Ezgo 605586 Repair And Service Manual
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Ezgo 605586 Repair And Service Manual

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

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Summary of Contents for Ezgo 605586

  • Page 1 605586 TECHNICIAN’S REPAIR AND SERVICE MANUAL GASOLINE POWERED GOLF CARS REVISED DATE : JANUARY 2007...
  • Page 2 S A F E T Y SAFETY For any questions on material contained in this manual, contact an authorized representative for clarification. Read and understand all labels located on the vehicle. Always replace any damaged or missing labels. On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface. To pre- vent loss of vehicle control and possible serious injury, speeds should be limited to no more than the maximum speed on level ground.
  • Page 3 TECHNICIAN’S REPAIR AND SERVICE MANUAL GASOLINE POWERED TXT GOLF CARS & PERSONAL VEHICLES FLEET GOLF CAR (9 hp, CE, CARB) ™ FREEDOM (9 hp, CE, CARB, SE, LE, HP) SHUTTLE 2 + 2 ( 9 hp, CE, CARB) STARTING MODEL YEAR 2007 TEXTRON Golf, Turf &...
  • Page 4 NO TES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacturer code. The use of non Original Equipment Manufacturer (OEM) parts may void the warranty. Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty.
  • Page 5 TABLE OF CONTENTS TITLE PAGE Safety ........................... Inside Covers Notes ..............................ii Safety Information ..........................v TITLE SECTION General Information & Routine Maintenance ...................A Safety ............................... B Body ..............................C Wheels and Tires ..........................D Front Suspension and Steering......................E Speed Control ..........................F Engine .............................
  • Page 6 TABLE OF CONTENTS NOTES: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    S A F E T Y I N F O R M A T I O N SAFETY INFORMATION This manual has been designed to assist in maintaining the vehicle in accordance with procedures developed by the manufacturer. Adherence to these procedures and troubleshooting tips will ensure the best possible service from the product.
  • Page 8 S A F E T Y I N F O R M A T I O N This vehicle conforms to the current applicable standard(s) for safety and performance requirements. These vehicles are designed and manufactured for off-road use. They do not conform to Federal Motor Vehicle Safety Standards of the United States of America (USA) and are not equipped for operation on public streets.
  • Page 9 S A F E T Y I N F O R M A T I O N • Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring. Remove the battery or cover exposed terminals with an insulating material. •...
  • Page 10 S A F E T Y I N F O R M A T I O N NOTES: Repair and Service Manual Page viii...

  • Page 11: Table Of Contents

    GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ’A’ SECTION TITLE PAGE NO. SERIAL NUMBER PLATE AND LOCATION ......................A - 1 STARTING THE VEHICLE WITH A DISCHARGED BATTERY ................. A - 1 SERVICING THE VEHICLE ............................A - 1 TOWING ..................................
  • Page 12 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. NOTES: Page A-ii Repair and Service Manual...

  • Page 13: Serial Number Plate And Location

    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. SERIAL NUMBER PLATE STARTING THE VEHICLE WITH AND LOCATION A DISCHARGED BATTERY The serial number and manufacture date code label are on the vehicle.

  • Page 14: Fig. 2 Initial Service Chart

    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. from the batteries before removing any TOWING heavy gauge battery wires. To prevent the possibility of motor disinte- gration, never operate vehicle at full throt- tle for more than 4 - 5 seconds while To prevent personal injury, do not ride on vehi-...

  • Page 15: Routine Maintenance

    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. Putting more than three pumps of grease in a grease fit- ting could damage grease seals and cause premature bearing failure.

  • Page 16: Care And Cleaning Of The Vehicle

    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. CARE AND CLEANING OF THE authorized Branch, or the Service Parts Department, among them are VEHICLE •...

  • Page 17: Winter Or Prolonged Storage

    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. TRAILERING Place the direction selector in the neutral position and engage the neutral lock (Ref. Fig. 3 on Page A-3) . Add fuel stabilizer to the tank in accordance with the manu- facturer’s recommendations.

  • Page 18: Periodic Service Schedule

    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. PERIODIC SERVICE SCHEDULE Check Clean, Adjust, etc. Replace NOTE: Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions DAILY BODY Clean body components as required...

  • Page 19: Fig. 7 Periodic Service Schedule

    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. SEMI-ANNUAL - 125 HOURS (includes items listed in previous tables & the following) Check for wear and smooth movement (lubricate shaft with light oil if required) DIRECTION SELECTOR Check shift cable spring length Check for excessive play and tightness of retaining nuts...
  • Page 20 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. NOTES: Repair and Service Manual Page A-8...
  • Page 21 SAFETY TABLE OF CONTENTS SECTION TITLE PAGE NO. GENERAL (ASME/ANSI) ............................B - 1 GENERAL (ASME/NGCMA) ............................B - 7 NOTES, CAUTIONS AND WARNINGS ........................B - 11 IMPORTANT SAFETY WARNING ........................... B - 11 MODIFICATIONS TO VEHICLE ..........................B - 11 GENERAL MAINTENANCE .............................
  • Page 22 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page B-ii Repair and Service Manual...

