Ezgo 605586 Repair And Service Manual page 99

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
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 specifica-
tions are as shown in the table contained in Section 'A'.
Feed the choke cable assembly (8) through the hole in
the bezel (7) (Ref. Fig. 3 on Page H-2). Insert the cable
and bezel into the seat panel and install the bezel
retaining bracket (6), lock washer (5) and nut (4) finger
tight. Slide the threaded portion of the housing through
the carburetor mounted bracket and attach the nuts (2)
to the choke cable housing finger tight. Pass the choke
cable through the choke arm swivel and tighten the
swivel screw (9) after being sure that the choke and
choke knob are both in the open position.
Adjust the position of the curved portion of the cable
housing to ensure that the cable does not contact the
belts or other moving parts. Check the cable to be sure
that there are no sharp bends or kinks in the cable
before firmly tightening the nuts at both ends of the
cable.
Carburetor Service
Be sure that the ignition system is functioning correctly
before determining that servicing the carburetor is
required. Refer to ELECTRICAL section for ignition sys-
tem information.
To prevent an ignition spark which could ignite
gasoline from the fuel system and result in
personal injury, the negative battery cable
must be removed from battery (see Section
'B').
Carburetor Removal
Tool List
Socket, 10 mm, 1/4" drive ........................................... 1
Ratchet, 1/4" drive....................................................... 1
Extension, 3", 1/4" drive .............................................. 1
Parallel jaw pliers ........................................................ 1
Straight blade screwdriver........................................... 1
Phillips screwdriver ..................................................... 1
Torque wrench, 1/4" drive, in. lbs. ............................... 1
Loosen the hose clamps (1) from each end of the air
intake hose (2). Remove hose (Ref. Fig. 4 on Page H-4).
Remove the two nuts (3) and two studs (4) that secure
the baffle (5) to the carburetor adapter (8).
Remove the two nuts (6) and two washers (7) that
secure the carburetor adapter (8) to the carburetor (10).
Remove PCV valve hose (9) from the rear of the carbu-
retor adapter.
Disconnect the fuel line (12) from the carburetor and
plug the fuel line. Disconnect the solid linkage (13) from
the carburetor throttle lever. See SPEED CONTROL
section. Remove the choke cable (14) from the choke
lever swivel (15).
Remove the choke bracket (16) and slide the carburetor
from the engine studs.
If the carburetor contacts the starter/generator, it will be nec-
essary to remove the starter belt and tilt the starter/generator
to permit carburetor removal. See the starter/generator adjust-
ment instructions in ENGINE section.
Carburetor Disassembly
Tool List
Socket, 12 mm, 1/4" drive ........................................... 1
Ratchet, 1/4" drive ....................................................... 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 wear or clogging of
internal passages with foreign material. Do not bend the float
pin during removal. See 'Carburetor Troubleshooting' else-
where in this section.
Remove the float bowl (1) by removing the retaining
Qty. Required
screw (Ref. Fig. 5 on Page H-5).
Inspect the bowl gasket (2) for nicks or cuts. Carefully
press out the float pin (3), float (4) and the inlet valve.
Inspect the float pin for wear at its tip.
Remove the main jet (5).
Remove the main nozzle (6) and inspect the holes.
Blow the nozzle clean with compressed air.
Repair and Service Manual
FUEL SYSTEM
Qty. Required
Page H-3
B
B