ELECTRICAL WIRING L MECHANICAL BRAKES M REAR SUSPENSION N REAR AXLE P TROUBLESHOOTING S GENERAL SPECIFICATIONS T ...

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

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

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

Page 9: ...ons therefore people attempting to maintain or repair the vehicle must have the skill and experience to recognize and protect themselves from potential situations that could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the potential for injury refer the repair or maintenance to a qualified mechanic VENTILATION Always store gasoline veh...

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

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

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

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

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

Page 15: ...e Fig 4 Neutral Lock 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 selector cam ROUTINE MAINTENANCE This vehicle will give years of satisfactory service pro viding it receives regular maintenance Refer to the Peri odic Service Schedule for appropriate service intervals Ref Fig 7 Some ...

Page 16: ...railering the vehicle The rated capacity of the trailer must exceed the weight of the vehicle see GENERAL SPEC IFICATIONS for vehicle weight and load Lock the parking brake and secure the vehicle to the trailer using ratchet tie downs TOP AND WINDSHIELD The top does not provide protection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects...

Page 17: ...not use hot water strong soap or harsh chemical detergents Rubber parts should be cleaned with non abrasive household cleaner Occasional cleaning and waxing with non abrasive products designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle T...

Page 18: ...is chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 80 of the torque required for dry fasteners 4 5 8 11 15 20 24 33 35 47 55 75 75 102 130 176 125 169 190 258 Grade 5 Grade 8 6 8 13 18 23 31 35 47 55 75 80 108 110 149 200 271 320 434 480 651 6 8 18 24 35 47 55 75 80 108 110 149 170 230 280 380 ...

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

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

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

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

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

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

Page 25: ...e or reach high temperatures Gasoline carbon monoxide battery acid and hydrogen gas could result in serious bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unforeseen situation occur Always use the appropriate tools listed in the tool list and wear app...

Page 26: ...nded spark plug If the spark function is to be observed at the spark plug be sure to install a spare spark plug into the open cylinder before operating the starter Never test the function of a fuel pump in the vicinity of a hot engine or other source of flame or combustion Never confuse the hoses to and from the fuel pump Verify that the carburetor and pulse lines are correctly installed before st...

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

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

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

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

Page 31: ...Repair C 10 LIST OF ILLUSTRATIONS Fig 1 Drill Out Metal Rivet C 1 Fig 2 Front Body Components C 2 Fig 3 Body Components Continued Express L4 Express S4 C 3 Fig 4 Body Components Continued Terrian 250 500 1000 C 4 Fig 5 Rear Body Components C 5 Fig 6 Seating Express L4 Express S4 C 6 Fig 7 Seating Terrian 250 500 1000 C 7 Fig 8 Plastic Bed Components Manual Lift C 8 Fig 9 Plastic Bed Components Pow...

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

Page 33: ...l provide additional protection In general body component replacement can be accom plished with a minimum of specialized tools Most body components are held in place with conventional remov able hardware nuts bolts washers and screws Some components are mounted with pop rivets which require that the rivet head be removed in order to push out the shank of the rivet The rivet head is easily removed ...

Page 34: ...d this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 2 Front Body Components 48 Brush Guard Front Basket Glove Box Door Splash Panel Instrumental Panel Front Fascia Fender Flare Cowl Splash Panel Floorpan ...

Page 35: ...nd this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 3 Body Components Continued Express L4 Express S4 Box Cooler and Bracket Box Cooler Floor Mat Fender Liner Seat Support Battery Tray Splash Panel Frame ...

Page 36: ...ng any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 4 Body Components Continued Terrian 250 500 1000 Side Panel Floor Mat Rocker Panel Battery Tray Splash Panel Seat Frame For TERRIAN 500 AND 1000 Seat Wrap W Louvers For TERRIAN 250 Floor Mount Gun Holder Ashtray ...

Page 37: ... this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 5 Rear Body Components Rear Fender Notched Rear Bumber Rear Panel TERRIAN 250 500 1000 EXPRESS L4 EXPRESS S4 Seat Hinge Plate Seat Hinge Plate Access Panel ...

Page 38: ...ular attention to Notices Cautions Warnings and Dangers Fig 6 Seating Express L4 Express S4 Front of Vehicle Top of Vehicle Seat Back Support Seat Back Support Seat Back Support Flip Flop Seat Bottom Assembly Seat Back Assembly Hip Restraint Seat Bottom Assembly Footrest Handle Handrail Footrest Weldment Seat Frame Weldment ...

Page 39: ...attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 7 Seating Terrian 250 500 1000 Seat Back Assembly Seat Bottom Assembly Seat Back Support Bracket Seat Back Support Bracket Seat Back Support Access Cover Hip Restraint TERRAIN 250 500 TERRAIN 1000 ...

Page 40: ... all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 6 Plastic Bed Components Manual Lift A A B B C C Plastic Bed Rubber Bumper Heat Shield Latch Plate Latch Handle ...

Page 41: ...ny procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 7 Plastic Bed Components Power Actuator Actuator may be rotated 90 on some models UP DOWN ELECTRIC DUMP RED from Battery BLK from Battery RED from Actuator WHT from Actuator Front of Vehicle Electric Actuator Plastic Bed ...

Page 42: ... clean the surface to be repaired with alco hol and dry 2 Mask the 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 be...

Page 43: ...Page C 11 Repair and Service Manual B B BODY Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

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

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

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

Page 47: ...could cause personal injury Tire inflation should be determined by the condition of the terrain See GENERAL SPECIFICATIONS 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 ...

Page 48: ...the cross sequence 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 with lug nuts Finger tighten lug nuts as shown Then tighten lug nuts to 50 85 ft lbs 70 115 Nm torque in 20 ft lbs 30 Nm increments following the same pattern Fig 1 Wheel and Tire Installation NOTICE ITEM NO TORQUE SPECIFICAT...

Page 49: ...Page D 3 Repair and Service Manual B B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 50: ...Page D 4 Repair and Service Manual B WHEELS AND TIRES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 51: ...7 Wheel Bearing Inspection Packing E 8 Seal Installation E 8 Bearing Adjustment E 8 King Pin Bushing Replacement E 8 Wheel Alignment E 9 Tire Wear Diagnosis E 9 LIST OF ILLUSTRATIONS Fig 1 Front Suspension Components E 2 Fig 2 Front Axle Alignment E 2 Fig 3 Tie Rod Replacement E 3 Fig 4 Steering Wheel Cover Removal E 4 Fig 5 Loosen Steering Wheel E 4 Fig 6 Steering Wheel Replacement E 4 Fig 7 Stee...