  • Page 23: General (Asme/Ansi)

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. GENERAL The following text is provided as recommended by part II of American Society of Mechanical Engineers / American National Standards Institute ASME/ANSI B56.8-2006.
  • Page 24 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 4.5.2 The user shall periodically inspect facilities and review procedures to be certain that appropriate paragraphs of ANSI/NFPA 505, are strictly complied with, and shall familiarize carrier operators with it. Hazardous Locations 4.6.1 The user shall determine the hazard classification of the particular atmosphere or location in which the car-...

  • Page 25: General (Asme/Ngcma)

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. (a) operational performance tests and evaluations during, and at completion of, the program. Personnel and Burden Carrier Operator Responsibility 5.3.1 Operators shall abide by the following safety rules and practices in paras.
  • Page 26 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 5.5.12 Do not drive carrier onto any elevator unless specifically authorized to do so. Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off power, and set parking brakes.
  • Page 27 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. (a) Before disconnecting any part of the engine fuel system of LP gas powered carriers, close the LP gas cylinder valve and run the engine until fuel in the system is depleted and the engine stops running.
  • Page 28 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page B-6...
  • Page 29 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. GENERAL The following text is provided as recommended by part II of ANSI/NGCMA 130.1-2004. EZGO, as a member of the National Golf Car Manufacturer’s Association (NGCMA), strongly endorses the content of this specification.
  • Page 30 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 5.2.5 Golf car/pedestrian interaction areas Areas where pedestrians and golf cars could interact should be avoided by rerouting the golf car traffic or the pedes- trian traffic.
  • Page 31 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 6.2.6 As required in 6.2.4, the manufacturer shall be contacted to secure new nameplates, warnings, or safety labels, as necessary, which shall be affixed in their proper place on the golf car if and as designated in the owner’s manual.
  • Page 32 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page B-10...

  • Page 33: Notes, Cautions And Warnings

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES, CAUTIONS AND WARNINGS Throughout this manual, the following NOTES, CAU- TIONS and WARNINGS are used. For the protection of Changes to the weight distribution or the cen- all personnel and the vehicle, be aware of and observe ter of gravity may make the vehicle unstable or...

  • Page 34: Battery Removal And Installation

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Set the parking ‘PARK’ brake before per- forming any work on the vehicle. If repairs are to be made that will require To prevent illness or death, observe the follow- welding or cutting, the battery and fuel ing:...

  • Page 35: Lifting The Vehicle

    SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Center of Front Axle Negative Positive Battery Hold Down Fig. 1 Battery Removal Flat Portion Connect the positive (+) battery cable first. Connect of Frame negative (-) battery cable last.
  • Page 36 SAFETY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page B-14...
  • Page 37 BODY TABLE OF CONTENTS FOR SECTION ’C’ SECTION TITLE PAGE NO. BODY ..................................C - 1 General ................................C - 1 BODY COMPONENT REPLACEMENT ........................C - 1 Instrument Panel Replacement ........................C - 1 Cowl Replacement ............................C - 5 Front Shield Replacement ..........................
  • Page 38 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page C-ii Repair and Service Manual...

  • Page 39: Body

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. BODY Drill Out Rivet Pop Rivet Head Only 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.
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Frame Fig. 2 Body Components (Front) Repair and Service Manual Page C-2...
  • Page 41 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Shuttle 2+2 Model Only Fig. 3 Body Components (Rear) Repair and Service Manual Page C-3...
  • Page 42 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 4 Shuttle 2 + 2 Components Repair and Service Manual Page C-4...

  • Page 43: Hardware

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. From underneath the cowl, remove the ratchet fastener (18) attaching the center of the splash panel (19) to the frame cross member.

  • Page 44: Body Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Body Replacement Remove the rivets (32) that secure the floor of the bag- well area to the frame underneath. Tool List Qty.

  • Page 45: Rear Bumper Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. To replace the bumper, place the rear bumper against the rear body panel and tighten the shoulder bolts (52) to 9 - 12 ft.
  • Page 46 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page C-8...

  • Page 47: Wheels And Tires

    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 Repair and Service Manual Page D-i...
  • Page 48 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page D-ii Repair and Service Manual...
  • Page 49 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. WHEEL AND TIRE SERVICE ing should be considered. On hard turf, it is desirable to have a slightly higher inflation pressure. On very soft Tools List Qty.
  • Page 50 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 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.
  • Page 51 FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ’E’ SECTION TITLE PAGE NO. MAINTENANCE ................................. E - 2 Lubrication ..............................E - 2 Wheel Bearing and King Pin Bushing Inspection ..................E - 2 Wheel Bearing Packing ..........................E - 2 Wheel Bearing Adjustment ..........................
  • Page 52 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. NOTES: Page E-ii Repair and Service Manual...
  • Page 53 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. Part of Frame Wave Washer Bearing Intermediate Outer Snap Ring Rack & Pinion Shaft with Inner Snap Ring Unit U-Joints...

