E-Z-GO 2Five Electric Service Manual
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E-Z-GO 2Five Electric Service Manual

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See also: Owner's Manual
2Five Electric
Repair & Service Manual
606779
ISSUED: APRIL 2010
REVISED: DECEMBER 2012

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Summary of Contents for E-Z-GO 2Five Electric

  • Page 1 2Five Electric Repair & Service Manual 606779 ISSUED: APRIL 2010 REVISED: DECEMBER 2012...

  • Page 2: Safety

    S A F E T Y For any questions on material contained in this manual, contact an authorized representative for clarification. Read and 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. To prevent loss of vehicle control and possible serious injury, speeds should be limited to no more than 25 mph.
  • Page 3 STARTING YEAR 2010 (MANUFACTURED BEGINNING April 2010) E-Z-GO Division of TEXTRON Inc. reserves the right to incorporate engineering and design changes to products in this Manual, without obligation to include these changes on units leased/sold previously. The information contained in this Manual may be revised periodically by E-Z-GO, and therefore is subject to change without notice.

  • Page 4: General Information

    GENERAL INFORMATION This vehicle has been designed and manufactured in the United States of America (USA). The Standards and Specifications listed in the following text originate in the USA unless otherwise indicated. The use of non-Original Equipment Manufacturer (OEM) approved parts may void the warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE SAFETY ........................Inside Covers MODELS ............................i GENERAL INFORMATION .......................ii SAFETY INFORMATION ......................... v TITLE SECTION GENERAL INFORMATION & ROUTINE MAINTENANCE ..............A SAFETY ............................B BODY ...............................C WHEELS AND TIRES ........................D ELECTRONIC SPEED CONTROL (AC MOTOR)................E FRONT SUSPENSION ........................
  • Page 6 TABLE OF CONTENTS Notes: Repair and Service Manual Page iv...

  • Page 7: Safety Information

    CAUTIONS, WARNINGS and DANGERS contained therein. If you have any questions regarding this vehicle, contact your authorized E-Z-GO LSV dealer or write to the address on the back cover of this publication, Attention: Customer Care Department.
  • Page 8 SAFETY INFORMATION Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Drive vehicle only as fast as terrain and safety considerations allow. Consider the terrain and traffic conditions.
  • Page 9 SAFETY INFORMATION Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. ALWAYS: use the vehicle in a responsible manner and maintain the vehicle in safe operating condition read and observe all warnings and operation instruction labels affixed to the vehicle use extreme caution in areas where pedestrians are present maintain adequate distance between vehicles...
  • Page 10 15-amp circuit for each battery charger, DO NOT permit other appliances to be plugged into the receptacle when the charger is in operation operate the charger in accordance with E-Z-GO’s recommendations or applicable electrical codes SEAT BELTS Always operate the vehicle with seat belts properly fastened.
  • Page 11 If you believe that a vehicle has a defect which could cause a crash or could cause injury or death, you should imme- diately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying E-Z-GO Division of Textron Inc.
  • Page 12 SAFETY INFORMATION Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page x Repair and Service Manual...
  • Page 13 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION ‘A’ SECTION TITLE PAGE NO. VIN LOCATION......................A - 1 Fig. 1 VIN Location ..................A - 1 SERIAL NUMBER LOCATION ................. A - 1 Fig. 2 Serial Number Location on Steering Column ........A - 1 Fig.
  • Page 14 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page A-ii Repair and Service Manual...

  • Page 15: General Information & Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Thank you for purchasing this vehicle. This repair man- In order to obtain correct components for the vehicle, the ual contains information that will assist you in repairing manufacture date code, serial number and vehicle and maintaining this vehicle.

  • Page 16: New Vehicle Initial Service

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. secured before transporting. The rated capacity of the NEW VEHICLE INITIAL SERVICE trailer or truck must exceed the weight of the vehicle Before a new vehicle is put into operation, the items (see GENERAL SPECIFICATIONS for vehicle weight) shown in the INITIAL SERVICE CHART must be per-...

  • Page 17: Servicing Vehicle

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. operations before reading and understand- ing all notes, cautions and warnings in this manual.

  • Page 18: Vehicle Cleaning And Care

    ITEM PART NUMBER Removal of oil, tar, asphalt, shoe polish, etc., requires ATC 10A (E-Z-GO P/N 35212G07) the use of a commercially available vinyl/rubber cleaner. Fuses ATC 7.5A (E-Z-GO P/N 35212G05)

  • Page 19: Hardware

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. HARDWARE Periodically, the vehicle should be inspected for loose fasteners. Fasteners should be tightened in accordance with the Torque Specifications table (Ref.