Page 52: ...ng and Front Suspension E 11 Fig 15 Lubrication Points E 12 Fig 16 Bearing Adjustment E 13 Fig 17 Wheel Alignment E 14 Fig 18 Disconnect Intermediate Shaft to Center Steering Wheel E 14 Fig 19 Front Suspension Components E 15 Fig 20 Axle Linkage Rod Replacement E 17 Fig 21 Front Axle Alignment E 18 Fig 22 Hub Replacement E 18 Fig 23 Seal Installation E 18 Fig 24 Wheel Bearing Replacement E 19 Fig ...

Page 53: ... iii Repair and Service Manual B B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 54: ... E iv Repair and Service Manual B FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 55: ...t 4 from the bottom of the shock absorber 1 at the front axle 2 Ref Fig 1 Compress the shock absorber to clear the mounting bracket Remove clamps securing the boot to the shock absorber and slide boot down and off the shock absorber Replace shock boot and reattach shock absorber as instructed above Front Axle Replacement Tool List Qty Wheel chocks 4 Floor jack 1 Jack stands 2 Impact wrench 1 Impac...

Page 56: ...r washer Replace front wheels per WHEELS AND TIRES section and lower vehicle Fig 1 Front Suspension Components Fig 2 Front Axle Alignment Front Spring Replacement Tool List Qty Wheel chocks 4 Floor jack 1 Jack stands 4 Impact wrench 1 Impact socket 3 4 1 Torque wrench ft lbs 1 Pliers 1 Wrench 3 4 1 Socket 9 16 1 Wrench 9 16 1 ITEM TORQUE SPECIFICATION 12 35 50 ft lbs 50 70 Nm Part of Frame Part of...

Page 57: ...r bolt at front of left spring Ref Fig 2 Tighten the spring hardware to 35 50 ft lbs 50 70 Nm torque Replace front wheels per WHEELS AND TIRES section and lower vehicle Tie Rod Wheel Bearing and King Pin Inspec tion Grasp the tie rod and check for any vertical motion which would indicate a worn condition and require replacement Grasp the top and bottom of the wheel and use a rocking motion to chec...

Page 58: ...ned remove retaining nut and remove steering wheel If installing new steering wheel assemble the steering wheel and rear collar hub 4 by aligning the retaining tabs on the hub with slots in back of steering wheel Squeeze tabs to allow insertion of hub Do not force Squeeze hub on top and bottom to fully seat Replace steering wheel by first lightly coating the splines of the steering shaft with a co...

Page 59: ...hat would require removing the housing from the vehicle would be the replacement of the bear ing 14 and bushing 15 Ref Fig 7 The bearing and bushing must be pressed out To remove the steering housing assembly remove the driver side front wheel remove the steering wheel 3 and remove the steering shaft 12 as instructed above Loosen the two nuts 16 until ball joint 17 end threads are protected Using ...

Page 60: ...in the steering housing Remove the spring 34 and tensioner Replace rack tensioner in the reverse order of removal replacing gasket 33 with a new one Tighten bolts 31 to the specified torque Lubricate through grease fitting 29 Rack Replacement Tool List Qty Wrench 9 16 1 Needle nose pliers 1 Wrench 11 16 1 Ball joint separator 1 Plastic faced hammer 1 Straight blade screwdriver 1 The rack can be re...

Page 61: ...new pinion bushing can then be inserted The rack and steering pinion must be replaced as a set MAINTENANCE Good routine maintenance of the front suspension and steering consists of routine lubrication See Lubrication Chart and the Periodic Service Schedule in Section A Be sure to use only the recommended lubricants Main tain the correct adjustment of the front bearings and repack them in accordanc...

Page 62: ...ers until the entire bear ing is coated in grease Fill the area between the rollers with grease and apply a light coating to the bearing race Install bearing in race Seal Installation Clean the hub seal surface to remove grease and press the inner bearing seal into place with the flange side of the seal facing into the bore Tap gently into place with a seal installation tool until it is flush with...

Page 63: ...gned will show even wear over the entire tread area A tire that is run under inflated will show wear on the outer edges of the tread Over inflation will result in wear occurring at the center of the tread Wear on either side of a correctly inflated tire indicates a tire that is out of alignment The toe in may be correct but if the toe in has not been set with the wheels in line with the body of th...

Page 64: ...is section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 13 Tire Wear NOTES ILLUSTRATIONS ARE DISTORTED FOR CLARITY DUE TO LOW WEIGHT OF VEHICLE LOW INFLATION PRESSURES TIRE SHAPE WILL BE LESS PRONOUNCED INDICATES AREAS OF EXCESSIVE TIRE WEAR ...

Page 65: ...ttention to Notices Cautions Warnings and Dangers Fig 14 Axle Mounted Steering and Front Suspension Components 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 Tie Rod Spacer Rack Ball Joint Rack Extension Page E 11 ...

Page 66: ...nts Do not use more than three 3 pumps of grease in any grease fitting at any one time Excess grease may cause grease seals to fail or grease migration into areas that could damage components Wheel Bearing and King Pin Bushing inspection To prevent possible injury or death resulting from a vehicle falling from a jack follow the lift ing procedure in Section B of this manual Be sure vehicle is on a...

Page 67: ... If performing a wheel bearing adjustment only lift and support front of vehicle per SAFETY section Remove dust cap 1 and cotter pin 2 and loosen castellated nut 3 If performing a wheel bearing adjustment as part of another procedure make sure wheel is mounted to hub hand tight with lug nuts 4 and hub is loosely retained on spindle 5 with castellated nut Ref Fig 16 Seat bearings by rotating wheel ...

Page 68: ...r flat section of tube The tie rod has different threads on each end The end with the flat area on the threaded tube has left hand threads clock wise to loosen while the end without the flat has conventional right hand threads counter clockwise to loosen 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...

Page 69: ...st Qty Wrench 9 16 1 Remove the nut 1 from the bottom of the shock absorber 2 at the front axle 3 Ref Fig 19 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 NOTE Tie Rod Not Shown for Clarity Part of Frame Part of...

Page 70: ...rt 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 locatio...

Page 71: ...25 27 securing rear of spring 17 to vehicle frame and discard lock nuts 27 To prevent stress and possible damage to the rack and pinion unit the driver side spring must be mounted to the axle with the hardware 20 23 installed in its original location Ref Fig 19 Driver side spring installation is the reverse order of dis assembly making sure to install the long bolt 20 spring plate 24 spacer 23 nut...