  • Page 54: Maintenance

    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. Wheel Bearing and King Pin Bushing MAINTENANCE Inspection In the following text, there are references to removing/installing To prevent possible injury or death resulting bolts etc.

  • Page 55: Wheel Bearing Adjustment

    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. the bearing is removed for inspection. It is recom- If completing a wheel bearing adjustment as part of mended that a bearing packer attached to a grease gun another procedure, tighten front wheels per WHEELS be used;...
  • Page 56 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. Test drive vehicle and confirm steering wheel is cor- rectly centered. If it is not centered, disconnect interme- Rear diate shaft from steering shaft and center steering wheel (Ref.

  • Page 57: Front Suspension

    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. FRONT SUSPENSION Part of Frame Part of Frame *NOTE: Tie Rod Not Shown for Clarity Fig.

  • Page 58: Front Axle Replacement

    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. Front Axle Replacement At the 3 1/2" long bolt (20) securing front of left spring, note location of washer (22) and remove it from end of Tool List Qty.
  • Page 59 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. Loosen front wheels. Lift and support front of vehicle per SAFETY section. In addition, support front axle with jack stands.

  • Page 60: Hub Replacement

    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. Wheel Bearing and Race Replacement Remove the dust cap (1), cotter pin (2) and castellated nut (3) (Ref.

  • Page 61: Steering

    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. STEERING Front of Vehicle Flat Section Fig. 11 Steering Components Rack Ball Joint Replacement To remove rack ball joint (1), loosen passenger side front wheel and lift and support front of vehicle per Tool List Qty.

  • Page 62: Tie Rod Inspection/Replacement

    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. Tie Rod Inspection/Replacement To install new rack ball joint close to its correct position, measure amount of threads exposed from jam nut (Ref. Tool List Qty.

  • Page 63: Bellows Replacement

    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. Remove cotter pin (9) and loosen castellated nut (10) until tie rod ball joint (6) threads are protected. Using a ball joint separator as a lever, apply pressure to ball joint and tap nut with plastic faced hammer to release tie rod from spindle arm.

  • Page 64: Spindle Replacement

    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. Spindle Replacement Tool List Qty. Required Needle nose pliers ............1 Secure rack and pinion unit in vice by the mounting ears Wrench, 11/16".............1 only.

  • Page 65: Rack And Pinion Unit Disassembly And Inspection

    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. Spindle installation is the reverse order of disassembly. (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).

  • Page 66: Rack And Pinion Unit Replacement

    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. Tighten castellated nut (3) to 36 ft. lbs. (50 Nm) torque and continue to tighten as needed to insert new cotter pin.

  • Page 67: Steering Wheel Replacement

    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. Front of Vehicle 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.
  • Page 68 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. Loosen the steering wheel retaining nut (6) two to three Loosen front wheels. Lift and support front of vehicle per turns (Ref.
  • Page 69 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. Install with arch Small up as shown Retaining Ring Steering Shaft Bearing Groove Fig. 23 Small Retaining Ring Orientation Slide wave washer into base of steering column.
  • Page 70 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. NOTES: Repair and Service Manual Page E-18...
  • Page 71 SPEED CONTROL - ALL CABLES TABLE OF CONTENTS FOR SECTION ’F’ SECTION TITLE PAGE NO. ACCELERATOR, GOVERNOR AND CARBURETOR LINKAGE ................F - 1 System Operation ............................F - 1 Governor Operation ............................F - 2 TROUBLESHOOTING ............................... F - 2 SPEED CONTROL CABLES ............................
  • Page 72 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. NOTES: Page F-ii Repair and Service Manual...

  • Page 73: Accelerator, Governor And Carburetor Linkage

    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. Accelerator Pedal Micro Switch Accelerator Clevis Return Spring Accelerator Rod Micro Switch Accelerator Cable Carburetor Throttle Plate Axle...

  • Page 74: Troubleshooting

    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. Governor Operation Until the vehicle reaches its governed speed, the vehi- cle will continue to accelerate in relation to the accelera- tor pedal position.

  • Page 75: Throttle Cable Installation

    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. Throttle Cable Installation Micro Accelerator To install the throttle cable, proceed in reverse order. Switch Cable Throttle Cable Adjustment...

  • Page 76: Micro Switch Adjustment

    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. Micro Switch Adjustment GOVERNOR COMPRESSION SPRING When the system is in correct adjustment, the micro ADJUSTMENT switch in the accelerator pedal box will click when the top of the accelerator pedal moves approximately 1/2"...
  • Page 77 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. Accelerator Cable Governor Pedal Carburetor Accelerator Cable Governor Throttle Cable Throttle Cable Fig. 5 Accelerator Linkage Repair and Service Manual Page F-5...
  • Page 78 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. NOTES: Repair and Service Manual Page F-6...
  • Page 79 ENGINE TABLE OF CONTENTS FOR SECTION ’G’ SECTION TITLE PAGE NO. POWERTRAIN MAINTENANCE ..........................G - 1 Checking the Oil Level ...........................G - 1 Changing the Oil ............................G - 1 AIR CLEANER INSPECTION/REPLACEMENT ......................G - 3 Cleaning the Air Filter Element ........................G - 3 STARTER/GENERATOR BELT TENSION ........................G - 3 Adjusting the Belt ............................G - 4 COOLING SYSTEM CLEANING ..........................G - 4...
  • Page 80 ENGINE TABLE OF CONTENTS FOR SECTION ’G’ SECTION TITLE PAGE NO. Fig. 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.