  • Page 20: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. PERIODIC SERVICE SCHEDULE - CHECK C&A - CHECK & ADJUST CL - CLEAN R - REPLACE ...
  • Page 21 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page A-7 Repair and Service Manual...
  • Page 22 GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page A-8 Repair and Service Manual...
  • Page 23 SAFETY TABLE OF CONTENTS FOR SECTION ‘B’ SECTION TITLE PAGE NO. NOTES, 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 Additional Warnings ..................
  • Page 24 SAFETY Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page B-ii Repair and Service Manual...
  • Page 25 SAFETY Read all of Section A and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. NOTICES, CAUTIONS, WARN- Always use the appropriate tools listed in the tool list and wear approved safety equipment. INGS AND DANGERS MODIFICATIONS TO VEHICLE Throughout this manual, the following NOTICES, CAU-...
  • Page 26 SAFETY Read all of Section A and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. solvents. The electrolyte in a storage battery is an acid solution which can cause severe burns Always turn the key switch to ‘OFF’ and to the skin and eyes.
  • Page 27 SAFETY Read all of Section A and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. ATTACH NEGATIVE WIRE FROM ACCESSORY TO (-) BATTERY TERMINAL ATTACH POWER WIRE FROM ACCESSORY TO (+) BATTERY TERMINAL Fig.

  • Page 28: Safety

    SAFETY Read all of Section A and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CONTROLLER BATTERY HOLD DOWN SPLASH SHIELD BATTERY TRAY LINER BATTERY TRAY CHARGER RECEPTACLE Fig. 2 Batteries, Charger Receptacle & Controller BATTERY REMOVAL &...
  • Page 29 SAFETY Read all of Section A and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 2. Using an insulated wrench, disconnect the main nega- tive (-) battery cable, BL-. 3. Using an insulated wrench, disconnect the main posi- tive (+) battery cable, BL+.
  • Page 30 SAFETY Read all of Section A and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 12. .Install the battery hold downs (3), tighten the hex 15. Tighten all battery terminal hardware to 95 - 105 in. head bolts (2) and nuts (3) to the specified torque lbs.
  • Page 31 SAFETY Read all of Section A and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. LIFTING THE VEHICLE jack may be left under the center front of the frame while the front end of the vehicle is on the jack stands. Tool List Qty.
  • Page 32 SAFETY Read all of Section A and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page B-8 Repair and Service Manual...

  • Page 33: Body

    BODY TABLE OF CONTENTS FOR SECTION ‘C’ SECTION TITLE PAGE NO. GENERAL......................... C - 1 Fig. 1 Body....................C - 1 Fig. 2 Christmas Tree Rivet Removal ............C - 1 BODY COMPONENT REPLACEMENT ..............C - 2 Front Fascia and Front Bumper ............... C - 2 Fig.
  • Page 34 BODY Read all of Section B and this section before working on vehicle. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page C-ii Repair and Service Manual...
  • Page 35 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. INSTRUMENT PANEL TRIM SEAT BACK COWL REAR BODY BUMPER BAG WELL UPPER ROCKER PANEL LOWER FLOOR MAT REAR BUMPER ROCKER PANEL...

  • Page 36: Body Component Replacement

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions Warnings and Dangers. BODY COMPONENT 3. Pull the fascia panel (6) with turn signals forward and off of the bolts. Disconnect the wires for the turn signal REPLACEMENT lights.

  • Page 37: Floor Mat

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Reassemble in reverse order. Replace any worn or damaged hardware as required. ITEM TORQUE SPECIFICATION Location of Short 27 - 44 in.

  • Page 38: Front Splash Guard

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions Warnings and Dangers. point the cowl is completely loose — remove the cowl. 3. Loosen the trim panel (15) by pulling it away from the To prevent the possibility of injury or death the instrument panel along the upper edge then grip the correct safety label must be on the instrument...

  • Page 39: Fender Liner

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 1. Remove four torx screws (26) and flat washers (27) that secure the seat back assembly (25) to the top support.
  • Page 40 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions Warnings and Dangers. Fig. 13 Rear Body 3. Unplug the cord from the charger receptacle (30) to 26 - 44 in. lbs. (3 - 5 Nm) the on board battery charger, disconnect the plug to the accessory harness.

  • Page 41: Rear Bumper

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Floorboard Rear Bumper (Ref. Fig. 14) Tool LIst Qty. Tool LIst Qty. Ratchet ................ 1 Torx Bit, T-50..............1 Ratchet Extension, 9"..........

  • Page 42: Rear Facing Seat & Foot Rest

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions Warnings and Dangers. SEAT BACK SEAT BOTTOM PASSENGER SIDE HIP RESTRAINT FOOT REST DRIVER SIDE HIP RESTRAINT Fig. 15 2 + 2 Rear Facing Seat & Foot Rest 2 + 2 REAR FACING SEAT &...
  • Page 43 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. secure the hip restraints to the rear facing seat floor board. The complete seat frame and seat back can now be removed from the vehicle.

  • Page 44: Frame

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions Warnings and Dangers. 23 1 FRAME ITEM TORQUE SPECIFICATION The vehicle frame is made up of five components, the frame weldment (1), the IP support weldment (2), the 6, 7 15 - 17 ft.

  • Page 45: Cleaning

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. BODY CARE MAINTENANCE 3-M 39009 Polishing Pad Glaze (for dark colors) ...1 qt. 3-M 05995 Polishing Pad Glaze (for light colors) ...1 qt. Coarse Cut Foam Compound Pad for Buffer....1 Cleaning Fine Cut Polish Pad for Buffer ........1...