Page 72: ...the bore Tap gently into place until seal is flush with end of hub Lubri cate lips of seal and spindle with grease Ref Fig 23 Place new hub onto spindle and fill the area between the two wheel bearings about 1 2 3 4 full with grease and apply a light coating to the outer bearing race Install outer wheel bearing 4 and secure hub loosely with castellated nut Place wheel onto hub and hand tighten lug...

Page 73: ... hub 1 is clean and place new race over bore of hub Evenly tap with hammer and bearing driver to drive race fully in bore Repeat on other side of hub Clean spindle 2 and pack new bearings with grease Wheel Bearing Packing on page E 12 Fig 24 Wheel Bearing Replacement Install inner wheel bearing 4 and new grease seal in hub and mount hub to spindle Hub Replacement on page E 18 Adjust bearing Wheel ...

Page 74: ...1 16 1 To remove rack ball joint 1 loosen passenger side front wheel and lift and support front of vehicle per SAFETY section Ref Fig 25 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 joint and tap nut wit...

Page 75: ...age E 13 Tie Rod Inspection Replacement Tool List Qty 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 Torque Wrench ft lbs 1 Crowfoot Socket 3 4 1 Grasp the tie rod 8 at ball joints 6 and check for any vertical motion which would indicate a worn condition and require replacement Ref Fig 25 To remove tie rod ...

Page 76: ...eel fully to the left Remove rack ball joint 2 and jam nut 3 from rack extension 4 Rack Ball Joint Replacement on page 20 Cut wire ties 5 6 and slide bellows off rack extension Install new bellows aligning small end over groove in rack extension and secure with new wire tie 5 Leave large end loose until rack extension to rack and pinion unit clearance is checked or adjusted Fig 28 Bellows Replacem...

Page 77: ...List Qty Needle Nose Pliers 1 Wrench 11 16 1 Ball Joint Separator 1 Plastic Faced Hammer 1 Wrench 3 4 1 Socket 3 4 1 Socket 11 16 1 Torque Wrench ft lbs 1 The spindle bearings are designed to be used dry Lubrication attracts dirt and will ruin the bearings Do not apply grease to the spindle bearings Loosen front wheel Lift and support front of vehicle per SAFETY section and remove front wheel If v...

Page 78: ...y are found to be damaged or excessively worn a new rack and pinion unit must be installed Secure rack and pinion unit in vice by the mounting ears only The rack and pinion unit is made of aluminum and can be damaged if held otherwise Remove rack and pinion unit from vehicle Anchor in vice by clamping on the mounting ears of the unit Disassemble rack and pinion unit 1 by first removing screw 13 an...

Page 79: ... Torque Wrench in lbs 1 To remove rack and pinion unit 12 Ref Fig 25 loosen front wheels and lift and support front of vehicle per SAFETY section Remove front wheels Remove bolt 13 and washer 14 securing intermediate shaft 15 to rack and pinion unit 12 Remove cotter pin 2 and loosen castellated nut 3 until rack ball joint 1 threads are protected Using a ball joint separator as a lever apply pressu...

Page 80: ... 8 gap Tighten jam nut 5 to 35 45 ft lbs 47 61 Nm torque Secure bellows to rack and pinion unit with new wire tie 14 Steering Wheel Replacement Tool List Qty Socket 15 16 1 Ratchet 1 2 drive 1 Plastic Faced Hammer 1 Ball Peen Hammer 1 Anti seize Compound 1 Torque Wrench ft lbs 1 To maintain correct orientation when replacing steering wheel first turn wheels straight ahead To prevent damage to the ...

Page 81: ...es ent 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 Ratchet 1 Socket 3 4 1 Socket 13 mm 1 Ratchet 1 Socket 9 16 1 Snap RIng Pliers 1 Bearing Separator 1 Gear Puller 1 Arbor Press 1 Bearing Driver Set 1 Torque Wrench ft lbs 1 Torque Wrench in lbs 1 Wh...

Page 82: ...seal in bushing 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 17 25 Nm torque Install front wheel s per WHEELS AN...

Page 83: ...ervice Manual B B FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES Page E 29 ...

Page 84: ...Service Manual B FRONT SUSPENSION AND AXLE MOUNTED STEERING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES Page E 30 ...

Page 85: ...erator Cable Adjustment F 3 Throttle Rod Removal F 3 Throttle Rod Adjustment F 3 PEDAL BOX ADJUSTMENTS F 4 Accelerator Pedal Arm Adjustment F 4 Micro Switch Adjustment F 4 Road Test F 5 LIST OF ILLUSTRATIONS Fig 1 Accelerator and Speed Control System F 1 Fig 2 Governor Cover Removal F 2 Fig 3 Accelerator Cable at Governor F 3 Fig 4 Pedal Box Access F 3 Fig 5 Accelerator Cable at Pedal Box F 3 Fig ...

Page 86: ...Page F ii Repair and Service Manual B SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 87: ...ility of the vehicle on the jack stands before starting any repair procedure Never work on a vehicle that is sup ported by a jack alone SYSTEM OPERATION Pedal Box Operation As the accelerator pedal is depressed the accelerator rod moves towards the rear of the vehicle by overcom ing the resistance of the accelerator return spring Ref Fig 1 As the accelerator pedal moves the parking brake is releas...

Page 88: ...te A possible governor failure within the rear axle Worn components in the governor system Improper adjustment of linkage system Other factors may effect the performance characteristics of the vehicle but they should be investigated only after confirming the linkage adjustment SPEED CONTROL Tool List Qty Phillips Screwdriver 1 Flat Blade Screwdriver 1 Needle Nose Pliers 1 Slip Joint Pliers 1 Open ...

Page 89: ... Fig 5 Accelerator Cable Adjustment Ref Fig 3 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 pedal Once correctly positioned tighten the cable securing nuts 13 on the bracket Throttle Rod Removal To remove the throttle rod from the carburetor throttle pla...

Page 90: ... accelerator pedal arm 1 contacts the accelerator pedal bracket 2 when in the released posi tion Ref Fig 8 If there is no contact loosen the jam nut 3 and rotate the rod 4 until contact is made Note that the factory applies a thread sealant to the accelera tor rod threads before threading the rod into the clevis Fig 8 Accelerator Pedal Arm Adjustment Micro Switch Adjustment When the system is in c...