  • Page 81: Changing The Oil

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. For further engine information, see Four Cycle Engine Oil should be added to bring the level into the safe oper- Shop Rebuild and Service Parts Manual, P/N 27615- ating range.
  • Page 82 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 'O' Ring Be aware that engine fluids may be hot and contact to the skin may cause severe burns. Wear rubber gloves to protect skin from expo- sure to the old oil and degreaser.

  • Page 83: Air Cleaner Inspection/Replacement

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

  • Page 84: Cooling System Cleaning

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. COOLING SYSTEM CLEANING Although not as accurate, a new belt may be depressed with a finger. A maximum deflection of 3/8" (10 mm) is At least once a year, or more often under adverse condi- acceptable (Ref.

  • Page 85: Spark Plugs

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Allow the water to flow freely over the cooling fins and FOUR CYCLE ENGINE through the blower housing. After flushing, dry with low Engine Specifications pressure compressed air.
  • Page 86 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. third, or power stroke by the expanding gases. As the portion) of the cam. If the gauge slides in and out with piston reaches BDC it enters the fourth cycle.
  • Page 87 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Screw Type Adjuster Cam Lobe Up Cam Lobe Down Valve Return Spring VALVE CLOSED VALVE OPEN VALVE OPERATION Valve Cover Timing Belt Camshaft...
  • Page 88 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Intake Exhaust INTAKE COMPRESSION First Revolution POWER EXHAUST Second Revolution NOTE: This is a simplified diagram for explanatory use only. Rockers, guides, seals, etc.
  • Page 89 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Adjust with screwdriver Release by turning wrench Screw type adjuster Cam lobe up Cam lobe down ADJUST Valve return spring Hold screwdriver .004 (.10 mm) Valve clearance...
  • Page 90 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. To properly perform an accurate compression test: Align Notch 1. Remove belt to clutch. and Mark 2. Remove the air filter to eliminate the possibility of a restricted air passage.
  • Page 91 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. c) Indicates 100 psi (690 kPa). This indication could All readings should be compared with the engine manu- be an engine with many hours of use.
  • Page 92 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 23 Engine Assembly Controls and Wiring Engine Installation Unplug the wiring harness from the engine and cut the wire tie securing the accelerator cable to the engine.
  • Page 93 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Plastic Washer Fig. 24 Engine Mounting DRIVE CLUTCH REMOVAL It is not necessary to remove the engine to remove the clutch.
  • Page 94 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Page G-13). Tighten a new starter/generator belt per Tighten the isolation mount bolt (10) to 21 - 25 ft. lbs. (28 ‘Starter/Generator Belt Tension’...
  • Page 95 FUEL SYSTEM TABLE OF CONTENTS FOR SECTION ’H’ SECTION TITLE PAGE NO. GENERAL .................................. H - 1 CARBURETOR OPERATION ............................ H - 1 Float System ..............................H - 1 Pilot Jet System ............................. H - 1 Main Jet System ............................H - 1 Choke System ...............................
  • Page 96 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page H-ii Repair and Service Manual...

  • Page 97: General

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. GENERAL 1" MIN. (2.5 cm) FUEL In the following text, there are references to removing/installing bolts etc. Additional hardware (nuts, washers etc.) that are removed must always be installed in their original positions unless otherwise specified.

  • Page 98: Choke Operation

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fuel Gauge Fuel Filter Sending Unit Fuel Pump Fuel Tank Fuel Line Carburetor Pulse Line Crankcase Fig. 2 Fuel System Choke Operation Pull the choke knob out to operate the choke (Ref.
  • Page 99 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Choke Cable and Housing Installation 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).

  • Page 100: Float Level Adjustment

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 16 15 14 13 Fig. 4 Air Cleaner Do not tamper with the pilot screw (7) or plastic cover. After adjusting float level, reassemble the carburetor in reverse order of assembly.
  • Page 101 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 5 Carburetor Repair and Service Manual Page H-5...

  • Page 102: Fuel Pump

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Float Tang #1 Float Side B Side A Gasket Do not let the carburetor vent hoses become clogged or Surface kinked.

  • Page 103: Fuel Lines And Filter

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. The length of the pulse hose from the fuel pump is important To prevent possibility of personal injury, tests for efficient pump operation.

  • Page 104: Fuel Lines & Filter - California Emission Requirement

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fuel Pump Fuel Filter Fuel Part of Tank Frame Fig. 9 California Emission Requirement FUEL LINES & FILTER - CALIFORNIA Carb Installation EMISSION REQUIREMENT 1 Disconnect the negative ground from the battery...