  • Page 46: Larger Scratches

    BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions Warnings and Dangers. Wet Sanding Block ............1 4. After painting, allow to dry overnight. Smooth the Soft Clean Cotton Cloths mask lines using 1200 grit “wet”...
  • Page 47 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page C-13...
  • Page 48 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page C-14 Repair and Service Manual...
  • Page 49 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 - 2 Fig. 1 Tire Mounting & Cross Sequence for Tightening......D - 2 Repair and Service Manual Page D-i...
  • Page 50 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page D-ii Repair and Service Manual...

  • Page 51: Wheels And Tires

    WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. turf. For vehicles being used on paved or hard surfaces, WHEEL AND TIRE SERVICE tire inflation pressure should be in the higher allowable range, but under no condition should inflation pressure Tools List Qty.
  • Page 52 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. onto the hub. Install lug nuts (1) finger tight; make sure Wheel Installation that the tapered end is against the wheel rim; and tighten in a ‘cross sequence’...
  • Page 53 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page D-3 Repair and Service Manual...
  • Page 54 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page D-4 Repair and Service Manual...
  • Page 55 ELECTRONIC SPEED CONTROL (AC MOTOR) TABLE OF CONTENTS FOR SECTION ‘E’ SECTION TITLE PAGE NO. GENERAL......................... E - 1 Fig. 1 Electronic Speed Control ..............E - 1 Fig. 2 Christmas Tree Rivet Removal ............E - 1 ACCELERATOR PEDAL ASSEMBLY ..............E - 2 Fig.
  • Page 56 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page E-ii Repair and Service Manual...

  • Page 57: Electronic Speed Control (Ac Motor)

    ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers. Controller Reverse Warning Indicator Run/Tow Switch Accelerator Pedal Pedal Cover Fig. 1 Electronic Speed Control The recommended method GENERAL Christmas Tree...
  • Page 58 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers. Pedal Cover Christmas Tree Rivet Fig. 3 Pedal Cover cover to floorboard. ACCELERATOR PEDAL ASSEMBLY 2.
  • Page 59 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers. Using an insulated wrench, disconnect the bat- tery cable at the negative (-), BL-, battery ter- minal.
  • Page 60 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers. the back terminal of the solenoid (4), secure in place Wrench, 15 mm............1 using a hex nut (5).
  • Page 61 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers. Fig. 8 Solenoid Connections OLD CONTROLLER ASSEMBLY Heatsink Solenoid Controller Fig. 9 Controller Connections Page E-5 Repair and Service Manual...
  • Page 62 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers. 5. Disconnect the Red wire (11) from the controller B+ 18. Reconnect wires to the battery pack. Replace any terminal to the back terminal of the solenoid.
  • Page 63 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers. 22. Connect the black wire (8) from the B- terminal to the negative (-), BL-, battery terminal. Do not over tighten the terminal bolt (7).
  • Page 64 ELECTRONIC SPEED CONTROL (AC MOTOR) Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions, Warnings and Dangers. Notes: Page E-8 Repair and Service Manual...

  • Page 65: Front Suspension

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION ‘F’ SECTION TITLE PAGE NO. MAINTENANCE ......................F - 1 Fig. 1 Front Suspension and Steering ............F - 1 Tire Wear Diagnosis..................F - 1 Fig. 2 Tire Wear ..................F - 2 Wheel Alignment ....................
  • Page 66 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page F-ii Repair and Service Manual...

  • Page 67: Maintenance

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. STEERING WHEEL STEERING COLUMN ASSEMBLY INTERMEDIATE SHAFT YOKE STRUT ROTOR ASSEMBLY AND HUB ASSEMBLY CALIPER ASSEMBLY TIE ROD END...

  • Page 68: Wheel Alignment

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Noti4ces, Cautions, Warnings and Dangers. of the tread. Wear on either side of a correctly inflated the wheels in line with the body of the vehicle it will result in scuffing of the tire tread tire indicates a tire that is out of alignment.

  • Page 69: Wheel Bearing Inspection

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 6. To adjust the wheel alignment, loosen the tie rod jam Torque Wrench, ft. lbs..........1 nut (1) and turn the tie rods and equal number of turns Flat Blade Screwdriver..........1 until the correct alignment is achieved.

  • Page 70: Wheel Bearing Packing

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Noti4ces, Cautions, Warnings and Dangers. the seal facing into the rotor and hub bore. Tap the grease seal (7) gently into place until the seal is flush with the end of the hub.

  • Page 71: Struts

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 6. Check for smooth and free rotation of the wheel and Struts (Ref Fig. 7) an absence of play when the wheel is grasped by the outside of the tire.

  • Page 72: A-Arm Assembly

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Noti4ces, Cautions, Warnings and Dangers. Tie Rod End Brake Caliper and Pads Fig. 7 Hub, Spindle, Strut and A-Arm Assemblies 4.

  • Page 73: Steering Wheel

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Steering Wheel (Ref Fig. 8) (Ref Fig. 9) (Ref Fig. 10) Tool List Qty. Socket, 24 mm ............

  • Page 74: Steering Column Assembly And Yoke

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Noti4ces, Cautions, Warnings and Dangers. Steering Column Assembly & Yoke (Ref Fig. Steering Column 11) (Ref Fig. 12) (Ref Fig. 13) Assembly Tool List Qty.