Page 91: ...Replace the access cover on the floor Replace floormat and rocker panel Road Test Install the negative battery cable Test drive the vehicle and confirm that the compression spring adjustment results in the maximum governed speed specified in the GENERAL SPECIFICATIONS section Determine speed by measuring the time it takes to travel a known set distance with vehicle at maximum speed Enter time and ...

Page 92: ...Page F 6 Repair and Service Manual B SPEED CONTROL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 93: ...10 Removing the Engine from the Vehicle G 10 Engine Installation G 10 DRIVE CLUTCH REMOVAL G 10 LIST OF ILLUSTRATIONS Fig 1 Oil Dipstick G 1 Fig 2 Check Oil Level on Dipstick G 1 Fig 3 Oil Viscosity Chart G 2 Fig 4 Cleaning Top of Engine G 2 Fig 5 Oil Drain Plug G 2 Fig 6 Remove Oil Filter G 2 Fig 7 Inspect Oil Filter G 3 Fig 8 Add Engine Oil G 3 Fig 9 Air Filter Assembly G 3 Fig 10 Checking Belt ...

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

Page 95: ...an be operated safely as long as oil is within the safe operating 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 Remember that oil expands as it gets hot Do not overfill Ref Fig 2 Check that the oil cap is firmly in place When adding oil between oil change...

Page 96: ...h to 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 installing the drain plug clean the area around the drain plug mount with a lint free cloth and inspect the drain plug 1 for damage replace if necessary Ref Fig 5 If the O ring 2 on the drain plu...

Page 97: ...qual ity oil that meets or exceeds API SF SG CC standards Ref Fig 3 Check oil level on dipstick Oil should be slightly below H to allow for expansion If necessary continue to add oil slowly and allow time for oil to flow down into engine Check oil level on dipstick Do NOT overfill Do NOT overfill engine Too much oil may cause smoking or allow oil to enter the air filter enclosure Fig 8 Add Engine ...

Page 98: ...ement or any part of the unit Install the element in the same way it was removed being sure that the cover clips are 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 generator belt tension should be checked after the first 15 20 hours and set to 75 80 lbs 34 36 kg A ...

Page 99: ... mm 1 Socket 15 mm 1 Torque wrench ft lbs 1 To prevent possibility of personal injury dis connect negative battery cable before beginning starter generator removal Remove the wiring from the starter generator Loosen the jam nut 11 and the adjusting nut 12 securing the starter generator adjuster until the starter generator belt can be removed from the drive clutch Remove the starter generator pivot...

Page 100: ...leaning Cooling System with Air SPARK PLUG Tool List Qty Spark Plug Socket 13 16 1 Feeler Gauge wire type 1 Ratchet Extension 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 and clean and re gap The spark plug should be properly gapped Ref Fig 17 and replaced...

Page 101: ...mpression as it does during normal running Stop the engine Disconnect the spark plug cap 3 and remove the spark plug 4 keeping the engine throttle and the choke valve fully open Attach the compression gauge 1 to the adapter 2 and insert firmly into the plug hole Fig 18 Compression Gauge Place the spark plug cap 3 on the removed spark plug 4 and ground the spark plug to the engine To prevent possib...

Page 102: ...temperature With the rocker cover removed 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 arm 8 and the valve stem end Valve Clearance when cold Inlet Exhaust 0 10 0 15 mm 0 004 0 006 in Fig 20 Measure Valve Clearance If the valve clearance is inc...

Page 103: ...ds for stability 4 Remove the drive belt 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 way 6 Remove the ground strap from the Starter Generator using a 10 mm socket 7 Remove the Starter Generator See Starter Generator Replacement in this section 8 Re...

Page 104: ...on When installing the fuel and pulse lines pay particular attention to assure that the lines are not confused It is important to follow the assembly sequence recom mended for mounting hardware With the assistance of a hoist or another person lower the engine into position over the engine support cast ings Install one rear horizontal and one front bottom engine bolt through the casting and engine ...

Page 105: ...Page G 11 Repair and Service Manual B B ENGINE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 106: ...Page G 12 Repair and Service Manual B ENGINE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 107: ...allation H 3 Carburetor Removal H 4 Carburetor Disassembly H 4 Float Level Alignment H 5 Carburetor Installation H 5 FUEL PUMP H 5 Fuel Pump Replacement H 6 FUEL LINES AND FILTER H 6 FUEL TANK REMOVAL H 7 CARB CANISTER H 7 LIST OF ILLUSTRATIONS Fig 1 Fuel System H 1 Fig 2 Fuel Tank H 2 Fig 3 Choke Cable Attachment H 3 Fig 4 Choke Cable and Housing H 3 Fig 5 Carburetor Operation H 4 Fig 6 Carbureto...

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

Page 109: ...cles it also includes the CARB Canister Ref Fig 1 To prevent serious injury or death resulting from a possible explosion do not smoke near the fuel tank or refuel near open flame or elec trical items which could produce a spark Always wear safety glasses while refueling to prevent possible eye injury from gas oline or gasoline vapor When refueling inspect the fuel cap for leaks or breaks that coul...

Page 110: ...and the setting of the pilot screw Main Jet System The main jet system function 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 nozzle This mixture passes into the carburetor venturi as atomized air fuel and is mixed with intake air and delivered to t...

Page 111: ...end of the choke cable and pull the choke cable out through the seat wrap Remove the choke cable bezel 8 from the seat panel Choke Cable and Housing Installation In the following text there are references to removing install ing bolts etc Additional hardware nuts washers etc that are removed must always be installed in their original positions unless otherwise specified Non specified torque specif...

Page 112: ...10 Carburetor Disassembly Ref Fig 6 Tool List Qty Socket 12 mm 1 Ratchet 1 Pliers 1 Straight blade screwdriver narrow 1 Before disassembling the carburetor drain the fuel bowl and clean the 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 are due to w...

Page 113: ...or equivalent Fig 7 Float Adjustment Carburetor Installation To prevent possible injury from explosion or fire check for clogged or kinked hoses Clogged or kinked carburetor hoses are not only detrimental to the proper operation and performance of the vehicle but can also be a safety hazard in the case of fuel leaking on a hot engine Air Cleaner Do not let the carburetor vent hose become clogged o...

Page 114: ...portant for efficient pump operation If the hose is to be replaced be sure to replace with a hose of the same length and approved material Observe and identify the supply and pulse hoses Remove the hoses plug the fuel lines and remove the fuel pump 1 by removing the two screws that secure it to the bracket located on the seat support frame near the fuel tank on the passenger side of the vehicle Re...

