E-Z-GO FLEET 1999 Technician's Repair And Service Manual
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E-Z-GO FLEET 1999 Technician's Repair And Service Manual

Gasoline powered golf cars and personal vehicles
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ii:f:U;t•mCompany
TECHNICIAN'S
REPAIR AND SERVICE MANUAL
GASOLINE POWERED GOLF CARS
AND PERSONAL VEHICLES
MODEL YEARS: 1999/2000
REVISED: 12/2000

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Summary of Contents for E-Z-GO FLEET 1999

  • Page 1 ii:f:U;t•mCompany TECHNICIAN'S REPAIR AND SERVICE MANUAL GASOLINE POWERED GOLF CARS AND PERSONAL VEHICLES MODEL YEARS: 1999/2000 REVISED: 12/2000...
  • Page 2 SAFETY Read and understand all labels located on the vehicle. For any questions on any of the information, contact an E-Z-GO representative for clarification. 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...
  • Page 3 E-Z-GO Division of Textron is not liable for errors in this manual or for incidental or consequential damages that result from the use of the material in this manual. E-Z-GO DIVISION OF TEXTRON, INC., P.O.BOX 388, AUGUSTA, GEORGIA USA 30903-0388...
  • Page 4 NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local distributor, E-Z-GO Branch or the E-Z-GO Warranty Department with vehicle serial number and manufacturer code. The use of non E-Z-GO parts may void the warranty.

  • Page 5: Table Of Contents

    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 ..........................

  • Page 6: Notes

    TABLE OF CONTENTS Notes: __________________________ _ Page iv Repair and Service Manual...

  • Page 7: Safety Information

    CAUTIONS and WARNINGS contained therein. It is further recommended that employees and other operators be encouraged to do the same. If you have any questions, contact your closest E-Z-GO representative or write to the address on the back cover of this publication, Attention: Product Service Department.
  • Page 8 SAFETY INFORMATION Always maintain adequate distance between vehicles. Always reduce speed in wet areas. Always use extreme caution when approaching sharp or blind turns. Always use extreme caution when driving over loose terrain. Always use extreme caution in areas where pedestrians are present. MAINTENANCE Always maintain your vehicle in accordance with the manufacturer's periodic service schedule.
  • Page 9 SAFETY INFORMATION VENTILATION Always store gasoline vehicles in a well ventilated area. Ventilation prevents gasoline fumes from accumulating. Never fuel a vehicle in an area that is subject to flame or spark. Pay particular attention to natural or propane water heater and furnaces.
  • Page 10 SAFETY INFORMATION Notes: _________________________ _ Page viii Repair and Service Manual...
  • Page 11 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION 'A' SECTION TITLE PAGE NO. SERIAL NUMBER PLATE LOCATION .................... A-1 STARTING THE VEHICLE WITH A DISCHARGED BATTERY ............A-1 FUEL ..............................A-1 SERVICING THE VEHICLE ......................A-2 TOWING ............................A-2 Neutral Lock ..........................
  • Page 12 GENERAL INFORMATION & ROUTINE MAINTENANCE TABLE OF CONTENTS FOR SECTION 'A' (CONT.) SECTION TITLE PAGE NO. Fig. 9 Cleaning the Top of the Engine .................... A - 5 Fig. 10 Cleaning the Oil Filter ......................A - 5 Fig. 11 Blowing Out Oil Filter ......................A - 5 Fig.

  • Page 13: Serial Number Plate Location

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings SERIAL NUMBER PLATE LOC ATION FUEL The serial and manufacturing numbers are stamped on a The fuel tank is located under the seat, on the passenger plate on the passenger side of the dash panel (Ref Fig.

  • Page 14: Servicing The Vehicle

    Tow bars are not intended for road use. fore should be considered potentially hazardous. Use Tow bars to fit vehicles are available from the E-Z-GO extreme care when working on any vehicle. When diag­ Service Parts Department. Tow bars are not intended for nosing, removing or replacing any components that are use on public roads or highways.

  • Page 15: Routine Maintenance

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Steering Unit ° Pull out and rotate 180 to unlock Fig. 4 Neutral Lock the transmission remains locked in the neutral position. To operate the transmission, pull the pin out and rotate until the pointed portion of the pin handle fits into the detent position in the transmission shift lever.

  • Page 16: Changing The Oil

    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 � Maximum oil level Fill cold engine - for hot engine to this point Do not overfill I L I �...

  • Page 17: Fig. 9 Cleaning The Top Of The Engine

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 11 Blowing Out Oil Filter oil left in engine. The oil must be high quality oil that meets or exceeds SAE SF, SG, CC standards (Ref F ig.

  • Page 18: Air Cleaner Inspection/Replacement

    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 be operated safely as long as the oil is within the safe Install the element in the same way it was removed, operating range as indicated on the dipstick.

  • Page 19: Starter/Generator Belt Tension

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings STARTER/GENERATOR BELT TENSION Adjusting the Belt Using a 3/4" socket and open end wrench, loosen the Tool List Qty.

  • Page 20: Spark Plugs

    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 DAILY BRAKE TEST After the vehicle has been put into service, it is recom­ mended that the brakes be checked daily by performing the following test: All driving brake te sts...

  • Page 21: Vehicle Care Products

    VEHICLE CARE PRODUCTS Clean with lots of water and a clean cloth. Minor E-Z-GO has several products, available through a local scratches may be removed using a commercial plastic Distributor, an E-Z-GO Branch, or the E-Z-GO Service polish or Plexus plastic cleaner available from E-Z-GO.