  • Page 75: Rod End / Ball Joint

    FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. yoke onto the shaft. Do not tighten the upper cross Inspect rod end or ball joint by grasping the end and bolt and nut.
  • Page 76 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Noti4ces, Cautions, Warnings and Dangers. spindle arm. steering box (16) to the vehicle frame. 4. Repeat steps 3 through 5 for the remaining tie rod 9.
  • Page 77 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page F-11 Repair and Service Manual...
  • Page 78 FRONT SUSPENSION AND STEERING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page F-12 Repair and Service Manual...

  • Page 79: Motor & Motor Brake

    MOTOR & MOTOR BRAKE TABLE OF CONTENTS FOR SECTION ‘G’ SECTION TITLE PAGE NO. GENERAL.........................G - 1 Fig. 1 Motor....................G - 1 SPEED SENSOR ...................... G - 1 Fig. 2 Speed Sensor Removal ..............G - 1 Fig. 3 Install Speed Sensor ...............G - 2 MOTOR ........................
  • Page 80 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page G-ii Repair and Service Manual...
  • Page 81 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Wires to Controller Wires to Motor Motor Brake Harness Fig. 1 Motor GENERAL The only serviceable items for the electric motor are the speed sensor and the entire Motor Brake.
  • Page 82 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. sor (2) straight up until it is clear of the motor. Tool List Qty. Ratchet ................1 Installation Torque Wrench, in.
  • Page 83 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 10. Pull the motor wires out through the bagwell. Note: The motor must be examined every 20,000 AMP-Hrs 11.
  • Page 84 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. tighten the terminal screws (27) & (28). . Disconnect the negative (BL-) battery cable with an insulated wrench before attempting to disconnect wires from the motor (see safety procedures in SAFETY section of this manual).
  • Page 85 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. DO NOT drop the brake assembly. Dropping or hitting the brake assembly will damage it. Installation 1.
  • Page 86 MOTOR & MOTOR BRAKE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page G-6 Repair and Service Manual...

  • Page 87: Batteries & Charging

    BATTERIES & CHARGING TABLE OF CONTENTS FOR SECTION ‘H’ SECTION TITLE PAGE NO. SAFETY ........................H - 1 Fig. 1 Batteries and Charging Receptacle ..........H - 1 BATTERY ......................... H - 2 BATTERY MAINTENANCE ..................H - 2 At Each Charging Cycle ................... H - 2 Monthly ......................
  • Page 88 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page H-ii Repair and Service Manual...

  • Page 89: Safety

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CONTROLLER BATTERY HOLD DOWN ACCESSORY HARNESS BATTERY TRAY ON BOARD CHARGER CHARGER RECEPTACLE WITH DC TO DC CONVERTER Fig.

  • Page 90: Battery

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. BATTERY MAINTENANCE Always wear a safety shield or approved safety goggles Tool List Qty. when adding water or charging batteries.

  • Page 91: Cleaning Batteries

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Cleaning Batteries This level will leave approximately 1/4" - 3/8" (6 - 10 mm) of space between the electrolyte and the vent tube. When cleaning the outside of the batteries and termi- The electrolyte level is important since any portion of the nals, do not use a water hose without first spraying with...
  • Page 92 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. BATTERY REMOVAL & INSTALLATION Tool List Qty. Insulated Wrench, 9/16" ..........1 Insulated Wrench, 15 mm..........1 Socket, 15 mm.............
  • Page 93 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. faces). The area should be washed with a solution of baking soda and water and dried thoroughly. All metal surfaces that have been cleaned must be primed and painted with a corrosion resistant paint.

  • Page 94: Prolonged Storage

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 16. Inspect all wires and terminals and clean any corro- battery cable, BL-, from the controller last. sion from the battery terminals or wire terminals with a 18.

  • Page 95: Battery Charging

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. charge. The batteries should be tested or recharged at • The power cord is fully inserted into the vehicle receptacle.

  • Page 96: Using A Hydrometer

    BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. trolyte temperature is significantly different from the ambi- ent temperature if the vehicle has been operated. Using A Hydrometer 1.
  • Page 97 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Fig. 13 Hydrometer Temperature Correction Repair and Service Manual Page H-9...
  • Page 98 BATTERIES & CHARGING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page H-10 Repair and Service Manual...
  • Page 99 BATTERY CHARGER TABLE OF CONTENTS FOR SECTION ‘I’ SECTION TITLE PAGE NO. CHARGER DESCRIPTION ..................I - 1 Fig. 1 Charger Installation ................I - 1 UNDERSTANDING THE CHARGER ................I - 1 LED DISPLAY INFORMATION...................I - 2 LED Operation Codes ..................I - 2 LED Fault Codes....................I - 2 MAINTENANCE INSTRUCTIONS ................I - 2 REPLACING THE CHARGER/DC to DC CONVERTER..........I - 2...
  • Page 100 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page I-ii Repair and Service Manual...
  • Page 101 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CHARGER DESCRIPTION The power cord may remain plugged into the AC outlet. To charge the vehicle refer to the instructions in the owner’s manual.
  • Page 102 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. LED DISPLAY INFORMATION MAINTENANCE INSTRUCTIONS 1. For flooded lead-acid batteries, regularly check the LED Operation Codes: water levels of each battery cell after charging and add distilled water as required to the level specified by SHORT GREEN FLASH = less than 80% charged...
  • Page 103 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 3. Unplug the cord (1) from the charger receptacle to the charger. 4. Unplug the Charger DC Output connector (2) and the DC-DC Output connector (3).
  • Page 104 BATTERY CHARGER Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page I-4 Repair and Service Manual...
  • Page 105 BRAKES TABLE OF CONTENTS FOR SECTION ‘J’ SECTION TITLE PAGE NO. GENERAL........................J - 1 Fig. 1 Brake System ...................J - 1 ROUTINE MAINTENANCE ..................J - 1 Fig. 2 Christmas Tree Rivet Removal ............J - 1 Check Brake Fluid.....................J - 1 Fig.
  • Page 106 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page J-ii Repair and Service Manual...