  • Page 105: Fuel And Storage

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. fuel stabilizer added to the bulk storage tank according to the manufacturers directions. Maintain as little fuel as possible in the individual vehicle fuel tank.
  • Page 106 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Condition Possible Cause Correction POOR FUEL ECONOMY Fuel level too high Adjust float Loose jets Tighten jets Choke not opening fully Adjust choke Dirty air cleaner...
  • Page 107 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION ’J’ SECTION TITLE PAGE NO. GENERAL ...................................J - 1 CLUTCHES .................................J - 1 Drive Clutch ..............................J - 1 Driven Clutch ..............................J - 1 Increased Load ...............................J - 1 Equilibrium ..............................J - 2 Drive Clutch Removal .............................J - 2 Drive Clutch Installation ..........................J - 3 Driven Clutch Removal ...........................J - 3...
  • Page 108 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. NOTES: Page J- ii Repair and Service Manual...

  • Page 109: General

    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. Driven Clutch Drive Clutch Starter/Generator Belt Fig. 1 Continuously Variable Transmission System (CVT) GENERAL cams by a compression spring. The drive belt disen- gages from the clutch sheave when engine speed is Power transmission from the engine to the rear axle is reduced to the point where the cams exert less force...

  • Page 110: Equilibrium

    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. conditions, the drive belt friction is overcome by the the vehicle that they are designed to operate. Changes additional load and the belt seeks a point where it can in vehicle weight or desired performance characteristics achieve adequate friction to overcome its slippage.

  • Page 111: Drive Clutch Installation

    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. Driven Clutch Removal Tool List Qty. Required External snap ring pliers ..........1 To prevent burns and other possible injuries: Socket, 5/8", 1/2"...

  • Page 112: Drive Belt

    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. DRIVE BELT Removing the Drive Belt With the vehicle on level ground, remove the drive belt by pulling the belt upwards which will cause the driven clutch sheaves to open and loosen the belt tension (Ref.

  • Page 113: Direction Selector

    DIRECTION SELECTOR TABLE OF 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) ......................
  • Page 114 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page K-ii Repair and Service Manual...
  • Page 115 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. DIRECTION SELECTOR tach the wires to the new buzzer. After restoring power, test the buzzer to ensure it is operational before con- Before removing direction selector and replacing the tinuing by moving the direction selector to ‘REVERSE’...
  • Page 116 DIRECTION SELECTOR Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Front Direction Selector Shift Cable Adjustment Shift Cable Adjustment Micro Switch Reverse Warning Buzzer Fig. 1 Direction Selector Repair and Service Manual Page K-2...
  • Page 117 ELECTRICAL TABLE OF CONTENTS FOR SECTION ’L’ SECTION TITLE PAGE NO. CIRCUITS AND CONTROLS ............................L - 1 STARTER ..................................L - 1 GENERATOR ................................L - 1 WIRING ..................................L - 1 TESTING IGNITION CIRCUIT .............................L - 1 Testing the Ignition Coil ..........................L - 4 Testing the Pulser Coil ............................L - 4 TESTING STARTING CIRCUIT ..........................L - 4 TESTING CHARGING CIRCUIT ..........................L - 6...
  • Page 118 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page L- ii Repair and Service Manual...

  • Page 119: Testing Ignition Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. CIRCUITS AND CONTROLS without regard to engine speed. However, the charging current will vary depending on the condition of the bat- The electrical system is a 12 volt negative ground sys- tery.

  • Page 120: Electrical System Wiring Diagram

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Battery Ignitor Reverse Solenoid Warning Fuse 7 AMP BLUE RED/WHT RED/WHT Ignition Coil Switch Voltage Regulator Pulser Coil Starter/generator Engine Letters Are For Reference Only...
  • Page 121 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Front of Vehicle Battery Starter/ Generator Ignition Coil Fig. 2 Electrical System (Physical Location) Repair and Service Manual Page L-3...