  • Page 22: 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 WINTER OR PROLONGED STORAGE changed as part of spring maintenance. This will remove any moisture that has accumulated during storage.

  • Page 23: Periodic Service Schedule

    GENERAL INFORMATION & ROUTINE MAINTENANCE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE ..a. ./ 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 24: Fig. 23 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 ./ Check for unusual tire wear, align per FRONT SUSPENSION AND FRONT WHEEL ALIGNMENT STEERING section ./ Check for bent/binding linkage rod PARKING (PARK) BRAKE...

  • Page 25: Safety

    SAFETY TABLE OF CONTENTS FOR SECTION 'B' SECTION TITLE PAGE NO. GENERAL ............................B-1 GENERAL ............................B-5 NOTES, CAUTIONS AND WARNINGS ................... 8 -8 IMPORTANT SAFETY WARNING ....................B -8 MODIFICATIONS TO VEHICLE ...................... 8 -8 GENERAL MAINTENANCE ......................8 -8 BEFORE SERVICING THE VEHICLE .....................
  • Page 26 SAFETY Notes: _ _ __________________________ _ Page B-ii Repair and Service Manual...

  • Page 27: General

    Where authorized modifications have been made, The following text is provided as recommended by part 11 the user shall ensure that capacity, operation, warning, of ASME/ANSI B56.8-1988. E-Z-GO strongly endorses and maintenance instruction plates, tags, or decals are the contents of this specification.
  • Page 28 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Control of Noxious Gases and Fumes (c) general safety rules contained within this Standard and the additional specific rules determined by the user 4.8.1 When equipment powered by internal com- in accordance with this Standard, and why they were for­...
  • Page 29 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Traveling Handle onl y stable and safel y arran g ed loads. 5.6.1 When handlin g off-center loads which cannot be cen­ Observe all traffic re g ulations , includin g autho- 5.5.1 tered , o p erate with extra caution.
  • Page 30 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings shall be performed in conformance with the manufac­ (o) The carrier manufacturer's capacity, operation, and turer's recommendations and the following practices. maintenance instruction plates, tags, or decals shall be maintained in legible condition.
  • Page 31 The following text is provided as recommended by part 11 In areas where steep grades exist, golf car operations of ANSI/ GCMA Z130.1 - 1993. E-Z-GO, as a member of should be restricted to the designated golf car pathways the Golf Car Manufacturers Association (GCMA), where possible, and shall be identified with a suitable strongly endorses the contents of this specification.
  • Page 32 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE liters per car per charge. Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air 6.1.
  • Page 33 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 7. FUELS HANDLING AND STORAGE/ governors and all other safety devices shall be inspected and maintained in a safe and proper operating condition BATTERY CHARGING and shall not be modified as supplied by the manufac­...

  • Page 34: Notes, Cautions And Warnings

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings NOTES, CAUTIONS AND WARNINGS GENERAL MAINTENANCE Throughout this manual, the following NOTES, CAU­ When any maintenance procedure or inspection is per­ TIONS and WARNINGS are used.

  • Page 35: Battery Removal And Lnstallation

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Never work on an engine that is hot. Battery Removal and Installation Tool List Qty. Required Never work around or operate a vehicle in an environ­ ment that does not ventilate exhaust gases from the Insulated wrench, 1/2"...

  • Page 36: Lifting The Vehicle

    SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings LIFTING THE VEHICLE To raise the entire vehicle, install chocks in front and behind each front wheel (Ref Fig. 2 on page B-10). Cen­ Some servicing operations may require the front wheels, ter the jack under the rear frame crossmember.
  • Page 37 Where authorized modifications have been made, The following text is provided as recommended by part II the user shall ensure that capacity, operation, warning, of ASME/ANSI B56.8-1988. E-Z-GO strongly endorses and maintenance instruction plates, tags, or decals are the contents of this specification.
  • Page 38 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 4.8 Control of Noxious Gases and Fumes (c) general safety rules contained within this Standard and the additional specific rules determined by the user 4.8.1 When equipment powered by internal com- in accordance with this Standard, and why they were for­...
  • Page 39 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 5.5 Traveling 5.6.1 Handle onl y stable and safel y arran g ed loads. When handlin g off-center loads which cannot be cen­ 5.5.1 Observe all traffic re g ulations , includin g autho- tered , o p erate with extra caution.
  • Page 40 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings shall be performed in conformance with the manufac­ (o) The carrier manufacturer's capacity, operation, and turer's recommendations and the following practices. maintenance instruction plates, tags, or decals shall be maintained in legible condition.
  • Page 41 The following text is provided as recommended by part II In areas where steep grades exist, golf car operations of ANSI/ GCMA Z130.1 - 1993. E-Z-GO, as a member of should be restricted to the designated golf car pathways the Golf Car Manufacturers Association (GCMA), where possible, and shall be identified with a suitable strongly endorses the contents of this specification.
  • Page 42 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE liters per car per charge. Because of the highly volatile nature of hydrogen gas and its propensity to rise and accumulate at the ceiling in pockets, a minimum of 5 air 6.1.
  • Page 43 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 7. FUELS HANDLING AND STORAGE/ governors and all other safety devices shall be inspected and maintained in a safe and proper operating condition BATTERY CHARGING and shall not be modified as supplied by the manufac­...
  • Page 44 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings NOTES, CAUTIONS AND WARNINGS GENERAL MAINTENANCE Throughout this manual, the following NOTES, CAU­ When any maintenance procedure or inspection is per­ TIONS and WARNINGS are used.
  • Page 45 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Never work on an engine that is hot. installed in their original positions unless otherwise specified. Non-specified torques are as shown in the table contained in Never work around or operate a vehicle in an environ­...
  • Page 46 SAFETY Read all of Section A and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings LIFTING THE VEHICLE To raise the entire vehicle, install chocks in front and behind each front wheel (Ref Fig. 2 on page B-10). Cen­ Some servicing operations may require the front wheels, ter the jack under the rear frame crossmember.