  • Page 107: Brakes

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CARRIER CALIPER CALIPER ROTOR CARRIER BRAKE PEDAL ROTOR BRAKE LINE ROTOR BELL CRANK CALIPER MASTER CYLINDER CALIPER ROTOR Fig.

  • Page 108: Brake Cable Adjustment

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Fig. 3 Master Cylinder Fill Line Fig. 4 Cable Adjusting Nut 3. Using locking pliers to hold the knurled end of the Never work on a vehicle supported by a jack brake cable adjust the nut on the end of the cable 1/8 - alone.

  • Page 109: Replacement Of Wear Items

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. REPLACEMENT OF WEAR ITEMS Brake Pad Replacement Brake pads should always be replaced as a full set on both front wheels or both back wheels.

  • Page 110: Spindle Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. For Hub Replacement, Wheel Bearing and Race 3. Mark the position of the retaining nut (12) on the Replacement, Wheel Bearing Packing and Wheel Bear- threaded portion of the pedal return spring rod (13).

  • Page 111: Bell Crank Bushings

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. During this process, it is likely that brake fluid will leak from the master cylinder. Avoid allowing brake fluid to contact the painted body components of the vehicle.

  • Page 112: Master Cylinder Replacement

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. MASTER CYLINDER REPLACEMENT Tool List Qty. Torque Wrench, ft. lbs..........1 Torque Wrench, in. lbs..........1 Ratchet ................1 Socket, 14 mm .............1 Socket, 1/2"..............1 Wrench, 1/2"...

  • Page 113: Bleeding Brakes

    BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. BLEEDING BRAKES Tool List Qty. Hose ................A/R Clean Container............1 Brake Fluid, DOT 3 ..........A/R Wrench, 1/4" box end ..........1 The hydraulic brake system must be free of air to oper- ate properly.
  • Page 114 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Bleeder Valve Bleeder Hose Fig. 18 Bleeding Brakes 4. Starting with the passenger side rear brake , then driver side rear brake, driver side front brake and pas- senger side front brake last.
  • Page 115 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page J-9 Repair and Service Manual...
  • Page 116 BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page J-10 Repair and Service Manual...
  • Page 117 ELECTRICAL COMPONENTS & WIRING TABLE OF CONTENTS FOR SECTION ‘K’ SECTION TITLE PAGE NO. MAIN WIRING HARNESS..................K - 1 Fig. 1 Main Electrical Harnesses ............... K - 1 REPLACING THE MAIN WIRING HARNESS ............K - 1 Fig. 2 Instrument Panel & Trim ..............K - 2 Fig.

  • Page 118: Table Of Contents For Section 'K' Section Title

    ELECTRICAL COMPONENTS & WIRING TABLE OF CONTENTS FOR SECTION ‘K’ (CONT.) SECTION TITLE PAGE NO. Top Mounted Brake Light Replacement..............1 Top Mounted Brake Light Bulb Replacement............1 Repair and Service Manual Page K-ii...

  • Page 119: Electrical Components & Wiring

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Strobe Light Top Brake Light Wiper Motor Switch 12 Volt Speedometer Outlet Rabbit/Turtle Head Light Switch Controller Switch...
  • Page 120 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. position and remove it from the switch. 16. Raise the front edge of the rear body several inches and support it with a block or piece of 2"...
  • Page 121 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 18. Remove the Run/Tow switch from the splash shield by removing the seal (4) and upper nut (5) then push the switch (7) through the splash shield.
  • Page 122 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. d) Place pedal assembly in position on the floorboard and secure with three Torx screws (6). e) Connect the wires to the brake pedal rotary posi- tion sensor (8).
  • Page 123 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. j) Connect the wire harness to the key switch, the m) OLD VEHICLES: Connect the green wire from the speedometer and the rabbit/turtle switch.
  • Page 124 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. o) NEW VEHICLES: Connect the bus bar from the Splash Shield controller B+ to the front terminal of the solenoid and secure in place using a hex nut (16).

  • Page 125: Replacing Electrical Components

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. REPLACING ELECTRICAL COMPO- NENTS Run / Tow Switch (Ref Fig. 16 on page K-7) Tool List Qty.