Page 115: ... the line to the CARB canister 5 if the vehi cle is so equipped Watch for gasoline leakage from the fuel line always use a drip pan and dispose of spent fuel safely Remove the forward hex nut 6 and bolt Remove the rear nut 7 and bolt Remove the tank from the engine compartment Installation is in reverse order Fig 10 Fuel Tank Removal CARBON CANISTER Ref Fig 11 Tool List Qty Flat Blade Screwdriver ...

Page 116: ...Page H 8 Repair and Service Manual B FUEL SYSTEM Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 117: ...eased Load J 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 Driven Clutch Assembly J 4 Driven Clutch Installation J 4 STORAGE J 4 LIST OF ILLUSTRATIONS Fig 1 Continuously Variable Transmission System CVT J 1 Fig 2 Removing the Drive Belt J 2 Fig 3 CVT Components J 3 ...

Page 118: ... Repair and Service Manual B CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 119: ... is 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 clutch sheaves and begins to rotate As the engine speed continues to rise the drive clutch sheave continues to move inwards forcing the drive belt to the outer diameter of the drive clutch sheaves which...

Page 120: ... the 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 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...

Page 121: ...he center of the drive clutch Raise the vehicle frame with the floor jack and allow the powertrain to drop so that the clutch puller bolt clears the spring hanger Remove the front eyebolt from the spring hanger using a 15 mm socket and a 15 mm wrench Install the clutch puller bolt in a clockwise posi tion and using the impact tool and universal joint remove the drive clutch from the shaft Remove t...

Page 122: ...impact socket on the clutch puller bolt remove the clutch then remove the clutch puller bolt and slide the 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 repairs may be made to the driven clutch Remove the retaining ring 9 and remove the outer sp...

Page 123: ...Repair and Service Manual B B CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 124: ... Repair and Service Manual B CONTINUOUSLY VARIABLE TRANSMISSION CVT Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 125: ...K i Repair and Service Manual DIRECTION SELECTOR DIRECTION SELECTOR K 2 Removing Direction Selector K 2 Replacing a Micro Switch K 2 Shift Cable Adjustment K 2 Neutral Lock Operation K 2 LIST OF ILLUSTRATIONS Fig 1 Direction Selector K 1 Fig 2 Neutral Lock K 3 ...

Page 126: ...Page K ii Repair and Service Manual B DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 127: ...rvice Manual B B DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 1 6 4 8 6 8 5 9 2 3 10 11 Fig 1 Direction Selector ...

Page 128: ...two electri cal wires from the switch Reattach the wires to the new switch Using a DVOM test the switch to ensure it is operational before continuing Once it is determined that the switch is functional continue reassembly of micro switch to the direction selector and installing to body Connect wires attaching to the switch and the screws 6 nuts 7 and washers 8 attaching the switch to the assembly ...

Page 129: ... before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 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 selector cam Fig 2 Neutral Lock 2 1 3 ...

Page 130: ...Page K 4 Repair and Service Manual B DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 131: ...t L 8 BATTERY VOLTAGE TEST L 8 STORAGE OF BATTERY L 9 DVOM DIGITAL VOLT OHM METER L 9 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 Wiring Diagram Continued L 3 Fig 3 Electrical System Physical Location L 4 Fig 4 Resistance Between A B and A C L 5 Fig 5 Resistance Between B A and B C L 5 Fig 6 Res...

Page 132: ...Page L ii Repair and Service Manual B ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 133: ... 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 any test of wirin...

Page 134: ...cal System Wiring Diagram F E A B S X A B X S RED RED WHT BLK BLK BLK BLK BLK OPTIONAL HOUR METER FRAME GRND SOLENOID COIL BLK BLK RED INLINE FUSE YEL RED RELAY BLK BRN BRN RED WHT BLK BLK BLK RED RED WHT BRN RED WHT ENG MAGNETO PEDAL BOX CONNECTOR TO OIL LIGHT SWITCH ON ENGINE KEY SWITCH CONNECTOR FUEL GAGE OIL LIGHT YEL BLK BLK BLU BLU REV BUZZER GRND TO ELE PLATE REVERSE MICRO FUEL SENDING UNIT...

Page 135: ...efore attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Fig 2 Electrical System Wiring Diagram A B x s BATTERY GND TO ELE PLATE VOLTAGE REG BLK RED FRAME GROUND SOLENOID COIL INLINE FUSE 1 2 3 WHT YEL GRN STARTER GENERATOR BLK TO ENGINE F2 DF F1 A1 A2 ...

Page 136: ...uffler cylinder etc Permanent damage may be caused to the coil or ignitor if the plug is 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 the spark plug wire as follows Using a spark plug that is known Battery Electrical Controller Starter Generator ...

Page 137: ... the Magneto Set the meter to the ohms scale and measure the resis tance as shown in the following illustrations Fig 4 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 KΩ A normal reading with the negative lead on A and the positive lead on C would be 2 18 KΩ A normal reading with the negative lead on B and the positive lead on A ...

Page 138: ...ion Turn the key switch to the ON position a Place the DVOM set to the appropriate DC volts scale negative probe 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 contacts are closed c If 0 voltage is not indicated while the accelerator pedal is pressed rep...

Page 139: ...r Inspection 1 Inspect the commutator for wear or damage 2 Inspect the brush assembly for wear and damage to the brush 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 Inspect the field coil insulators and lead wire 5 Check the bearings for free rotation and...

Page 140: ...ushes removed using 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 shell If continuity is indicated the field coils are grounded against the frame and the field coils must be replaced 5 Clean all parts to be reinstalled and reassemble in the reverse ord...

Page 141: ...n dimly the battery should be tested before trying to troubleshoot the lighting circuit Example 2 If a problem occurs in the lighting circuit that results in only one of the headlights not working there is no reason to check battery wiring or the fuse since it is obvious that voltage is present Since bulbs will burn out over time the obvious place to start is at the headlight that is not functioni...

Page 142: ...hat lower than battery voltage A reading of 1 volt below battery voltage is acceptable 3 Check power wire Firmly attach the black probe to the battery post with the black wire attached and the red probe to the green wire terminal at the fuse block A reading of battery voltage indicates that the power wire is in good condition The power wire supplies power to the entire fuse block 4 Check fuse Plac...