  • Page 47: Body

    BODY TABLE OF CONTENTS FOR SECTION 'C' SECTION TITLE PAGE NO. BODY .............................. C-1 General ..........................C -1 BODY COMPONENT REPLACEMENT ..................C-1 LIST OF ILLUSTRATIONS Fig. 1 Drill Out Metal Rivet ......................C -1 Fig. 2 Body Components (Front) ....................C -2 Fig.
  • Page 48 BODY Notes: _ _ __________________________ _ Page C-ii Repair and Service Manual...
  • Page 49 BODY Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings BODY In the following text, there are references to Drill Out Rivet NOTE Pop Rivet removing/installing bolts etc. Additional hard­ Head Only ware (nuts, washers etc.) that are removed must always be installed in their original positions unless otherwise specified.
  • Page 50 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings --­ TYPE • • EZGOD1v1s1ana!Tntran Inc PO 8ox31111 Augusta Georgia USA30903031111 -- FRONT SHIELD COMPONENTS --- \---IS( - - -� Fig.
  • Page 51 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Seat Wrap for Metal Body Vehicles Floormat Fig. 3 Floor Pan, Rocker Panels and Seat Wrap Page C-3 Repair and Service Manual...
  • Page 52 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 4 Caddy I Shuttle 2+2 Models Only Fig. 4 Rear Body Components for TXT Models Page C-4 Repair and Service Manual...
  • Page 53 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 5 Rear Body Components for Metal Body Vehicles Page C-5 Repair and Service Manual...
  • Page 54 BODY Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 4 CADDY/ SHUTTLE 2+2 COMPONENTS FOR METAL BODY VEHICLES 4 CADDY/ SHUTTLE 2+2 COMPONENTS FOR TXT MODELS Fig. 6 4 Caddy/ Shuttle 2+2 Components Page C-6 Repair and Service Manual...

  • Page 55: 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 Page D-i Repair and Service Manual...
  • Page 56 WHEELS AND TIRES Notes: __________________________ _ Page D-ii Repair and Service Manual...
  • Page 57 WHEELS AND TIRES Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings WHEEL AND TIRE SERVICE If the tire is flat, remove the wheel and inflate the tire to the maximum recommended pressure for the tire.
  • Page 58 WHEELS AND TIRES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Tire style may vary 'CROSS SEQUENCE' Fig. 1 Wheels and Tires Page D-2 Repair and Service Manual...

  • Page 59: Front Suspension And Steering

    FRONT SUSPENSION AND STEERING TABLE OF CONTENTS FOR SECTION 'E' SECTION TITLE PAGE NO. FRONT SUSPENSION ........................E - 1 Front Shock Absorber Replacement ..................E - 1 Front Axle Replacement ......................E - 1 Front Spring Replacement..................... E - 2 Tie Rod, Wheel Bearing and King Pin lnspection ..............
  • Page 60 FRONT SUSPENSION AND STEERING Notes: ________________________ _ Page E-ii Repair and Service Manual...
  • Page 61 FRONT SUSPENSION AND STEERING Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings FRONT SUSPENSION On metal body vehicles, bend the tabs that secure the flexible grass shield (3) to the cowl down and pull the N OTE In the following text, there are references to grass shield down to provide access to the top of the...

  • Page 62: Hardware

    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 nut (9) until the threaded end of king pin (8) is Tighten the shock absorber mounting hardware until the protected.
  • Page 63 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 a new spring by first attaching the rear of the Torque wrench, 1 /2" drive, ft. lbs ......... 1 spring to the vehicle frame with hardware (13) and then Ball joint separator.
  • Page 64 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 pull down, and then push up to release the two top clip­ board retaining tabs (Ref Fig. 6 on page E-4). Steering Wheel Replacement Loosen the steering wheel retaining nut (6) two to three Tool List...
  • Page 65 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 Indicates Epoxy Patch Bolt. Do not reuse; replace with new bolt of same type Fig.
  • Page 66 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 until ball joint (17) end threads are protected. Using a ball To remove the tensioner, remove the bolts (31 ), the cover joint separator as a lever, apply pressure to ball joint and plate (32) and gasket (33) that secures the rack ten­...
  • Page 67 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 MAINTENANCE Rack Ball Joint Installation Clean threads. Apply primer (LOCTITE LOCQUIC Good routine maintenance of the front suspension and PRIMER T, #7471) and thread locking adhesive (LOC­...
  • 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 Remove the dust cap (14), cotter pin (15) castellated nut (16), outer roller bearing (18) and hub assembly (17) from the spindle (Ref Fig.
  • 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 King Pin Bushing Replacement Wheel Alignment Tool List Qty. Required Tool List Qty. Required Floor jack ..............1 Floor jack ..............
  • 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 nuts (3) and adjust the drivers side tie rod (2) until the spindle arm contacts the 'U' bracket with the steering wheel turned fully to the left.