  • Page 122: Testing Starting Circuit

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. TESTING STARTING CIRCUIT Do not arc spark plug wire to ground. Connect to a known good spark plug and ground plug to a clean metal To prevent the possibility of injury resulting surface (muffler, cylinder, etc.).
  • Page 123 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. (b) Press the accelerator pedal. The DVOM will indi- (c) If “0” voltage is not indicated while the accelerator cate “0”...
  • Page 124 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. field wire to ground. If the voltage rises above TESTING CHARGING CIRCUIT its prior reading, replace the regulator. Tool List Qty.
  • Page 125 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 5 Starter/Generator Brush Spring Puller Brush Brush Bearing Adapter (Puller) Spring Position for Spring Position Removing/Replacing for Installed Brushes Brushes Fig.
  • Page 126 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. BATTERY VOLTAGE TEST Starter/Generator Inspection 1. Inspect the commutator for wear or damage. Battery voltage can be checked using a voltmeter. Attach the negative (-) lead of the DVOM to the ground 2.
  • Page 127 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. the make and model. Always follow the meter manufac- obvious that voltage is present. Since bulbs will burn out turer’s recommendations and instructions for the use over time, the obvious place to start is at the headlight and care of the meter.
  • Page 128 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ing indicates (a) a poor connection between the ACCESSORY WIRING probes and the battery terminals; (b) a faulty DVOM. A voltage reading below 11 volts indicates poor battery After determining that there is power to the fuse panel, condition and the vehicle should be recharged before...
  • Page 129 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Passenger Side Driver Side Marker Headlight Marker Turn Turn Headlight BLU/WHT Horn ORN/WHT 15 AMP Fuse Brake 15 AMP Block BLU/WHT BLU/WHT...
  • Page 130 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page L-12...
  • Page 131 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ’M’ SECTION TITLE PAGE NO. BRAKE SYSTEM OVERVIEW ...........................M - 1 General Description ............................M - 1 How the Service Brake Works ........................M - 2 Equalizer Link ..............................M - 2 Automatic Adjuster Mechanism ........................M - 2 How the Parking Brake Works ........................M - 2 Compensator Assembly ..........................M - 3 Kick-Off Actuating Linkage ..........................M - 3...
  • Page 132 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION ’M’ SECTION TITLE PAGE NO. Fig. 20 Checking Parking Brake Latching Pressure ....................M - 15 Fig. 21 Brake Assembly ............................M - 16 Fig. 22 Wheel Brake Lubrication Points ........................M - 17 Fig.
  • Page 133 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Parking Brake Pedal Torsion Springs Push Nut Identification Hole* Hinge Pin Pedal Latch Service Brake Pedal Kick Off Spacer Catch Bracket Brake Pedal Pivot Bolt...
  • Page 134 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. closely related. It is very important to maintain the proper relationships to assure braking performance and Brake Lever the best wheel brake adjustment.
  • Page 135 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Compensator Assembly Older The compensator assembly contains a spring, which is Models compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref.
  • Page 136 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. TROUBLESHOOTING FLOWCHART Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Condition of: Replace Includes...
  • Page 137 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Adjuster Tries Disassemble Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure.
  • Page 138 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. TROUBLESHOOTING TABLE Test (PBPT), and Aggressive Stop Test is performed (Ref. Fig. 6 on Page M-6). Refer to the following troubleshooting table only after the thorough visual inspection, Periodic Brake Performance Condition Possible Cause...
  • Page 139 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Condition Possible Cause Correction Neither wheel locks when park brake Incorrect compensator spring adjust- Return to factory specification is latched.
  • Page 140 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. TROUBLESHOOTING AND INSPECTION New Vehicles A new vehicle will undergo an initial break-in of compo- nents including brake cables and brake shoes. In this break-in period, it is not uncommon for the brake pedal 1/4"...
  • Page 141 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. may indicate wheel brakes not adjusting, wear in the 5. Check the clevis pins. cables and linkages or initial break-in of components. Check clevis pins attaching the brake cables to the Not enough pedal free travel may indicate improper brake lever.
  • Page 142 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 12. Inspect kick-off cam linkage and bushings. Hinge Torsion Check for wear and damage. The kick-off cam pivot Springs and bushings should move freely and be free of corro- sion.
  • Page 143 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. pedal. The vehicle should stop aggressively. The wheel brakes may or may not lock. Observe the vehicle stop- ping location or measure the vehicle stopping distance from the point at which the brakes were latched.
  • Page 144 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. friction surface being significantly worn and leaving a ledge of unworn drum. Inspect the splines for galling, wear and corrosion.
  • Page 145 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. If adjuster arm engages star wheel but fails to rotate it, the adjuster assemblies must be replaced The pattern of normal brake shoe wear is with new color-coded adjusters.
  • Page 146 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Straight blade screwdriver, narrow.......1 Pliers ................1 Vernier/Dial calipers .............1 Heavy Shoe Spring Plastic tipped hammer ..........1 Puller (P/N 15947-G1) ..........1 Light Pry bar .................1 Shoe...
  • Page 147 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. 7/8" - 1 1/8" (2.2 - 2.9 cm) Jam Nut Clevis Pin Loose? Fig. 19 Check Clevis Pins The parking brake latching force can be checked as ver- ification after setting brake pedal free travel.
  • Page 148 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Brake Drum Removal and Installation Remove the dust cap (1) to gain access to the castel- lated nut (2) and the cotter pin (3) (Ref. Fig. 21 on Page Pay particular attention to the location of the inner brake drum M-16).
  • Page 149 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Install the actuator components, adjuster components and brake shoes. “Brake Shoe and Adjuster Replacement” on Page M 18 If the brake shoes and drum are not to be Do NOT use a commercial brake cleaner unless the replaced, sand the friction surfaces lightly with emery entire brake has been disassembled.
  • Page 150 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Brake Shoe and Adjuster Replacement Clean the backing plate with a commercial brake cleaner. Allow to dry completely. Lubricate the friction points of the shoes and moving anchor with Multi Pur- pose Grease (MPG) lubricant (Ref.
  • Page 151 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Adjust the brake pedal free travel. “Adjusting Brake Pedal Installation is the reverse of removal. Use new cotter Free Travel”...
  • Page 152 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Parking Brake Pedal, Removal and Installa- Inspect the shoulder bolt for corrosion that could cause binding. This bolt and both bushings (7) must be tion replaced with new ones if corrosion or wear is found.
  • Page 153 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Parking Brake Release Linkage Removal Parking Brake Kick-Off Cam Removal, and Replacement Replacement and Installation Remove the cotter pin (2), washers (3) and bushings (4) Disconnect the parking brake release linkage as from linkage rod (1).
  • Page 154 MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page M-22...