  • Page 126: Speedometer

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 3. Remove the two torx head screws (10) securing the reverse warning indicator (11) to the splash shield. 4.
  • Page 127 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. BRAKE SENSOR GREEN PINK BLACK PINK GRN / BLK BLUE / WHT LT GREEN BLK / WHT ORANGE / RED RED / WHITE...
  • Page 128 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. GREEN GRN/WHT GRN/BLK Fig. 20 Main Wiring Harness (AFTER 1 FEBRUARY 2012) Repair and Service Manual Page K-10...
  • Page 129 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. PURPLE GRY / BLK BROWN GRY / BLK GRY / BLK GREEN BLACK RED / WHT RED / WHT RED / WHT WHITE...

  • Page 130: Accessory Wiring Harness

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Wiper Motor Strobe Light 12 Volt Headlight/Turnsignal Outlet Center Brake Light Headlight Switch Connection to Fuse Holder Fan Relay Main Harness Brake...
  • Page 131 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. brake light harness from the accessory harness then it follows the proper path. remove the OPS, upper and lower rocker panels, the a) Starting in the cup holder, route the forward section floormat, the front cowl, the top portion of the cup holder of the harness in the tabs on the front splash...

  • Page 132: Replacing Electrical Accessories

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. i) Route the wires and connector for the fuse block, 19. Be sure that all wires are connected properly before DC to DC converter, on-board battery charger and installing the body components that were removed to the driver side brake light between the rear body...

  • Page 133: Head Light Bulb Replacement

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Head Light Bulb Replacement Make sure that the vehicle key switch is in the ’OFF’ position and the key has been removed.

  • Page 134: Turn Signal Switch Replacement

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Turn Signal Switch Replacement Tail Light Assembly Replacement Make sure that the vehicle key switch is in the ’OFF’ Make sure that the vehicle key switch is in the ’OFF’...

  • Page 135: Horn Button Replacement

    ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Horn Button Replacement Top Mounted Brake Light Replace- ment Make sure that the vehicle key switch is in the ’OFF’ position and the key has been removed.
  • Page 136 ELECTRICAL COMPONENTS & WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page K-18 Repair and Service Manual...

  • Page 137: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION ‘L’ SECTION TITLE PAGE NO. GENERAL......................... L - 1 Fig. 1 Rear Suspension ................L - 1 SHOCK ABSORBER ....................L - 1 Fig. 2 Shock Absorber................L - 2 REAR LEAF SPRING ....................L - 2 Fig.
  • Page 138 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page L-ii Repair and Service Manual...
  • Page 139 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Shock Absorber Frame Rear Axle Leaf Spring bracket Leaf Spring Shackle Fig. 1 Rear Suspension GENERAL SHOCK ABSORBER (Ref Fig.
  • Page 140 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Removal and installation of the shock is the same for both sides of the vehicle. Replace any worn or damaged hardware Using an insulated wrench, disconnect the bat- with new as required.
  • Page 141 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Installation torque. 13. Torque all hardware as specified making sure that the 7. Install the large flanged urethane bushings (6) and leaf spring pin remains aligned with the holes in the spacer (5) in the end of the leaf spring (16) and place axle mounting bracket and the leaf spring mounting...
  • Page 142 REAR SUSPENSION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page L-4 Repair and Service Manual...
  • Page 143 REAR AXLE TABLE OF CONTENTS FOR SECTION ‘M’ SECTION TITLE PAGE NO. REAR AXLE MAINTENANCE...................M - 1 Fig. 1 Rear Axle ..................M - 1 Replacing the Lubricant ...................M - 1 Fig. 2 Fill Plug ..................M - 2 REAR AXLE DISASSEMBLY ...................M - 2 Rear Hub......................M - 2 Fig.
  • Page 144 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page M-ii Repair and Service Manual...

  • Page 145: Rear Axle

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Motor Motor Brake Axle Fig. 1 Rear Axle REAR AXLE MAINTENANCE The only maintenance required for the first five years or 1000 hours of operation is the periodic inspection of the To reduce the possibility of personal injury, fol- lubricant level.

  • Page 146: Rear Axle Disassembly

    REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 8. Insert the flexible tubing into the opening where the fill low the lifting procedure in Section B of this plug was removed manual.

  • Page 147: Axle Shaft, Bearing And Seal Removal And Disassembly

    Bearing Separator Needle Nose Pliers............1 Internal Snap Ring Pliers..........1 Slide Hammer (E-Z-GO P/N 18753-G1)...... 1 Seal Puller ..............1 Seal Installer (E-Z-GO P/N 18739-G1)......1 Ball Peen Hammer ............1 Remove the wheel and the hub from the axle.
  • Page 148 Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 6. Install the new oil seal using the seal installer (E-Z-GO P/N 18739-G1) to drive the seal into its correct posi- tion.