  • Page 71: Speed Control

    SPEED CONTROL 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 GENERAL LINKAGE ADJUSTMENT PROCEDURE ..............F - 2 Linkage Removal ........................
  • Page 72 SPEED CONTROL Notes: _ _ _______________________ _ Page F-ii Repair and Service Manual...

  • Page 73: Accelerator, Governor And Carburetor Linkage

    SPEED CONTROL Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Accelerator Pedal Micro Switch Accelerator Rod Accelerator Return Spring Accelerator Cable Carburetor Throttle Plate Front Bellcrank Long Horizontal Linkage Rod Fig.

  • Page 74: Governor Operation

    (Ref Fig. 3 on page F-2). Rotate ball joint socket as rized E-Z-GO service branch or distributor who will reseal the necessary to lengthen or shorten until hole in socket governor after calibration.
  • Page 75 SPEED CONTROL Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Adjust the ball joint socket on the disconnected end of the long linkage until it exactly matches the ball on the front bellcrank (3) at the carburetor using procedure pre­...

  • Page 76: Pedal Box Adjustments

    SPEED CONTROL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings PEDAL BOX ADJUSTMENTS Tool List Qty. Required Needle nose pliers ............1 Rocker Panel Phillips screwdriver ............1 Open end wrench, 9/16"...
  • Page 77 SPEED CONTROL Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings <.O T"" T"" ��� T"" m } � � ,-- Fig. 7 Accelerator Linkage Page F-5 Repair and Service Manual...

  • Page 78: Governor Compression Spring Adjustment

    (24 kph) when driven at governed speed (100 yards in 14 rized E-Z-GO service branch or distributor who will reseal the seconds). If the speed is not within the specified speed governor after calibration.

  • Page 79: Engine

    ENGINE TABLE OF CONTENTS FOR SECTION 'G' SECTION TITLE PAGE NO. FOUR CYCLE ENGINE ........................G - 1 Engine Specifications ......................G - 1 Engine Description ....................... G - 1 Engine Operation ........................G - 1 Valve Adjustment........................G - 1 Adjustment Procedure ......................
  • Page 80 ENGINE Notes: _ _ _________________________ _ Page G-ii Repair and Service Manual...

  • Page 81: Engine Specifications

    Engine model ............EH29 starts down, the first cycle is repeated. Type ......Four cycle, overhead cam, OHV In the E-Z-GO engine, there are two pistons that rise and fall simultaneously, however the valve cycles are stag­ Number of cylinders ........2 (In-line) gered.
  • Page 82 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 CLOSED VALVE OPEN VALVE OPERATION � Valve Cover Timing Belt �Camshaft Pulley...
  • Page 83 ENGINE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings (> Intake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

  • Page 84: Valve Cover Installation

    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 Hold screwdriver .004 (.10 mm) 1----'--�---1...

  • Page 85: Tim16Ing Belt Adjustment

    Incorrect use of a compression gauge can result in unnecessary work and expenditures (Ref Fig. 6 on page G-6). Compression gauge E-Z-GO part number 72524-G01 is recommended. To properly perform an accurate compression test: 1.

  • Page 86: Compression Test Readings

    If so, a top end overhaul should be considered. Refer to Engine Rebuild manual, E-Z-GO part number 27615-G01. Compression Test Readings a) Indicates 140 psi (965 kPa) (Ref Fig. 6 on page G- 6). Compression is good and the engine may be new or rebuilt.

  • Page 87: Engine Removal

    ENGINE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ENGINE REMOVAL contained in Section "A". This operation will remove the engine through the top of the Tool List Qty.

  • Page 88: Controls And Wiring

    Impact socket, 13/16", 1/2" drive ........ 1 tor and remove the belt. Remove the short control rod Clutch puller, (E-Z-GO P/N 19779-G2) ......1 from the bellcrank and the governor. Remove the short Remove the clutch bolt (16). (Ref Fig. 8 on page G-9).
  • Page 89 ENGINE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Plastk Washer ) � Fig. 8 Engine Mounting Fig. 9 Cleaning Cooling System with Air Allow the water to flow freely over the cooling fins and through the blower housing.

  • Page 90: Starter/Generator Installation

    ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Fig. 12 Checking Belt Tension with Gauge existing belt or 3/8" (10 mm) for new belt is acceptable (Ref Fig.

  • Page 91: Engine Isolation Mount Removal

    ENGINE Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ENGINE ISOLATION MOUNT REMOVAL MUFFLER REMOVAL Tool List Qty. Required Tool List Qty. Required Floor jack ..............1 Socket, 12 mm, 3/8" drive ........... 1 Socket, 9/16", 3/8"...
  • Page 92 ENGINE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: _____________________________ _ Page G-12 Repair and Service Manual...

  • Page 93: Fuel

    M _ _ _ _ _ _ _ _ _ _ _ _ __.I 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 ........................

  • Page 94: Fuel System

    FUEL SYSTEM Notes: _ _ ________________________ _ Page H-ii Repair and Service Manual...

  • Page 95: General

    a.,_ F M _ _ _ _ _ _ _ _ _ _ _ _ __.I Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GENERAL exceeds the fuel pressure on the needle valve, the float closes the needle valve.

  • Page 96: Choke System

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Choke System Choke Cable and Housing Installation The choke functions to make initial starting of the engine N O TE In the following text, there are references to easier in cold weather conditions.