Page 143: ...UT RED RED RED RED CAP IN LINE FUSE 1 ORANGE 12 VOLTS BATTERY HORN SWITCH YELLOW A B HORN BLACK CONNECT TO MAIN HARNESS IGNITION SWITCH POWER 12V SWITCHED RED FUEL GAUGE OIL LIGHT WHITE BLUE OIL LIGHT SWITCH BLACK FUEL SENDING UNIT BLACK BLACK CAP HEAT SHRINK BALCK CAP IN LINE FUSE 2 PS S T T LIGHT DS S T T LIGHT BLACK BLUE WHITE WHITE YELLOW DS TURN LT PS TURN LT BLACK PS HEADLIGHT BLACK BLACK BL...

Page 144: ...Page L 12 Repair and Service Manual B ELECTRICAL Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 145: ...nd Equalizer Assembly Removal and Installation M 16 Compensator Assembly Removal and Installation M 17 Brake Pedal Removal and Installation M 17 Parking Brake Catch Bracket Removal and Installation M 18 Parking Brake Pedal Removal and Installation M 18 Pedal Bumper Adjustment M 18 Parking Brake Release Linkage Removal and Replacement M 18 Parking Brake Kick Off Cam Removal and Installation M 18 LI...

Page 146: ... 14 Fig 21 Wheel Brake Lubrication Points M 15 Fig 22 Backing Plate Removal and Installation M 15 Fig 23 Brake Shoes and Springs M 16 Fig 24 Setting Adjuster Screw M 16 Fig 25 Brake Cable Equalizer and Compensator M 17 Fig 26 Brake Pedal Removal and Installation M 17 Fig 27 Catch Bracket and Latch Arm M 18 Fig 28 Pedal Bumper Adjustment M 18 Fig 29 Parking Brake Release Linkage and Kick Off Cam M ...

Page 147: ...n 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 reliably When the brake is released there must be slack in the system so the brakes will release fully and the adjusters will function Free pedal travel pedal force shoe to drum cleara...

Page 148: ...juster will result Adjustment takes place only when the brake is fully applied and released while the vehicle is moving Ref Fig 2 It is very important that the brake cables permit the brake levers to release fully when the brake pedal is in the released position Fig 2 Wheel Brake Adjustment Brakes adjust only while the vehicle is moving When the brake pedal is depressed the brake lever moves towar...

Page 149: ...from the catch 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 s...

Page 150: ...heck and adjust per manual End of brake cable loose from anchor brackets Check and repair Cracked brake drum Replace In excess of 1 1 8 2 9 cm free pedal travel Soft Pedal In Excess of 2 1 4 5 4 cm free peda travel Soft Pedal Low pedal force at parking brake latch Adjust per manual Brake cables damaged Replace Brake return bumper out of adjustment Adjust per manual End of brake cable loose from an...

Page 151: ...quires 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 remove rust until condition is relieved Brake Pivot binding Check and replace poor components Parking brake hard to latch ...

Page 152: ... 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 gap exists bet...

Page 153: ...se conditions are found replace both cables and equalizer as a set 5 Check the clevis pins Check clevis pin attaching the brake cables to the brake levers They must be loose when the brake pedal has been released If the clevis pins are not loose but brake pedal free travel is correctly adjusted and the brake cables move freely the problem is likely in the wheel brake 6 Inspect the brake cable equa...

Page 154: ...esulting 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 section of this manual as ...

Page 155: ...the Periodic Brake Performance Test three more times second set of three If the vehicle passes two of three Periodic Brake Perfor mance Tests check that the clevis pins at the brake levers are loose If they are loose return vehicle to ser vice If they are tight adjust free travel Free Travel Adjustment on Page M 13 Then repeat the Periodic Brake Performance Tests If vehicle fails remove from servi...

Page 156: ...sms Remove excess dust and dirt from the drum with a brush The drum must not be turned to true a worn friction surface Turning will make the drum too thin causing drum failure and a loss of brakes which could cause severe 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 excessiv...

Page 157: ... shoes and by the moving anchor 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 any point on the shoe It is normal for the shoes to show more wear at the leading and trailing edges Ref Fig 15 If the brake shoe thickness is approaching 060 1 5 mm it is r...

Page 158: ...he 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 parts are replaced Brake pedal free travel is ...

Page 159: ...t The parking brake latching force can be checked as verifi cation after setting brake pedal free travel To check park ing brake latching force place a bathroom scale on the service and parking brake pedals Using both feet press the scale down against the parking brake pedal until it latches The parking brake should latch between 65 and 75 lbs 29 34 kg indicated on the scale Fig 18 Check Clevis Pi...

Page 160: ...ll cotter pin Install the remaining hardware and tighten the nut to 80 90 ft lbs 108 122 Nm torque Continue to tighten until a new cotter pin can be installed through the castel lated nut and the hole in the axle Maximum torque is 140 ft lbs 190 Nm Wheel Brake Service Wheel brake service consists of disassembly cleaning inspection lubrication and re assembly of the wheel brake Worn or damaged comp...

Page 161: ...ube Ref Fig 22 Fig 22 Backing Plate Removal and Installation Remove the clevis pin securing the brake cable to the brake lever Installation is the reverse of removal Connect the brake cable to the wheel brake with the clevis pin installed from the top down and a new cotter pin Install the brake assembly or backing plate to the axle tube flange Install new hardware locknut should only be used once ...

Page 162: ...ef Fig 23 The opposite end of the adjuster spring is hooked to the adjuster with the hook end facing out The brake shoe springs must be installed with the light spring closest to the adjuster mechanism with the hook installed down through the rear brake shoe and up through the front brake shoe The heavy top spring is installed with both spring hooks installed down through the brake shoes Check to ...

Page 163: ...ake pedal free travel Adjusting Brake Pedal Free Travel on Page M 12 Brake Pedal Removal and Installation Disconnect the compensator assembly 1 from the brake pedal by removing the cotter pin 2 and the clevis pin 3 Unplug the wiring harness on models equipped with brake lights Unhook the torsion spring 4 by insert ing a thin blade screwdriver between the small hook and the bracket Move the hook ba...

Page 164: ...g brake arm latch is a hardened part Do not grind or file it as doing so will cause the part to lose its hardness char acteristics A new part must be used Installation is in the reverse order of disassembly Use a new push nut or push nuts If required adjust the kick off cam 3 See If required adjust the kick off cam 3 Ref Fig 27 Pedal Bumper Adjustment Loosen the bumper lock nut and adjust the bump...

Page 165: ... and Kick Off Cam Removal and Installation Installation is in the reverse order of disassembly With the parking brake engaged and fully latched there mus be no gap between the top of the cam and the latch arm To adjust the kick off cam 6 engage the parking brake and loosen the two cam setscrews 5 and rotate the cam until it contact the latch arm Tighten the set screws to 45 55 in lbs 5 6 Nm torque...