  • Page 149: Weather Protection

    WEATHER PROTECTION TABLE OF CONTENTS FOR SECTION ‘N’ SECTION TITLE PAGE NO. TOP AND WINDSHIELD................... N - 1 Fig. 1 Top and Windshield................. N - 1 WINDSHIELD......................N - 2 Fig. 2 Windshield Trim Removal ..............N - 2 Fig. 3 Remove Urethane Bead ..............N - 2 Fig.
  • Page 150 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page N-ii Repair and Service Manual...
  • Page 151 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. CANOPY WINDSHIELD WINDSHIELD TRIM Fig. 1 Top and Windshield TOP AND WINDSHIELD WINDSHIELD Tool List Qty. Windshield Knife ............1 Handle with Suction Cups..........2 Pry Bar.................1...
  • Page 152 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Installation Remove the windshield wiper arm; if the vehicle is equipped with a windshield wiper motor. 1.
  • Page 153 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. the urethane adhesive to cure to a working state. 11. Install the windshield wiper arm if the vehicle is equipped with a windshield wiper motor.
  • Page 154 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Installation 4. Remove the bolts (4) and nuts (5) securing the front 1. Clean the bottom edge of the canopy top (6) and seat belt anchor straps (3) attach the weather seal along both sides and the front to the vehicle frame.
  • Page 155 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 8. Make sure that the hoist and sling are positioned to 7. Install the front seat belt anchor straps (3) with shoul- take the weight of the OPS.
  • Page 156 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 4. Remove the four screws (11) and cover (12) from the wiper motor. Release Tab Fig. 10 Wiper Arm Release Tab 5.
  • Page 157 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Front Strut Header Bar 4. Install flat washer (5), rubber washers (6) and cup washer (7) with cup towards the windshield. 5.
  • Page 158 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Motor Pivot Shaft 12. Slide wiper arm (1) straight onto the motor pivot shaft and lower wiper arm onto the glass. 13.
  • Page 159 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page N-9...
  • Page 160 WEATHER PROTECTION Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page N-10 Repair and Service Manual...
  • Page 161 TROUBLESHOOTING AND DIAGNOSTICS TROUBLESHOOTING AND DIAGNOSTICS TABLE OF CONTENTS FOR SECTION ‘O’ SECTION TITLE PAGE NO. HOW TO USE THE HAND HELD DIAGNOSTIC UNIT ..........O - 1 MENUS ........................O - 2 Diagnostics Report...................O - 2 Diagnostics Report Real-Time .................O - 6 Battery and Warranty ..................
  • Page 162 TROUBLESHOOTING AND DIAGNOSTICS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page O-ii Repair and Service Manual...

  • Page 163: How To Use The Hand Held Diagnostic Unit

    Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. HOW TO USE THE HAND HELD DIAGNOSTIC UNIT The E-Z-GO Hand Held Diagnostic Unit, P/N 614400 is used for troubleshooting, tuning, programming and the retrieval of warranty information on the 2Five vehicle.

  • Page 164: Menus

    TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. MENUS The Hand Held Diagnostic Unit, when connected to the vehicle, will provide access to information on the following: LSV DIAGNOSTIC REPORT BATTERY FUNCTIONS (1 - 3) 1.
  • Page 165 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 5. THROTTLE SWITCH POSITION: displayed as ’THROTTLESW’, the next line displays the switch voltage as ’NORMAL’ or ’HIGH’. LSV DIAG REPORT THROT VOLT _______________________________________________________...
  • Page 166 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 9. MOTOR SPEED SENSOR displayed as ’SPEED SENSOR’, the next line displays the speed sensor is working or not. LSV DIAG REPORT _______________________________________________________ CMD SPEED...
  • Page 167 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 14. FAN function is displayed as "FAN", the next line displays whether or not the controller cooling fan is on or off. LSV DIAG REPORT _______________________________________________________ HEAT SINK TEMP...

  • Page 168: Diagnostics Report Real-Time

    TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. OUTPUT FUNCTIONS (18 - 19) 18. REVERSE WARNING BUZZER: displayed as ’BUZZER’, the next line displays the buzzer state as ’ON’ or ’OFF’. LSV DIAG REPORT _______________________________________________________ BUZZER...
  • Page 169 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 2. CALCULATED BATTERY CURRENT: displayed as ’CURRENT’, the next line displays calculated current as ’LOW’, the actual num- LSV DIAG REAL TIME ber in DC Amps.
  • Page 170 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 6. THROTTLE SWITCH POSITION: displayed as ’THROTTLESWIT’, the next line displays the switch voltage as ’OPEN’ or ’CLOSED’. LSV DIAG REAL TIME _______________________________________________________ CHARCONN...
  • Page 171 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 10. MOTOR SPEED SENSOR displayed as ’SPEED SENSOR’, the next line displays the speed sensor is working or not. LSV DIAG REAL TIME _______________________________________________________ SPEED SENSOR...
  • Page 172 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 15. FAN function is displayed as "FAN", the next line displays whether or not the controller cooling fan is on or off. LSV DIAG REAL TIME _______________________________________________________ HEAT SINK TEMP...
  • Page 173 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. OUTPUT FUNCTIONS (19 - 20) 19. REVERSE WARNING BUZZER: displayed as ’BUZZER’, the next line displays the buzzer state as ’ON’ or ’OFF’. LSV DIAG REAL TIME _______________________________________________________ BUZZER...

  • Page 174: Battery And Warranty

    TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 23. BRAKE LIGHT: displayed as ’BRAKELIGHT’, the next line displays the brake light state as ’ON’ or ’OFF’. LSV DIAG REAL TIME BRAKE _______________________________________________________...
  • Page 175 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 3. TOTAL NET AMP-HOURS: displayed as ’TOTAL NET AH’, this is the total net Amp-Hours used for the life of the vehicle. STATUS _______________________________________________________ SOC BATT...
  • Page 176 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. HISTORY (1 - 3) The HISTORY screen displays the total number of amp hours, the min- utes and the miles of the vehicle.