  • Page 97: Carburetor Installation

    FUEL SYSTEM Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Coil Bracket Mounted to Engine ..c ..1 1 1 - ..,��\ l l [JJ\ : :I_ "n ��0�...

  • Page 98: Carburetor Disassembly

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Copper Gasket Bowl �,E!c, , Drain Screw etaining crew � Fig. 4 Carburetor Carburetor Disassembly Inspect the bowl gasket (2) for nicks or cuts. Carefully press out the float pin (3), float (4) and the inlet valve.

  • Page 99: Throttle Shaft Adjustment

    FUEL SYSTEM Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Turn the carburetor upside down. Remove the bowl. With tacts the tab on the throttle shaft; turn the screw clock­ the carburetor inverted, the 'B' side top edge of a prop­...

  • Page 100: Fuel Pump Replacement

    FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings As the pistons move down in the cylinders, a positive Fuel is supplied to the fuel pump and carburetor through pressure is formed in the crankcase which causes the flexible fuel hoses.

  • Page 101: Prolonged Storage

    FUEL SYSTEM Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Prolonged Storage using drain screw and re-tighten the drain screw. Remove the air filter and spray a commercial fogging or The recommended storage method is to operate the cylinder oil into the carburetor while operating the starter vehicle for the later part of the operational season with...
  • Page 102 FUEL SYSTEM Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings CARBURETOR TROUBLESHOOTING Condition Possible Cause Correction HARD STARTING Choke plate not operating properly Adjust choke system Dirty carburetor Clean carburetor Loose carburetor Tighten carburetor...

  • Page 103: Continuously Variable Transmission (Cvt)

    CONTINUOUSLY VARIABLE TRANSMISSION (CVT) TABLE OF CONTENTS FOR SECTION 'J' SECTION TITLE PAGE NO. GENERAL ............................J-1 CLUTCHES ............................Drive Clutch ........................... Driven Clutch ......................... Increased Load ........................Equilibrium ..........................Drive Clutch Removal ......................Drive Clutch Installation ......................Driven Clutch Removal ......................Driven Clutch Repair ......................
  • Page 104 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Notes: _______________________ _ Page J-ii Repair and Service Manual...
  • Page 105 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 111 / :.: i 1.:::.: > -�-)\! � 1·1: \\ � - -'11 \· , _ .. \· , 1 i' ·...
  • Page 106 Ratchet, 3/8" drive ............1 cams in the drive clutch. This forces the belt lower into Clutch puller (E-Z-GO P/N 19779-G2) ......1 the drive clutch which increases the drive ratio. This Impact socket, 1 1/8", 1/2" drive ........1 'downshifting' applies more torque to the rear axle with­...
  • Page 107 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Disable the electrical Torque wrench, 1 /2" drive, ft. lbs ......... 1 AwARNINGA system before attempt­ Remove the drive belt (1) (Refer to 'Removing The Drive ing to remove the drive Belt' procedure elsewhere in this section).
  • 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 Drive Belt Service Fig. 3 on page J-4). The belt may then be rolled off the driven clutch.

  • Page 109: Electrical

    ELECTRICAL TABLE OF CONTENTS FOR SECTION 'K' SECTION TITLE PAGE NO. CIRCUITS AND CONTROLS ......................K-1 STARTER ............................K-1 GENERATOR ........................... K -1 WIRING ............................K-1 TESTING IGNITION CIRCUIT ......................K -1 Testing the Ignition Coil ......................K -4 Testing the Pulser Coil ......................K -4 TESTING STARTING CIRCUIT .......................
  • Page 110 ELECTRICAL Notes: _ _ ________________________ _ Page K-ii Repair and Service Manual...

  • Page 111: Circuits And Controls

    • accelerator limit switch with a DVOM (Digital Volt Ohm Meter) available through • fuse the E-Z-GO Service Parts Department (E-Z-GO P/N • key switch 27 481-G01 ). Any DVOM may be used, however the con­ trols, displays and features may vary depending on the •...
  • Page 112 ELECTRICAL Battery Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings ORN/ Reverse Warning Fuse 7 AMP BLUE RED/WHT < RED/WHT � Ignition C oil Switch � Voltage Regulator •...
  • Page 113 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings lg n i tor,,, To Pos. B a ttery To F2 O n ' , , St a rter / Ge n eratpr �1 0 �...

  • Page 114: Testing The Ignition Coil

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings If the engine will not run, but the starter will turn the sary with a 7 amp fuse. engine, proceed as follows: 3.
  • Page 115 ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings 3. l nl Primary Secondary 5.2 nl "" "" sa•.,.. $; _ s .. • ,.$;,. · - @· " ·...

  • Page 116: Starter/Generator

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings STARTER/GENERATOR The charging circuit consists of a starter/generator, volt­ age regulator and battery (Ref Fig. 1 on page K-2). The Starter/Generator Removal solenoid must be functional in order to start the vehicle, but is not considered part of the charging circuit.
  • Page 117 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 Bearing Adapter (Puller) Spring Position for Spring Position Removing/Replacing for Installed Brushes Brushes Fig.

  • Page 118: Starter/Generator Repair And Replacement

    ELECTRICAL Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings N OTE Starter/Generator Repair and Replacement If the temperature of the battery or the ambient temperature is below 6rP F (15° C), the capac­ Tool List Qty.