Page 166: ...Page M 20 Repair and Service Manual B MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 167: ...ual REAR SUSPENSION REAR SUSPENSION N 1 General N 1 Shock Absorber Removal N 2 Shock Absorber Installation N 2 Rear Leaf Spring Removal N 2 Rear Leaf Spring Installation N 2 LIST OF ILLUSTRATIONS Fig 1 Rear Suspension N 1 Fig 2 Rear Suspension Express L4 Express S4 TERRIAN 500 1000 N 3 ...

Page 168: ...Page N ii Repair and Service Manual B REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 169: ...he rear axle is covered in the section in this book titled REAR AXLE Shock Absorber Tool List Qty Wheel Chocks 4 Jack Stands 4 Floor Jack 1 Wrench 1 2 1 Insulated Wrench 9 16 1 Wrench 3 4 1 Socket 1 2 1 Socket 9 16 1 Deepwell Socket 9 16 1 Extension 3 1 Ratchet 1 Torque Wrench ft lbs 1 To reduce the possibility of personal injury fol low the lifting procedure in section B of this manual Place whee...

Page 170: ...e diameter as the shock absorber washer Install the vinyl cap 31 Removal and installation of the shock is the same for both sides of the vehicle Replace any worn or damaged hardware with new as required Rear Leaf Spring Removal Tool List Qty Wheel Chocks 4 Jack Stands 4 Floor Jack 1 Wrench 1 2 1 Insulated Wrench 9 16 1 Socket 1 2 1 Socket 9 16 1 Socket deep well 9 16 1 Ratchet 1 Torque Wrench ft l...

Page 171: ...g plates 18 22 Install the U bolts 21 and four washers 23 then secure in place with the four hex nuts 24 Torque all hardware as specified making sure that the leaf spring pin remains aligned with the holes in the leaf spring mounting plates Removal and installation of the leaf spring is the same for both sides of the vehicle Replace any worn or damaged hardware with new as required Fig 2 Rear Susp...

Page 172: ...Page N 4 Repair and Service Manual B REAR SUSPENSION Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 173: ...isassembly 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 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 174: ...Page P ii Repair and Service Manual B REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 175: ... 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 selector cam Spring loaded mechanism To prevent possibil ity of fingers becoming pinched in the direction selector mechanism hold direction selector lever when releasing neutral lock pin handle Fig 1 Neutral Lock Direction Selector REAR AXLE...

Page 176: ... one regardless 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 Place wheel chocks in front and behind the front wheels and check the stability of the vehicle on the jack stands before starting any repair procedure Never work on a vehicle that is supported by ...

Page 177: ...r surface of axle tube at the sealing area Replace the seal by lightly tapping around the circumfer ence with a plastic faced hammer Tighten bolts 4 to 26 31 ft lbs 35 42 Nm torque Axle Shaft Replacement Carefully insert the axle shaft and bearing through the oil seal Rotate the shaft until the spline engages with the differential side gears Install the outer snap ring Coat the outboard spline of ...

Page 178: ...Page P 4 Repair and Service Manual B REAR AXLE Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 179: ...or 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 Power Insufficient Air S 7 Surging S 7 Starter Generator S 7 Starter is Noisy S 7 Rectification is Imperfect S 8 Generator Does Not Charge S 8 Suspension and Steering S 8 Uneven Tire Wear S 8 Stiff ...

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

Page 181: ... Field 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 connections are faulty Check for any defect of leads at bend or joint Replace wire leads Mechanical problem inside starter generator Check Internal engine damage Inspect and repair Crankcase over f...

Page 182: ...ffler 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 choke Dirty or incorrectly gapped spark plug Clean plug and set gap Faulty magneto Check and or replace Leak in carburetor gasket Inspect and replace if required Faulty ignition wiring Repair replace ...

Page 183: ... adjustment Check and adjust Faulty governor adjustment Check and adjust POOR MIDRANGE OR HIGH SPEED PERFORMANCE Spark plug fouled Clean or replace Weak spark Check magneto Carburetor float not level Adjust Incorrect or plugged main jet Check size for appropriate altitude Clean Dirty air filter Clean or replace Brake dragging Perform brake maintenance Low compression Check engine Governor not adju...

Page 184: ... valve 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 recommended oil Dirty oil Change Crankcase overfilled with oil Drain and fill to recommended level Clogged PCV valve Replace Piston rings worn or broken Replace Valves worn Replace Valve seals or ...

Page 185: ...h solvent Carburetor float sticking Disassemble and correct per the service manual Faulty fuel pump Check for correct output Verify fuel is not returning through the pulse line Clean vent screen Faulty accelerator adjustment function Correct per the service manual Dirty or restricted air filter Replace and clean air box High pressure in the fuel system Check fuel cap for venting Make sure car bure...

Page 186: ...VERFLOW LEAK Worn inlet valve or dirty valve seat Replace valve or clean valve seat Worn float mounting tang Replace float Worn float pin Replace pin Damaged float bowl gasket Replace gasket Damaged float Replace float POOR LOW SPEED PERFORMANCE Clogged pilot port Clean pilot port Clogged low speed jet Clean low speed jet Loose low speed jet Tighten jet POOR FUEL ECONOMY Loose jets Tighten jets Ch...

Page 187: ... or replace Clogged air or fuel filter Replace Poor fuel quality Replace with fresh fuel LOSS OF POWER INSUFFICIENT FUEL Faulty fuel pump Replace fuel pump Dirty carburetor Clean carburetor Dirt in fuel tank or hoses Clean Clogged fuel filter Replace fuel filter Air leak in system Check mounting hardware and gaskets Repair or replace LOSS OF POWER INSUFFICIENT AIR Dirty air cleaner Clean replace f...

Page 188: ...e regulator ground connection Repair Open or short circuit Repair or replace Faulty starter generator Repair starter generator Condition Possible Cause Correction Condition Possible Cause Correction UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure Improper alignment Incorrect toe in Align front tires Damaged or worn components Replace STIFF STEERING Rusted or contaminated k...

Page 189: ...Check brake cable and replace if sticky or damaged Brake shoes severely worn Replace Brake shoes glazed Sand shoes with emery cloth provided that shoes have 06 1 5 mm min material System not adjusted properly Check and adjust per manual End of brake cable loose from anchor brackets Check and repair Cracked brake drum Replace IN EXCESS OF 1 2 5 CM FREE PEDAL TRAVEL SOFT PEDAL Low pedal force at par...