  • Page 177: Error Messages

    TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ERROR MESSAGES SERVICE MENU DIAG REPORT BATTERY/WARRANTY ERRORS WARNINGS COURSE ENERGY 1. Current Error Message is displayed on the ERROR STATUS screen.

  • Page 178: Course Energy Consumption

    TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. COURSE ENERGY CONSUMPTION (read only) 1. Scroll down to ’CLEAR’ and press the enter key (button 3) to clear the energy consumption.
  • Page 179 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. 5. NET AMP-HOURS USED FOR THE ROUND: displayed as a whole number. . COURSE ENERGY CLEAR _______________________________________________________ START...
  • Page 180 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Turn key to ’OFF’ and then back ’ON’. If car does not run proceed to step 2.
  • Page 181 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Verify that all battery wires are securely fastened and have less than 0.1 ohms resis- tance between wire terminal and battery post.
  • Page 182 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Check both +5V and 5V GND to chassis, 1.
  • Page 183 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Verify that the 5 volt out put range is 5 ±0.1 volts.
  • Page 184 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. Allow time to cool. 1.
  • Page 185 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. ACTION (post diagnos- CODE DESCRIPTION POSSIBLE CAUSES DIAGNOSTIC STEP tics) 1. The current in an open drain 1.

  • Page 186: Troubleshooting

    TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. DIGITAL VOLT OHM METER A typical DVOM (digital volt ohm meter) is shown. A recommended model is available through the Service Parts Depart- ment as P/N 27481-G01.

  • Page 187: Power Supply

    TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. is set to continuity. Place the negative (-) probe on a wire terminal at the beginning of the circuit and work towards the device that is not working with the positive (+) probe.
  • Page 188 TROUBLESHOOTING & DIAGNOSTICS Read all of this manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notices, Cautions, Warnings, and Dangers. Notes: Repair and Service Manual Page O-26...
  • Page 189 LIGHTNING PROTECTION AND GROUNDING TABLE OF CONTENTS FOR SECTION ‘P’ SECTION TITLE PAGE NO. GROUNDING REQUIREMENTS................P - 1 GROUND SYSTEMS ....................P - 1 LIGHTINIG PROTECTION REQUIREMENTS............P - 1 EQUIPMENT FAULT AND PERSONAL SAFETY SYSTEM ........P - 1 GROUND NETWORK REQUIREMENTS..............
  • Page 190 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page P-ii Repair and Service Manual...

  • Page 191: Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 1.

  • Page 192: External Grounding Requirements

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE: EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding Rev -, ECN 027194 10/19/92 6.

  • Page 193: 10. Equipment Fault And Personal Safety System

    LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. REVISION: GS-726-006 TITLE : EFFECTIVE: SUPERCEDES: General Specification: Lightning Protection and Grounding 10/19/92 Rev -, ECN 027194 trating or structurally damaging the building.
  • Page 194 LIGHTNING PROTECTION AND GROUNDING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page P-4 Repair and Service Manual...

  • Page 195: Specifications

    SPECIFICATIONS TABLE OF CONTENTS FOR SECTION ‘Q’ SECTION TITLE PAGE NO. 2Five TWO-PASSENGER VEHICLE SPECIFICATIONS..........Q - 1 2Five FOUR-PASSENGER VEHICLE SPECIFICATIONS........Q - 2 Fig. 1 Vehicle Dimensions .................Q - 3 Fig. 2 Vehicle Incline Specifications and Turning Diameter .......Q - 4 Repair and Service Manual Page Q-i...
  • Page 196 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page Q-ii Repair and Service Manual...
  • Page 197 UL Listed and CSA Certified. ** DO NOT use low inflation pressure tires on any E-Z-GO vehicle. DO NOT use any tire which has a recommended inflation pressure less than the inflation pressure recommended in the Owner’s Guide.
  • Page 198 UL Listed and CSA Certified. ** DO NOT use low inflation pressure tires on any E-Z-GO vehicle. DO NOT use any tire which has a recommended inflation pressure less than the inflation pressure recommended in the Owner’s Guide.
  • Page 199 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. 52.1” (132.3 CM) SIDE MIRROR TO OUTSIDE REAR WHEEL TWO-PASSENGER 71.4" (181.4 cm) FOUR-PASSENGER 71.2” (180.8 cm) TWO-PASSENGER 46.4"...
  • Page 200 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. MAX RAMP GRADE 25% OR 14° MAX SIDE TILT 25% OR 14° Fig. 2 Vehicle Incline Specifications and Turning Diameter Repair and Service Manual Page Q-4...
  • Page 201 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual Page Q-5...
  • Page 202 SPECIFICATIONS Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers. Notes: Page Q-6 Repair and Service Manual...
  • Page 203 NOTICE NOTICE Read the following warnings before attempting to operate the Read and understand the following text and warnings before vehicle attempting to service vehicle: In any product, components will eventually fail to perform properly as the result of normal use, age, wear or abuse. It is virtually impossible to anticipate all possible compo- To prevent personal injury or death, ob- nent failures or the manner in which each component...
  • Page 204 E-Z-GO Division of Textron Inc. 1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA 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. Technical Communications Department...

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