  • Page 119: Accessory Wiring

    ACCESSORY WIRING TABLE OF CONTENTS FOR SECTION 'L' SECTION TITLE PAGE NO. DVOM (DIGITAL VOLT OHM METER) .................... L - 1 TROUBLESHOOTING ........................L - 1 POWER SUPPLY ..........................L - 3 ACCESSORY WIRING ........................L - 3 LIST OF ILLUSTRATIONS Fig.
  • Page 120 ACCESSORY WIRING Notes: __________________________ _ Page L-ii Repair and Service Manual...
  • Page 121 E-Z-GO Service the technician must be able to use the wiring diagram Parts Department as P/N 27481-G01. For the purpose of and a DVOM.
  • Page 122 ACCESSORY WIRING 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 Turn Headlight Marker Turn BLU/WHT Flasher Turn Signal Switch Pressure Light Solenoid Oil Pressure Solenoid Sender...
  • Page 123 ACCESSORY WIRING Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings POWER SUPPLY 3. Check power wire Qty. Required Firmly attach the black probe (-) to the battery post Tool List with the black wire attached and the red probe (+) to .................
  • Page 124 ACCESSORY WIRING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: _____________________________ _ Page L-4 Repair and Service Manual...

  • Page 125: Mechanical Brakes

    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 ....................
  • Page 126 MECHANICAL BRAKES TABLE OF CONTENTS FOR SECTION 'M' (CONT.) SECTION TITLE PAGE NO. Fig. 21 Brake Assembly ........................ M - 15 Fig. 22 Wheel Brake Lubrication Points ..................- 16 Fig. 23 Backing Plate Removal and Installation ................- 17 Fig.

  • Page 127: Brake System Overview

    MECHANICAL BRAKES Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Parking Brake Pedal Service Brake Pedal Brake Pedal Pivot Bolt Spherical Nut Jam Nut ,, (0,\\ //\\ Part of Frame \: �...

  • Page 128: Automatic Adjuster Mechanism

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings the system and still apply the shoes to the drums, the braking effort at the wheel brake will not be adequate. The self adjusting mechanism in the wheel brakes requires enough cable travel at the wheel brake to work reliably.

  • Page 129: Compensator Assembly

    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 The compensator assembly contains a spring, which is compressed until the stop tube within the spring is engaged and the linkage becomes solid (Ref Fig.

  • Page 130: Troubleshooting Flowchart

    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 Adjust Visually Correct Check Replace Condition of: Brake Cables: Frayed Damaged Good Seized Sticky Replace Secured/Hardware Adjust Pedal...

  • Page 131: Brake Test

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Disassemble Brake, Install Wheel and Tire, Clean, Lube. Check Tire Pressure. Replace Torque Lug Nuts. Adjuster Both Sides. Replace Both Sides...

  • Page 132: Troubleshooting Table

    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 Fails Brake Performance Test by stop Wheel brake failure due to severely...
  • 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 Neither wheel locks when park brake Incorrect compensator spring adjust­ Return to factory specification is latched. (Note: At full speed the ment wheels may not lock, but should brake Excessive brake pedal free travel...

  • Page 134: Troubleshooting And Inspection

    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 free travel (and the effort required to latch the parking brake) to change.
  • 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 Inspect the brake cable equalizer linkage. Inspect for signs of corrosion, damage, wear or Measured Amount of Free Travel excessive misalignment (Ref Fig.

  • Page 136: Periodic Brake Performance Test (Pbpt)

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Periodic Brake Performance Test (PBPT) All brake tests must be WARNING.A. done in a safe location with regard for the safety of all personnel.

  • Page 137: Aggressive Stop Test

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings times as described below, then repeat the Periodic Brake Performance Test three more times (second set of three). If the vehicle passes two of three Periodic Brake Perfor­...

  • Page 138: Wheel Brake Inspection

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Wheel Brake Inspection adjuster function as follows: Push the front brake shoe in the direction of the rear Wear a dust mask and of the vehicle and hold in position.
  • 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 9. Measure the brake shoe thickness. 1 0. Inspect the brake shoe springs. Be sure that they are not broken or damaged and are Measure at the most worn area.

  • Page 140: Adjusting Brake Pedal Free Travel

    Straight blade screwdriver, narrow ......1 Pliers ................1 Vernier/Dial calipers ............ 1 Plastic tipped hammer ..........1 Puller (E-Z-GO P/N 15947-G1) ........1 Pry bar ................. 1 Dust mask ..............1 Emery cloth ..............1 Parts Replacement vs. Repair Some maintenance or repair tasks can take considerable labor to do correctly.

  • Page 141: Brake Drum Removal And Installation

    Brake Drum Removal and Installation from the axle shaft or use drum puller (E-Z-GO P/N 15947-G1 ). Remove the dust cap (1) to gain access to the castel­...

  • Page 142: Wheel Brake Service

    MECHANICAL BRAKES Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings directly over the brake mechanism. Use a small straight Do NOT use a commercial brake clean­ CAUTION blade screwdriver to raise the adjuster arm just above er unless the entire brake has been dis- assembled.
  • 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 Install the actuator components, adjuster components Brake Shoe and Adjuster Replacement and brake shoes. See 'Brake Shoe and Adjuster Replace­ NOT E ft is recommende '! that when bra �...
  • 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 Clean the backing plate with a commercial brake cleaner. Repeat on other side of vehicle. Allow to dry completely. Lubricate the friction points of Adjust the brake pedal free travel.
  • 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 Loosen and remove the jam nut and the spherical nut connecting the compensator rod to the equalizer link. Remove the compensator assembly.
  • 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 Parking Brake Pedal, Removal and Installa­ If required, adjust the kick-off cam (6). See 'Parking Brake Kick-Off Cam Removal, Replacement and Installation' on tion page M-20.