  • Page 155: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR 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 ..........................
  • Page 156 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page N-ii Repair and Service Manual...
  • Page 157 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. REAR SUSPENSION 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) In the following text, there are references to removing/install- expand to diameter of the shock absorber washer (5)
  • Page 158 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Fig. 1 Rear Suspension Repair and Service Manual Page N-2...
  • Page 159 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. REAR AXLE REMOVAL Remove the accelerator cable from the accelerator bracket and take off the push nut holding the cable on Tools List Qty.
  • Page 160 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page N-4...

  • Page 161: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION ’P’ SECTION TITLE PAGE NO. NEUTRAL LOCK ................................ P - 1 REAR AXLE ................................P - 1 Checking the Lubricant Level ........................P - 1 REAR AXLE DISASSEMBLY ............................. P - 1 Axle Shaft Removal and Disassembly ......................P - 2 Axle Shaft Seal Removal and Replacement ....................
  • Page 162 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page P-iii Repair and Service Manual...

  • Page 163: Neutral Lock

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. For further axle information, see Four Cycle Transaxle REAR AXLE Shop Rebuild and Service Parts Manual P/N 27660- The rear axle is provided with a lubricant level check G01.
  • Page 164 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Attach a slide hammer to the axle shaft thread and remove the axle and bearing from the axle tube (Ref. Handle all gears with extreme care since each is part of a Fig.
  • Page 165 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Thrust Inner Snap Washer Cotter Lock Ring Use care to prevent damage to the inner surface of axle Washer Spline tube at the sealing area.
  • Page 166 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page P-4...
  • Page 167 WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ’Q’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD ............................Q - 1 Trailering ................................Q - 1 GOLF CAR SUN TOP ..............................Q - 1 Rear Support Installation ..........................Q - 1 Front Strut ..............................Q - 1 Sun Top .................................Q - 1 SHUTTLE 2+2 SUN TOP ............................Q - 3 Rear Support Installation ..........................Q - 3...
  • Page 168 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page Q- ii Repair and Service Manual...

  • Page 169: Top And Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. TOP AND WINDSHIELD 4. At the lower hole, slide a teflon washer (item 5) between rear strut and seat back support and align holes.
  • Page 170 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. FRONT OF VEHICLE 1, 18 DETAIL A DETAIL D (REAR) FRONT OF VEHICLE 1, 18 DETAIL C (FRONT) DETAIL B Fig.

  • Page 171: Front Strut

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. SHUTTLE 2+2 SUN TOP Sun Top Installation 1. Position sun top (item 1) onto struts (See Detail C). Rear Support Installation 2.
  • Page 172 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. REAR OF (PASSENGER VEHICLE SIDE SHOWN) DETAIL D (REAR) (DRIVER'S SIDE SHOWN) DETAIL A (OUTSIDE TUBING ON SUN TOP) FRONT OF VEHICLE DETAIL C...

  • Page 173: Split Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Position top grips (item 8) as shown (See Detail D) at top hole on each side of front strut. Secure with top grip SPLIT WINDSHIELD fasteners (item 9).

  • Page 174: One-Piece Front Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. ONE-PIECE FRONT WINDSHIELD 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).