Page 190: ...s wet or glazed Check again when shoes are dry Rusted or sticky brake pivot hardware Replace NEITHER WHEEL LOCKS Brake system requires complete adjustment Adjust entire system Brake pedal not returning 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 spe...

Page 191: ...Page S 11 Repair and Service Manual B B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 192: ...Page S 12 Repair and Service Manual B TROUBLESHOOTING Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 193: ...IONS Fig 1 Vehicle Dimensions for EXPRESS L4 EXPRESS S4 T 3 Fig 2 Vehicle Incline Specifications and Turning Clearance Diameter for EXPRESS L4 EXPRESS S4 T 4 Fig 3 VehicleDimensions InclineSpecificationsandTurningClearanceDiameterfor TERRAIN 250 T 6 Fig 4 Vehicle Dimensions for TERRIAN 500 TERRIAN 1000 T 9 Fig 5 Vehicle Incline Specifications and Turning Clearance Diameter for TERRIAN 500 TERRIAN ...

Page 194: ...age T ii Repair and Service Manual B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 195: ... cc Valve Train Horsepower kW Electrical System Batteries Qty Type Air Cleaner Cooling System Gear Selection Rear Axle Ratio Single Cylinder OHV 13 hp 9 7 kW Exceeds SAE J1940 Std Starter Generator Solid State Regulator One 12 Volt Maintenance Free Replaceable Dry Cartridge Key or Pedal Start Pedal Lubrication Pressurized Oil System Oil Filter Spin On Air Cooled 38 0 in 97 0 cm 80 0 in 203 0 cm Ve...

Page 196: ...01 0 cc Valve Train Horsepower kW Electrical System Batteries Qty Type Air Cleaner Cooling System Gear Selection Rear Axle Ratio Single Cylinder OHV 13 hp 9 7 kW Exceeds SAE J1940 Std Starter Generator Solid State Regulator One 12 Volt Maintenance Free Replaceable Dry Cartridge Key or Pedal Start Pedal Lubrication Pressurized Oil System Oil Filter Spin On Air Cooled 38 0 in 96 0 cm 78 0 in 198 0 c...

Page 197: ...attention to Notices Cautions Warnings and Dangers Front 38 5 in 97 cm Rear 38 0 in 96 cm 78 0 in 198 0 cm 49 0 in 125 0 cm 107 0 in 272 0 cm 65 5 in 166 cm 6 0 in 15 0 cm EXPRESS S4 46 5 in 118 0 cm Front 38 5 in 98 cm Rear 38 0 in 97 cm 80 5 in 203 0 cm 49 0 in 124 0 cm 107 0 in 272 0 cm 65 5 in 166 0 cm 5 5 in 15 0 cm EXPRESS L4 46 5 in 118 0 cm ...

Page 198: ...ion B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TURNING CLEARANCE DIAMETER EXPRESS S4 20 5 ft 6 3 m EXPRESS L4 20 5 ft 6 3 m RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX ...

Page 199: ...n 113 0 cm Cargo Box Length inside 30 5 in 77 0 cm 400 lb 180 kg 400 lb 180 kg Cargo Box Depth inside 7 5 in 19 0 cm Steering Suspension Cargo Box Capacity 5 9 cu ft 0 17 m3 Steering Self compensating rack and pinion Cargo Box Material Roto molded polyethylene Front Suspension Leaf springs with hydraulic shock absorbers Vehicle Power Rear Suspension Leaf springs with hydraulic shock absorbers Powe...

Page 200: ...ion to Notices Cautions Warnings and Dangers 49 0 in 124 0 cm Rear 38 0 in 97 0 cm Front 37 0 in 94 0 cm TERRAIN 250 9 5 in 24 0 cm 44 5 in 113 0 cm 30 5 in 77 0 cm 65 5 in 166 0 cm 4 3 in 15 0 cm 103 0 in 260 0 cm 15 0 in 38 0 cm RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX TURNING CLEARANCE DIA Approx 24 0 ft 7 3 m ...

Page 201: ...argo Box Capacity 5 9 cu ft 0 17 m3 Cargo Box Material Roto molded polyethylene 4 Cycle 24 5 cu in 401 0 cc Valve Train Horsepower kW Electrical System Batteries Qty Type Air Cleaner Cooling System Gear Selection Rear Axle Ratio Single Cylinder OHV 13 hp 9 7 kW Exceeds SAE J1940 Std Starter Generator Solid State Regulator One 12 Volt Maintenance Free Replaceable Dry Cartridge Key or Pedal Start Pe...

Page 202: ...10 5 in 27 0 cm Cargo Box Capacity 9 2 cu ft 0 27 m3 Cargo Box Material Roto molded poly 9 6 cu ft 0 27 m3 4 Cycle 24 5 cu in 401 0 cc Valve Train Horsepower kW Electrical System Batteries Qty Type Air Cleaner Cooling System Gear Selection Rear Axle Ratio Single Cylinder OHV 13 hp 9 7 kW Exceeds SAE J1940 Std Starter Generator Solid State Regulator One 12 Volt Maintenance Free Replaceable Dry Cart...

Page 203: ...260 0 cm 65 5 in 166 0 cm Front 38 0 in 96 0 cm Rear 38 5 in 97 0 cm 28 75 in 73 0 cm 30 5 in 77 0 cm 49 0 in 124 0 cm 49 0 in 124 0 cm 79 5 in 186 0 cm 10 0 in 25 0 cm 15 0 in 38 0 cm 5 3 in 15 0 cm TERRAIN 1000 111 5 in 283 0 cm 78 5 in 199 0 cm Front 38 0 in 97 0 cm Rear 38 5 in 98 0 cm 30 25 in 76 8 cm 36 0 in 91 0 cm 49 5 in 126 0 cm 49 5 in 126 0 cm 73 0 in 185 0 cm 11 5 in 29 0 cm 18 0 in 4...

Page 204: ...on B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers TURNING CLEARANCE DIAMETER TERRAIN 500 20 5 ft 6 3 m TERRAIN 1000 23 5 ft 7 2 m RECOMMENDED MAX RAMP GRADE 25 or 14o MAX RECOMMENDED MAX SIDE TILT 25 or 14o MAX ...

Page 205: ...ge T 11 Repair and Service Manual B B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 206: ...age T 12 Repair and Service Manual B GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers NOTES ...

Page 207: ......

Page 208: ... of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road Augusta Georgia 30906 3852 USA Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Genuine E Z GO Parts Accessories Department or at www shopezgo com ...

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