  • Page 147: Rear Suspension

    REAR SUSPENSION TABLE OF CONTENTS FOR SECTION 'N' SECTION TITLE PAGE NO. REAR SUSPENSION ........................GENERAL ............................Shock Absorber Removal..................... N - 1 Shock Absorber Installation ....................N - 1 Rear S p rin g Removal ......................Rear S p rin g Installation ......................N - 1 REAR AXLE REMOVAL.
  • Page 148 REAR SUSPENSION Notes: __________________________ _ Page N-ii Repair and Service Manual...
  • Page 149 REAR SUSPENSION Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings REAR SUSPENSION Compress the shock absorber (2) and remove the top shock absorber nut (3). N O TE In the following text, there are references to Remove the shock absorber.
  • Page 150 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 Page N-2 Repair and Service Manual...
  • Page 151 REAR SUSPENSION Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings T hread locking sealant..........AR Remove the clevis pin from both brake cables where they attach to the wheel brake levers. Remove the brake cable 12 mm socket.
  • Page 152 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-4 Repair and Service Manual...

  • Page 153: Rear Axle

    REAR AXLE TABLE OF CONTENTS FOR SECTION 'P' SECTION TITLE PAGE NO. REAR AXLE DISASSEMBLY ......................P-1 Axle Shaft Removal and Disassembly ................... P -1 Axle Shaft Seal Removal and Replacement................P -2 Axle Shaft Replacement ......................P -2 LIST OF ILLUSTRATIONS Fig.
  • Page 154 REAR AXLE Notes: _ _ __________________________ _ Page P-ii Repair and Service Manual...
  • Page 155 Bearing separator ............1 Needle nose pliers ............1 Internal snap ring pliers ..........1 Slide hammer, E-Z-GO P/N 18753-G1 ....... 1 For brake drum removal, see BRAKES section. Remove the outer snap ring from the axle tube (Ref Fig.
  • Page 156 REAR AXLE Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Axle Shaft Seal Removal and Replacement Using a seal puller, remove the axle shaft seal (5) from the casing.

  • Page 157: Paint

    PAINT TABLE OF CONTENTS FOR SECTION 'Q' SECTION TITLE PAGE NO. PAINTING ............................Q - 1 Minor Scratches ........................Q - 1 Larger Scratches ........................Q - 1 Complete Panel Repair ......................Q - 1 Page Q-i Repair and Service Manual...
  • Page 158 PAINT Notes: _ _ __________________________ _ Page Q-ii Repair and Service Manual...
  • Page 159 The finish will include an application of a primer coat, a Clean with alcohol and dry base color coat and a clear coat. E-Z-GO does not sup­ ply these materials due to the variety of paint manufac­ (Optional but recommended) Follow this process turers and the preferences of the individual painter.
  • Page 160 PAINT Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings Notes: _____________________________ _ Page Q-2 Repair and Service Manual...

  • Page 161: Troubleshooting

    TROUBLESHOOTING TABLE OF CONTENTS FOR SECTION 'R' SECTION TITLE PAGE NO. GASOLINE VEHICLE PERFORMANCE ..................R - 1 STARTER/ GENERATOR ......................R - 5 SUSPENSION AND STEERING ..................... R - 6 Page R-i Repair and Service Manual...
  • Page 162 TROUBLESHOOTING Notes: _ _ _______________________ _ Page R-ii Repair and Service Manual...
  • Page 163 TROUBLESHOOTING Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings GASOLINE VEHICLE PERFORMANCE STARTER DOES NOT TURN Weak or bad battery Recharge or replace as necessary Terminals are loose or corroded Clean and retighten Poor wiring connections Repair or replace wire and/or connections...
  • Page 164 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings (CONT.) STARTER ROTATES BUT Fuel pump faulty Repair or replace VEHICLE WILL NOT START OR Fuel line clogged or clamp loose Clean or replace if required HARD TO START Cracked or broken fuel line...
  • Page 165 TROUBLESHOOTING Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings POOR LOW SPEED Plugged gas tank vent Clean or repair PERFORMANCE Choke on Push choke in Carburetor float level incorrect Adjust Pilot screw Clean or adjust as necessary...
  • Page 166 TROUBLESHOOTING Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings CARBURETOR FLOODS ENGINE Inlet valve/seat dirty Clean or replace Fuel contamination Clean fuel system/carburetor Incorrect float level Adjust Vent hose pinched or clogged Clear or replace Clogged air filter element...
  • Page 167 TROUBLESHOOTING Read all of Section Band this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings STARTER/GENERATOR Starter/generator has foreign matter insid Clean starter/generator interior Replace Bearings are faulty Replace Bearings contain foreign matter Replace Bearing needs grease RECTIFICATION IS IMPERFECT Load exceeds specification...
  • Page 168 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 Incorrect tire pressure Inflate to recommended pressure Improper alignment (Incorrect toe in) Align front tires STIFF STEERING Water has entered steering box and may Remove steering column, pinion and bear...