  • Page 175: Rear Windshield

    WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. REAR WINDSHIELD with washer (item 5) and lock nut (item 7) (See Detail B). Do not over-tighten or squeeze grommet. Remove protective covering from rear windshield (item 2) (Ref.
  • Page 176 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page Q-8...
  • Page 177 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 Repair and Service Manual Page R-i...
  • Page 178 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page R-ii Repair and Service Manual...
  • Page 179 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. PAINTING 3. Apply spray touch up paint in light even overlapping strokes. Multiple coats may be applied to provide ade- Follow the paint manufacturer’s recommendations for quate coverage and finish.
  • Page 180 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page R-2...
  • Page 181 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 Repair and Service Manual Page S-i...
  • Page 182 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page S-ii Repair and Service Manual...
  • Page 183 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. GASOLINE VEHICLE PERFORMANCE Condition Possible Cause Correction STARTER DOES NOT TURN Weak or bad battery Recharge or replace as necessary Terminals are loose or corroded Clean and retighten Poor wiring connections...
  • Page 184 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Condition Possible Cause Correction STARTER ROTATES BUT VEHICLE Weak Battery Recharge or replace as necessary WILL NOT START OR HARD TO Corroded or loose battery connections Clean and tighten battery connections.
  • Page 185 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Condition Possible Cause Correction ENGINE RUNS ROUGH OR LOSS Dirty or clogged air filter element Wash or replace as required OF POWER Incorrect choke adjustment Adjust choke...
  • Page 186 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Condition Possible Cause Correction POOR MIDRANGE OR HIGH SPEED Spark plug fouled Clean or replace PERFORMANCE Weak spark Check ignition coil Faulty ignitor Check and adjust...
  • Page 187 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. Condition Possible Cause Correction 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...
  • Page 188 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. STARTER / GENERATOR Condition Possible Cause Correction STARTER IS NOISY Bolts are loose Retighten Starter/generator has foreign matter inside Clean starter/generator interior Bearings are faulty Replace Bearings contain foreign matter...
  • Page 189 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. SUSPENSION AND STEERING Condition Possible Cause Correction UNEVEN TIRE WEAR Incorrect tire pressure Inflate to recommended pressure Improper alignment (Incorrect toe in) Align front tires STIFF STEERING Water has entered steering box and may...
  • Page 190 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Repair and Service Manual Page S-8...

  • Page 191: Limited Warranty

    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 Repair and Service Manual Page T-i...
  • Page 192 LIMITED WARRANTY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page T-ii Repair and Service Manual...
  • Page 193 VEHICLE WARRANTIES - FEDERAL (2006) FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE - This emission warranty is applicable in all States, except the State of California Fuji Heavy Industries Ltd. and E-Z-GO Division of Textron Augusta, Georgia, (herein “E-Z-GO”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Non-road engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S.
  • Page 194 VEHICLE WARRANTIES - FEDERAL (2006) deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled mainte- nance. As the engine owner, you should however be aware that E-Z-GO may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 195: California Evaporative Emission Control Warranty Statement

    VEHICLE WARRANTIES - CALIFORNIA (2007) CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS: The California Air Resources Board and the E-Z-GO Division of Textron Inc. (E-Z-GO) are pleased to explain the evaporative emission control system (EECS) on your 2007 gasoline powered vehicle.
  • Page 196 VEHICLE WARRANTIES - CALIFORNIA (2007) MAINTENANCE, REPAIR, AND REPLACEMENT OF EVAPORATIVE EMISSION RELATED PARTS: Any E-Z-GO approved replacement part used in 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.

  • Page 197: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ’U’ SECTION TITLE PAGE 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......................
  • Page 198 GENERAL SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings. NOTES: Page U-ii Repair and Service Manual...
  • Page 199 GENERAL SPECIFICATIONS TXT GASOLINE - FLEET CAR WEIGHT (dry fuel tank)............669 lbs. (304 kg) fuel capacity 31 lbs. (14 kg) TIRES (4 ply rated) ..............18 X 8.50 x 8 TIRE PRESSURE ..............18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ......
  • Page 200 GENERAL SPECIFICATIONS TXT GASOLINE - FREEDOM AND FREEDOM HP WEIGHT (dry fuel tank)............679 lbs. (308 kg) fuel capacity 31 lbs. (14 kg) TIRES (4 ply rated) ..............18 X 8.50 x 8 TIRE PRESSURE ..............18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ......
  • Page 201 GENERAL SPECIFICATIONS TXT GASOLINE - SHUTTLE 2+2 WEIGHT (dry fuel tank)............765 lbs. (347 kg) fuel capacity 31 lbs. (14 kg) TIRES (4 ply rated) ..............18 X 8.50 x 8 TIRE PRESSURE ..............18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ......
  • Page 202 GENERAL SPECIFICATIONS 67 in. (170 cm) 49 in. (124 cm) Front 65.5 in. (166 cm) 33.5 in. (85 cm) 92.5 in. (235 cm) Rear 105 in. (267 cm) 38 in. (97 cm) NOTE: Shaded Area Indicates SHUTTLE 2+2 46.5 in. (118 cm) Fig.
  • Page 203 GENERAL SPECIFICATIONS RECOMMENDED MAX SIDE TILT RECOMMENDED MAX RAMP 25% GRADE or 14 25% GRADE or 14 TURNING CLEARANCE DIAMETER 19 ft. (5.8 m) Fig. 2 Vehicle Dimensions, Incline Specifications and Turning Clearance Diameter Repair and Service Manual Page U-5...
  • Page 204 GENERAL SPECIFICATIONS NOTES: Repair and Service Manual Page U-6...
  • Page 205 Some components are heavy, spring loaded, highly cor- rosive, explosive or may produce high amperage or reach high temperatures. Gasoline, carbon monoxide, Read and understand the following warnings before attempting battery acid and hydrogen gas could result in serious to operate the vehicle: bodily injury to the technician/mechanic and bystanders if not treated with the utmost caution.
  • Page 206 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 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of E-Z-GO Division of Textron Inc.

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