  • Page 169: Limited Warranty

    LIMITED WARRANTY TABLE OF CONTENTS FOR SECTION 'S' SECTION TITLE PAGE NO. FEDERAL EMISSION COMPONENT DEFECT WARRANTY ............S - 1 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT ..........S-3 LIMITED WARRANTY ........................S -3 Page S-i Repair and Service Manual...
  • Page 170 LIMITED WARRANTY Notes: __________________________ _ Page S-ii Repair and Service Manual...
  • Page 171 As the engine owner, you should, however, be aware that E-Z-GO may deny you warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 172 E-Z-GO reserves the rights to deny warranty coverage if the engine has not been properly maintained. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep maintenance records.
  • Page 173 The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have any questions regarding your warranty rights and responsibilities, you should contact the E-Z-GO War­ ranty Department at 1-800-241-5855.
  • Page 174 All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or distributors or warranty stations authorized by E-Z-GO. In the event that any emission-related part is found to be defective during the warranty period, you should notify E-Z-GO Warranty Department at 1-800- 241-5855 and you will be given the appropriate warranty service facilities where the warranty repair is per­...
  • Page 175 LIMITED WARRANTY (5) Miscellaneous Items Used in Above Systems (i) Fuel hoses, clamps and sealing gaskets I. MAINTENANCE STATEMENTS It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 1995 and later Owner's Manual and to retain proof that inspection and maintenance services are performed at the times when recommended.
  • Page 176 LIMITED WARRANTY Notes: __________________________ _ Page S-6 Repair and Service Manual...

  • Page 177: General Specifications

    GENERAL SPECIFICATIONS TABLE OF CONTENTS FOR SECTION 'T' SECTION TITLE PAGE NO. TXT GASOLINE - FLEET CAR ......................T- 1 METAL BODY GASOLINE - FLEET CAR ..................T- 2 TXT GASOLINE - FREEDOM AND FREEDOM HP ................ T- 3 TXT GASOLINE - 4 CADDY SHUTTLE 2+2 ..................
  • Page 178 GENERAL SPECIFICATIONS Notes: _________________________ _ Page T-ii Repair and Service Manual...
  • Page 179 GENERAL SPECIFICATIONS TXT GASOLINE - FLEET CAR WEIGHT (dry fuel tank) ............669 lbs. (304 kg) TIRES ..................18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE ..............18 - 22 psi (12 - 150 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ........

  • Page 180: Tires

    GENERAL SPECIFICATIONS METAL BODY GASOLINE - FLEET CAR WEIGHT (dry) ................674 lbs. (306 kg) fuel capacity 31 lbs. (14 kg) TIRES ..................18 x 8.5 x 8 (4 ply rated) TIRE PRESSURE ..............18 - 22 psi (120 - 150 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ........
  • Page 181 GENERAL SPECIFICATIONS TXT GASOLINE - FREEDOM AND FREEDOM HP WEIGHT (dry fuel tank) ............679 lbs. (308 kg) TIRES ..................18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE ..............18 - 22 psi (120 - 150 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ........
  • Page 182 GENERAL SPECIFICATIONS TXT GASOLINE - 4 CADDY / SHUTTLE 2+2 WE / SHUTTLE 2+2IGHT (dry fuel tank) ......... 765 lbs. (347 kg) TIRES ..................18 x 8.50 x 8 (4 ply rated) TIRE PRESSURE ..............18 - 22 psi (120 - 150 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ........
  • Page 183 GENERAL SPECIFICATIONS METAL BODY GASOLINE - FREEDOM AND FREEDOM HP WEIGHT (dry) ................674 lbs. (306 kg) fuel capacity 31 lbs. (14 kg) TIRES ..................18 x 8.5 x 8 (4 ply rated) TIRE PRESSURE ..............18 - 22 psi (120 - 150 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) ........
  • Page 184 GENERAL SPECIFICATIONS METAL BODY GASOLINE - SHUTTLE 2+2 / 4 CADDY WEIGHT (dry) ................770 lbs. (349.3 kg) fuel capacity 31 lbs. (14 kg) TIRES (4 ply rated) ..............18 x 8.5 x 8 TIRE PRESSURE ..............18 - 22 psi (124 - 152 kPa) LOAD CAPACITY (including operator, passenger, cargo and accessories) .......
  • Page 185 GENERAL SPECIFICATIONS TXTMODEL METAL BODY MODEL NOTE: Shaded Area Indicates 4 CADDY/ SHUTTLE 2+2 Outline 46.5 in. (118cm) Fig. 1 Vehicle Dimensions Page T-7 Repair and Service Manual...
  • Page 186 GENERAL SPECIFICATIONS 67 in. (170 cm) 47 in. (119 cm) Front RECOMMENDED MAX SIDE TILT 33.5 in. (85 cm) 25% GRADE or 14 i MAX Rear 38 in. (97 cm) NOTE: TXT FREEDOM MODEL SHOWN TURNING CLEARANCE DIAMETER 19 ft. (5.8 m) RECOMMENDED MAX RAMP 25% GRADE or 14 i MAX Fig.
  • Page 187 Read and un � erstand the followin g_ warnings Some components are heavy, spring loaded, highly cor­ NOTE '-· ----'· before attempting to operate the vehicle: rosive, explosive or may produce high amperage or reach high temperatures. Battery acid and hydrogen gas prevent personal could result in serious bodily injury to the technician/...
  • Page 188 E-Z-GO Division of Textron Inc. P .O. Box 388 Augusta, Georgia 30903-0388 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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